Discovery 3 Engine re-build

tyregeezer · Jun 21, 2024

Water pump went this morning almighty squeal on 07, all of a sudden, didn't have one locally so fitted Stype one I had hoarded same as D3 so fitted problem solved, quick pic of difference in size between main bearing oil feed and an OEM bearing, king bearing hole matches size of feed in block, cleaning and painting block this weekend

Andy Warren · Jun 23, 2024

Hi,wonder if the smaller hole helps with higher oil pressure?
Not sure I could find enough time for all the great work you get through, I've struggled the last few days just doing an engine service/air con rad & a few tweeters on the D2 (although I do like to clean everything), all the best.

tyregeezer · Jun 23, 2024

Hi mate, you may well be right, at the end of the day there's only a choice of bearings or oil pump that have been improved? I don't know being honest, thinking of going with king's main bearings and the 15mm pump, basically what the guy on lr time did, with no loss of pressure, does this allow higher flow rate whilst maintaining pressure? Again not sure, kings are highly rated by my machine shop and lots of builders on line and uber tube, but at the end of the day you pick your own poison, I'm at least semi retired now (20hrs) so have more time for the workshop, I know it can be difficult to time do all the necessary maintenance that they demand but I love to hear of people keeping on top of all those jobs themselves all the best

gstuart · Jun 24, 2024

tyregeezer said:
Hi mate, you may well be right, at the end of the day there's only a choice of bearings or oil pump that have been improved? I don't know being honest, thinking of going with king's main bearings and the 15mm pump, basically what the guy on lr time did, with no loss of pressure, does this allow higher flow rate whilst maintaining pressure? Again not sure, kings are highly rated by my machine shop and lots of builders on line and uber tube, but at the end of the day you pick your own poison, I'm at least semi retired now (20hrs) so have more time for the workshop, I know it can be difficult to time do all the necessary maintenance that they demand but I love to hear of people keeping on top of all those jobs themselves all the best

Hi mate

Talking of oil that funny enough I’ve bought myself an oil pressure digital monitor where the small screen is fitted inside the cabin and an adaptor where it accepts an extra oil pressure sensor ,

It’s like a Y piece that is screwed into the oil sensor then the oem screwed back in then the extra one

Will be interesting to see what the oil pressure is on tickover and higher revs when driving

Have wondered if it shows a lower pressure if the oil filter became clogged and therefore lowers the pressure

Would be very interesting to see if that would work or if the oil pump degrades over time

Plus of course will be going over to 5/40 but will be testing the oil pressure and db readings before and after changing the oil

Once again , many thks for taking us along for the ride with these awesome projects and all ur hard work

Also found a deeper coin tray

Have a great week my friend

gstuart · Jun 24, 2024

This where I’ve started making the wires longer and putting the wires inside conduit

Managed to very carefully put the small
Screen into the rh side trim , will need tidying up

tyregeezer · Jun 24, 2024

Hi mate have mulled over the idea too but just never got around to it, pic or two when done? would be interested in your findings and thoughts please, convinced the 40w part will help maintain viscosity at higher temperatures, should you be interested in anything on the D4 build would be happy to take a specific picture for you let me know, cleaning the block outside at the moment ready for machine shop and costing the build (frightening) will show you later

tyregeezer · Jun 24, 2024

Spent another day cleaning the outside of the block today should finish tomorrow, finished rough costing of expected parts, it's only approximate and I've probably missed bits, waiting to finalize after verdict from ivor Searle I'm thinking about £1500 ish for a build like this whereas used motor is about £3500 and I wouldn't know the condition, and would want to change oil pump, belts, etc so seemed most logical

gstuart · Jun 25, 2024

tyregeezer said:
Hi mate have mulled over the idea too but just never got around to it, pic or two when done? would be interested in your findings and thoughts please, convinced the 40w part will help maintain viscosity at higher temperatures, should you be interested in anything on the D4 build would be happy to take a specific picture for you let me know, cleaning the block outside at the moment ready for machine shop and costing the build (frightening) will show you later

