Discovery 3 Engine re-build

Managed to get motor on stand yesterday, started stripping. Brushes and sealant arrived. Only visible differences in block between 276dt is extra breather on top of motor on 306dt leading to an extra collector box branded Peugeot/citroen, other jobs took longer than expected so will be monday before get to machine shop, thanks @gstuart for recommending ultrasonic cleaner surprisingly came down in price since I last looked, may I ask can anyone reccomend a technical data download for 276dt motor was looking for ford one but can't seem to find a source

tyregeezer said:

Managed to get motor on stand yesterday, started stripping. Brushes and sealant arrived. Only visible differences in block between 276dt is extra breather on top of motor on 306dt leading to an extra collector box branded Peugeot/citroen, other jobs took longer than expected so will be monday before get to machine shop, thanks @gstuart for recommending ultrasonic cleaner surprisingly came down in price since I last looked, may I ask can anyone reccomend a technical data download for 276dt motor was looking for ford one but can't seem to find a source

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Hi mate

Have sent u over a pm with a link ref a full workshop manual which includes specs etc , alas couldn’t post it here because of copyright

Hope it’s useful to u my friend

Excellent mate will download manual to my laptop many thanks
Heads off today nothing but a clean and new lifters, some blow past on rings but no scoring or any real signs of wear on pistons, big ends have the usual wear patterns, but a couple of bearings have started to pick up a little. Mains look ok although one main shell has picked up/roughened on the groove just started to leave a mark on the crank although you can't feel it, think will just get it polished hopefully tomorrow, crank and rods both look newish for some reason but just a feeling, have oiled old block bores and mains 50/50 with oil and pre-lube

Took crank over to ivor Searle today seems likely to be just a check and polish, turns out they agreed it is a most likely a new crank, got a bit of a lesson in main bearings kings come in grades apparently, regular bearings are called a sputter bearing, because of its manufacture I googled it when I got home, king also make a silver bearing described as k-796 looking into this but then don't get out much, couple of days to decide until crank comes back, fitting rings, rods and pistons back together, were very helpful and interested it what I was up to, have loads more questions for them, quite a big pile of exchange motors

Bet u was also pleased with the block as looks amazing

As always Doing a sterling job there mate , massive respect my friend

Shame the crankshafts don’t have serial numbers as always thought if it then possible to try and track the bad ones

Sorry asking as I imagine you've already said , do u run urs on 5/40 plse

Many thks and keep up the great work mate

Oh and saw this the other day 5.0 D4 , droool

In my favourite colour too , alas nearly 30k for a 2012

Thanks mate yes coming up nice, indeed 5w 40 wanted to ask you what Millers you use several different flavors of fully synthetic what do you use please, just about to do oil change on 07 but have half a shell helix so just need another 5l helix, but will run new motors on millers as someone highly recommended it to me can't remember who it was Lol, you're gonna get one might as well bite the bullet mate gonna move into ivor Searles

tyregeezer said:

Thanks mate yes coming up nice, indeed 5w 40 wanted to ask you what Millers you use several different flavors of fully synthetic what do you use please, just about to do oil change on 07 but have half a shell helix so just need another 5l helix, but will run new motors on millers as someone highly recommended it to me can't remember who it was Lol, you're gonna get one might as well bite the bullet mate gonna move into ivor Searles

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Hi mate

This is what I got , funny enough was a lot cheaper buying 2 x 5 litres of 5/40 , however next time I’ll get some 1 x litre bottles due to the shelf life once opened

Also got an oil filter and some Bosch aero twin wipers at the same time

Also change my fuel filter every other year , do everything regardless of mileage or time which the latter seems to come round quicker seeing I do such low mileage

Did get a vacuum oil pump for the engine oil to save me trying to get underneath , can hook it up to my compressor as well, ordered it from the states

Defentily a dream motor that’s for sure and hopefully one day that one will pop up that’s needs some work

Hope that’s useful my friend and thks again for ur fantastic thread

Thanks mate will put on order also have a meyle filter yes somtimes cheaper to buy two, is how I buy brake cleaner too save £5. Read through the king bearing catalogue PDF download last night have a read through most interesting. Waiting for call about crank then can order shells, Searles are hiring thinking about asking if they need a tea boy, the stack of engines waiting for collection for rebuilding is unbelievable

Picked up crank today £72 for polish and health check, they reckon its not original one nearly new, turns out Mark's on one journal was just coating from the shell, but was caught before damage occurred also priced 306dt for dipping the block, and rebore also picked up six main oil gallery plugs old one will be removed for final clean

Oops did it again king std mains and con rod bearings ordered today, all bolts on order that was the shocker more expensive than all the bearings going to start assembling pistons and rods this weekend and a bit more cleaning

Wow that’s a great price mate , ref suppliers who do u normally use please , know u mentioned ivor Searles but assume that’s for just the engine work

Just wonder if there are more competitive ones out there but of course understand need to ensure there quality parts

Hope u get on ok this weekend my friend

Ie some prices , don’t know how they compare mate 2.7 , inc of vat

E274105 Conrod Bolts £6.00 each​

CR6838SV S601.STD Con Rod Bearing Set £194​

BR4108 08-432400-00Standard Piston Ring Set (One Piston) £20.48​

Kings , inc vat

Conrod bearing set £110
Main bearing set £110
Main bearing cap bolt £9.00 each
Conrod bolt £4.00
Std piston ring set 1 x piston £22.00

Also assume the Citreon oil pumps are cheaper than JLR ones seeing I think being the same

