Discovery 3 Engine re-build

Yes mate always suprising here in Norfolk, have seen some blogs/information says code some says re-learn we'll see, was the actuator, your right about timer, try letting just epoxy soak into the foam before applying microfiber or filler to the mix, what a day mate done it gotta tell you just bought a D4 2009 xs great condition inside under and out 143k from local dealer played little over peanuts bet you can't guess what's wrong though Lol, going to collect this afternoon will do some pics

tyregeezer said:

Yes mate always suprising here in Norfolk, have seen some blogs/information says code some says re-learn we'll see, was the actuator, your right about timer, try letting just epoxy soak into the foam before applying microfiber or filler to the mix, what a day mate done it gotta tell you just bought a D4 2009 xs great condition inside under and out 143k from local dealer played little over peanuts bet you can't guess what's wrong though Lol, going to collect this afternoon will do some pics

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Bless u for letting me know about the epoxy , thks as it’s appreciated

Congrats on the D4 , Erm, let’s think, u can’t lift the bonnet to get to the engine

Gluten for punishment my friend but to be honest extremely interesting and look forward how u get on plse

Plus more things to learn from ur good self

Went over and collected D4 yesterday hired a trailer locally, D4 was at a dealership 10miles from home what attracted me was its mint inside and out, and here's the but, has a broken crank, to my horror he started it describing it as a knock, you probably heard a scream about 3PM that was me. Managed to cut a good deal as he had been messed about twice on evilbay sold for £1800 and £1650 but on both occasions was timewasters so was getting desperate to get rid so got it for much less so loaded it up brought it home, is now in a queue behind jaguar, took 09 for a little drive is noticeably tighter quieter that the 07 still have few odds and sods to do mot Monday or Tuesday

Back in the workshop (shed) today stripped the rest of the front of the jag, fiddly but not too bad everything now off or disconnected apart from wiring plugs and power steering tank coming off with the motor. Gearbox well all it's connections to do, have been wd40ing the subframe bolts for a couple of days, plan to drop the motor, box, and subframe down and out the front, might need a few inch taller stands though. Bought some Allen keys and a pick set from aldi today seem usable we'll see. Weather been awful today hopefully better over weekend and can get on with the 09 brakes, @Graculus did you know you and landyzone got a mention and a thanks on YouTube, not economically viable, sorry if you already knew

No I didn't mate - that's more than I get at work!

Your not alone there mate Lol, was watching it as he was working on a range rover couldn't get dash lights to work have a watch

Finished 09 today last few bits of under shields etc mot on Monday, going to have to sell 07 though, yard looks like Discovery central. Made a decision to borrow the bottom end of the jag to put in D4, which I am sure has a broken crank, doesn't seem too many differences in a sense of removal, but obviously two intercooler pipes, gearbox loom seems to go to the other side near the dynamics unit and what I think is the transfer control module, finishing removing jag motor first re-build and quick switch over, well that's the plan so far anyway

Finished off taking motor out of jag today came out ok dropped it down subframe onto the engine hoist, gearbox onto my gearbox lift slowly and together lowered then pulled it out the front just fitted, removed a few bit tonight to wd all the exhaust nuts and bolts, only issue I had was one of the engine loom plugs wouldn't undo the one with the 10 mm bolt spent hours trying everything I could think of but to no avail, so have cut the engine harness, will replace this, not needed for D4 but still need to resolve stuck plug situation, trying to get on stand tomorrow and start stripping, never seen so many sensors on an exhaust system

Got on well today took subframe off and refitted to jag, next gearbox off, removed front pipes first, was stuck on the dowels but came off with persuasion, put it on the stand and got rid of the hoist as I'd smacked my head on it thirty times
Jag and D3 have lots of vacuum controlled or monitored systems removed this along with wiring and coolant pipes, had removed the lefthand turbo, egr, starter, and manifold to remove torque converter bolts, I always spray electrical cleaner in and on all the plug clips before pressing, just have to clean up and plug up and bag everything ready for tomorrow hopefully can get to remove L/h rocker cover as I suspect the fun starts there