Many thks and indeed will take some pics once all done along with results , alas at the end of the day just trying my best to keep the d3 going as long as possible

Mainly as my next dream motor would be a D4 5.0 V8 and blimey there keeping there value at around 30k so well out my price range , but never know maybe one day , particularly if I find one with a bad timing chain tensioner issue

Big thks as well ref any D4 pics , will indeed be very handy if I manage to get one at some stage

If I then got rid of my D3 im considering about sending it to Ukraine as in reality its useless around here with the ulez on my doorstep , at least it could then go to a good home but fingers crossed I can keep it going for as long as fesable

as always many thks for the piccies and update and find it very interesting

gstuart · Jun 25, 2024

tyregeezer said:
Spent another day cleaning the outside of the block today should finish tomorrow, finished rough costing of expected parts, it's only approximate and I've probably missed bits, waiting to finalize after verdict from ivor Searle I'm thinking about £1500 ish for a build like this whereas used motor is about £3500 and I wouldn't know the condition, and would want to change oil pump, belts, etc so seemed most logical

Think that’s an absolute bargain in costs , decent exchange I’ve seen an average of around 5k so it well in there doing it all yourself plus knowing it’s been done correctly

Awesome work my friend

tyregeezer · Jun 25, 2024

No problem there mate your D3 looks mint from the pictures I've seen, it must be a pain with ulez on your doorstep, D3 or D4 prices plummet with issues, that's why I bought the D4 didn't intend to but had been looking, between you and me was £1300 and apart from the engine is immaculate so if anyone is looking for a D4 if you or you and a mate can fix it, you could be all in for about £3000 with a good motor labour is the killer with LR, example for me to service just heads inspect, clean, grind in valves and new stem seals takes probably 20-30hrs well me anyway

gstuart · Jun 25, 2024

tyregeezer said:
No problem there mate your D3 looks mint from the pictures I've seen, it must be a pain with ulez on your doorstep, D3 or D4 prices plummet with issues, that's why I bought the D4 didn't intend to but had been looking, between you and me was £1300 and apart from the engine is immaculate so if anyone is looking for a D4 if you or you and a mate can fix it, you could be all in for about £3000 with a good motor labour is the killer with LR, example for me to service just heads inspect, clean, grind in valves and new stem seals takes probably 20-30hrs well me anyway

Many thks and indeed I’ve been very lucky as made sure when I bought it the chassis was solid , then of course made Sure the entire chassis inside and out was treated with dinitrol

Wow mate that’s an incredible price and massive respect to u for all the hard work

Remember that well in helping my dad grind in valves by hand , seen some where u can use a drill to speed up the process using a special adaptor

tyregeezer · Jun 25, 2024

Yes mate credit to you looks great, definitely has the look, have learned dealers want to unload stuff that's damaged not salable, and will take a loss at the end of the day bet he made on the car he sold and who you know helps. I prefer to grind by hand sound and feel play a part, stanleysteamer mentioned tool also, quick story my first lesson was in about 1980 apprentice first engine job was grinding valves on a sdi rover they set me up and off I went grinding away spent two days fingers raw arms stiff boss kept checking, when I eventually finished mechanics gathered round and boss declared best valve grinding job I have ever seen you can imagine I was chuffed then he stated next time we'll show you the coarse end Lol decided to clean block myself over weekend and paint drop off to engineers Monday enjoy the sun all the best

tyregeezer · Jun 27, 2024

Finished cleaning up block, cleaned the water canals, and jacket, oil ways etc gave the outside a couple of coats of engine enamel not strictly necessary but looks good, booked in to ivor Searles Monday so will get a few days to harden in the sun, still hoping to hone but is some rust at the bottom of two bores will see, crank hopefully just a polish again should be done by Friday, so can start to accumulate parts, once sure on what will need, waiting to get bottom end built then will get D4 in and motor out, also hoping to use D4 heads, although managed to source two xfs heads with cams locally in good nick so could use these if necessary, but all good so far