Yes mate ivor Searles for machining, but saying that they are pricing me for pistons for the D4 meyle and nural, going to have the block dipped and re-bored, plucking up courage to ask for the full tour, they couldn't match price on mains and big ends.
Generally now I only buy OEM quality by this I mean reinz, fia, elring, not stuff advertised as such on evilbay, but much i buy is OEM.
People I buy from craddocks, advanced factors, maltings, paddocks, to name a few, but all the usual suspects I do tend to shop around
Kings Mains and conrod bearings were a deal at £225 from apex parts
Crank bolts all of them just over £300 I think, from turners and craddocks
Conrod bolts £65
Rings were £130 std full set
Similar prices to yours mate but I do look for a bargain too
Remaining gaskets, seals, trigger wheel oem, and bolts come in at round about £400 all reinz worth bearing in mind if taking on a project, but really enjoying it so far issues and all enjoy the sunshine mate have a great week end too

Finished final cleaning, for now, removed main oil galley plug, you can just see number 4 journal feed flushed with brake cleaner in a pressure vessel and lots of compressed air from all directions, bolts have arrived bottom and side crank caps, and crank pulley bolt all OEM £196, starting either tomorrow or Monday with the crank.
Thanks mate for the workshop manual all the information needed and successfully downloaded spot on much appreciated
Been fiddling today with the 07 still trying to calibrate suspension, where I'm at, putting in measurements was too much keep getting incorrect measurements refusal so put in smaller increments but in the right direction if you see what I mean, this was acceptable and vehicle raised with information on dash rising, then says lowering to normal position nothing happens, then it asks for next set of measurements, starting to think the cheap Chinese compressor is not responding to diagnostic requests well the exhaust valve anyway so going to switch back to an amk which is a bit weak but works in the morning see what happens

tyregeezer said:

Finished final cleaning, for now, removed main oil galley plug, you can just see number 4 journal feed flushed with brake cleaner in a pressure vessel and lots of compressed air from all directions, bolts have arrived bottom and side crank caps, and crank pulley bolt all OEM £196, starting either tomorrow or Monday with the crank.
Thanks mate for the workshop manual all the information needed and successfully downloaded spot on much appreciated
Been fiddling today with the 07 still trying to calibrate suspension, where I'm at, putting in measurements was too much keep getting incorrect measurements refusal so put in smaller increments but in the right direction if you see what I mean, this was acceptable and vehicle raised with information on dash rising, then says lowering to normal position nothing happens, then it asks for next set of measurements, starting to think the cheap Chinese compressor is not responding to diagnostic requests well the exhaust valve anyway so going to switch back to an amk which is a bit weak but works in the morning see what happens

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Ur so very welcome mate and so pleased it’s useful to u , funny enough I useto store alot of parts upside down to prevent any dirt ingress or anything falling in them , laying any machined surfaces on foam, but put the foam inside a black bag first so that no fibres came off the foam

Funny enough I was going to say that about ur suspension of entering smaller numbers but see you’ve done that , have got a few scanners ie, Autel , mx808, ap200 and the gap iid, found the mx808 really good seeing it does multiple vehicles , updated it for the first year and didn’t bother updating as they want £2-300 and it seems it’s just for new vehicles so doesn’t effect me

So handy having the AP200 for the glovebox but see there are ones loaded with different software , if u ever want to get one plse let me know and will send the link over, sorry if you’ve already got one

Other thing I like about the mx808 is its bigger bi directional capabilities, did learn ages ago after getting caught out in continuity testing , this one wire passed using a meter but failed using a test light , it tripped me up for hours and found the connection pin was bad , live and learn that’s for sure

But of course know ur extremly knowledgeable my friend , sorry with me waffling as per usual

Don’t know if you’ve done the same but when I’ve been storing parts ready for assembly I’ve sprayed them very lightly with machine oil to prevent them from flash rusting until such times there used

Thks again as always allowing us to be part of the great project , really hope one day I’ll be able to pop in for a cuppa

Stay safe and well my friend and always here if I can help in any way

Yes mate was spot on got all the data I needed many thanks, have been using Lucas prelube thinned with a little oil to keep rust at bay stored on trays in my cabinet can re-oil from time to time.
Yes suddenly thought multiple smaller increments seemed to be working rear right now correct well within 2mm was 20mm high fitted new OEM r/h sensor before calibration to replace cheap one going to drive it around the village and retry f/l still high but think I might be getting the hang of it Lol, incidentally got a quote on block chemical dip, rebore and supply new meyle or nural pistons for D4 it's £1000ish depending on your choice, finally plastigauge time this week thanks once again and all the best mate

tyregeezer said:

Yes mate was spot on got all the data I needed many thanks, have been using Lucas prelube thinned with a little oil to keep rust at bay stored on trays in my cabinet can re-oil from time to time.
Yes suddenly thought multiple smaller increments seemed to be working rear right now correct well within 2mm was 20mm high fitted new OEM r/h sensor before calibration to replace cheap one going to drive it around the village and retry f/l still high but think I might be getting the hang of it Lol, incidentally got a quote on block chemical dip, rebore and supply new meyle or nural pistons for D4 it's £1000ish depending on your choice, finally plastigauge time this week thanks once again and all the best mate

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That’s awesome and well chuffed u found all the data u needed

I wondered what u used for flash rusting etc, many thks , oh wow that’s a lot of money

Thks again mate and have a great Sunday

Started fitting crank today, piston coolers first, plastigauge quite difficult easy to smudge see journal 4 on pic, as mains caps are interference fit the tapping/levering can dislodge the bearing slightly making plastigauge inaccurate, need more practice but getting there all seem at bottom end of tolerance, note some pictures look bronze, rusty or tainted but are all clean and uniform in color just comes out that way on phone, going to stop until tomorrow workshop now 96°