In workshop again today. Fuel system has a balance pipe between fuel rails took it off as complete as possible,stripped down to heads this morning, Oops timing chain broken and bits missing other is completely AWOL will find it later several exhaust rockers broken, l/h cams intact but scored not a mark in guides though, but cap bolts loose, slight marking on piston tops, but have clearly had an impact, will strip other head off tomorrow hopefully no worse, my thinking so far strip to block get it dipped water galleries rusty before honing bores look unmarked new bearings maybe kings, will have to check everything else, will take heads at same time or will use the D4 ones, also was interesting a number was written on every injector but none cosponded to the cylinder it was in, also only one dowel in l/h cylinder head, and lots of oil leaks looking forward to re-build

Removed r/h head today more broken rockers, cams again look scored, but guides look ok apart from one score starting to think it was made from older well used parts. I have a good useable l/h head and cams also silicon everywhere and lots of it. Found AWOL chain, pistons just carbon valve marks, took off sump and extension Popped off a couple of big ends definitely marked crank, can't feel them but their there hopeful will polish up will get advice from ivor Searle, hopefully block cleaned, honed what I can see of the barrels looks ok so far, crank would be nice to get away with polish, bearings, block rings and a hone well fingers crossed

Pistons 4-5-6 out today, ages cleaning carbon lips from bores Mark's on the skirt of one, dink mark on another, been knocked but little vertical wear, big ends look ok nothing sinister bores no scoring but extreme glazing, will see what machine shop recommend taking it over next week, 09 passed its mot on Friday no advisory all good but has developed a injector or bleed off pipe leak as always number 6, bought a degreasing tank from evilbay £25 faded but works other pistons tomorrow crank out on Wednesday

Blimey you’ve been busy mate , congrats on getting ur 09 through its MOT

Massive respect my friend , bet it’s nice to at least have a space that u can keep dry in horrible weather

Can’t wait to see the end result of how ur getting on including the D4

Thks again for sharing these fantastic projects

Thanks mate but is just my ramblings, want to do D4 a bit quicker, just haven't decided what to do with rods and pistons some have taken a bit of a hit, keep an eye on me won't you? All the best

tyregeezer said:

Thanks mate but is just my ramblings, want to do D4 a bit quicker, just haven't decided what to do with rods and pistons some have taken a bit of a hit, keep an eye on me won't you? All the best

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Not ramblings at all my friend but some fantastic insight of all the hard work that you’ve done

Can see how knowledgeable that you’ve become as the thread has progressed and massive credit to u and huge amount of respect mate

Many thanks mate you've been a big help at some difficult times been much appreciated.
Been fiddling today removed pistons 1-2-3 first thing, all look good but do have minor valve impact Mark's, another thing to ask engineers about, checked crank end float 0.27, tolerance is 0.20-0.40 I believe, will reduce slightly with new thrusts, crank again looks ok will be crack tested, peaned and hopefully just polished, some interesting wear patterns on mains not sure will pick machine shops brains, plastigauge on order. Waiting to see what the heads are like on the D4 before making a decision, refurb myself or if they need complete rebuild, decided to clean block myself, spent a couple of hours cleaning the block today machine shop next week

ur so welcome that I’ve been able to help in a small way as I know there are far more knowledgeable members than myself

still very grateful for the kind words, thk u so much

Have a great weekend mate and following with interest

Ps, did u manage to see that video i posted on AG plse titled, SVR RRS , never seen anything like it with water coming out the spark plus

Would be interested to see what u think eplse

All the best mate

Will check it out mate, extreme head gasket failure or a crack springs to mind? All the best

tyregeezer said:

Will check it out mate, extreme head gasket failure or a crack springs to mind? All the best

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Cheers as would be interesting; what ur thought were please

Wondered at first if maybe the supercharger had something to do with it considering its water cooled , alas not sure if it has egrs being a petrol

Thks again mate and have a great weekend

Yes mate if its supercharged definitely, have a good weekend too