tyregeezer · Jun 30, 2024

All of a sudden not so good 09 developed a leak seems like between gearbox and motor at each bottom corner sure its transmission fluid, torque converter seal?, couple of things not to happy with runs fine but little noisy top end couple of louder than I would like lifters so mulling over fitting a new set if I pull the motor/box also over last day or two getting an egr pressure faults, were brand new, D4 motor off this week gonna book off and crack on

tyregeezer · Jul 4, 2024

Slight change of plans, brake cleaned gearbox again and surrounding area and re-run motor spent twenty minutes watching with a floodlight, leak reappeared both bottom corners, but more concerning was bottom end noises, not terminal big end but suprising, checked against 07 much quieter, after much deliberation have decided the motor is to valuable to take a chance especially with the bottom end, my mistake have a gut feeling about it, will show what I find but am sure it's close to major issues I should have stripped the whole motor, so decided to re-build the 06 motor I have had it checked and honed last year pistons cleaned one left to do, using heads as they were originally fitted to this motor and have been serviced, going to cost in a few seals and gaskets but everything else would need to be bought anyway, going to start stripping motor out tomorrow, as want to see for myself and may use the crank depending on condition, oem torque converter seal turned up today made in Hungary

tyregeezer · Jul 6, 2024

Cleaning last pistons today one left to do, soaked in berrymans chem dip, be careful with this stuff scraped ring grooves with a piece of old ring sharpened and burrs removed, quick re dip and wipe crown with a fine scotch brite and ready for rings, I mark the gugeon pins the same side as the red dot on the piston this way I remember to put them back in the same, crank bolts, conrod bolts on order, also elring top end set minus head gaskets been looking for a bottom end set as is a bit cheaper as a set but no luck so far, waiting for rain to stop as I can't get D3 in workshop just into doorway so looking for couple of days break in weather hoping to use the crank in this build

gstuart · Jul 6, 2024

tyregeezer said:
Cleaning last pistons today one left to do, soaked in berrymans chem dip, be careful with this stuff scraped ring grooves with a piece of old ring sharpened and burrs removed, quick re dip and wipe crown with a fine scotch brite and ready for rings, I mark the gugeon pins the same side as the red dot on the piston this way I remember to put them back in the same, crank bolts, conrod bolts on order, also elring top end set minus head gaskets been looking for a bottom end set as is a bit cheaper as a set but no luck so far, waiting for rain to stop as I can't get D3 in workshop just into doorway so looking for couple of days break in weather hoping to use the crank in this build

Hi mate

May I ask a daft question plse , Would an ultrasonic cleaner be more effective or not suitable for cleaning some things plse

Assume u would get in trouble if u use the dishwasher to clean engine parts

Always Remember my pops teaching me that trick with a snapped piston ring to scrape out the build up

tyregeezer · Jul 6, 2024

Yes it probably would be mate by hand, is one of those things I learned to do as you said your dad did, diesel carbon can be extremely stubborn it's the most effective way i have found, berrymans softened it no scratches at all sharpend ring piece most important to remove all burs from scraper I do this with an oil stone and keep my thumb over the end while scraping to stop it popping out of the groove and scratching the piston probably an hour per piston between soaks 138k I think not a mark on any of these pistons, still looking at rings, thanks so much for confirmation of logo removal saga steve

tyregeezer · Jul 6, 2024

PS can't afford a ultrasonic cleaner just bought £600 worth of bolts, gaskets and seals Lol

tyregeezer · Jul 8, 2024

Guess what I managed today, well getting practiced now Lol, pulled it in the workshop yesterday, didn't do to much exhaust and props drained the transmission fluid and re-caned it, bought a new bucket to catch it in, started at 7am got done about 7.30pm would be quicker with two going to try get it on engine stand I was bought for father's day tomorrow before work, and a good tidy up too, have a few paying jobs but will try to get crank to machine shop this week

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