Discovery 3 Engine re-build

gstuart · Aug 10, 2024

tyregeezer said:
Yes mate exactly, going to borrow blacksmiths lathe make a couple of insert tools at some point couple of days off and then finish over next week or so, done the bit was most worried about, learned a bit, much more to go but do it in stages don't want to wear out my welcome at engineers seems to have taken me under his wing a bit spent a hour or more lecturing about cranks, has an interesting theory or two, kettle always on no one gets away with out drinking tea Lol

Many thks mate , that’s great as have seen those insert tools but think there silly money

Must confess I’m getting more and more tempted to drop in to say hi , more than likely would end up getting locked in the workshop for the value of the many cups of tea

Often wondered if things like this would ever work or be cheaper ?

21X Camshaft Crankshaft Oil Seal Bearing Remover Installer Rings Tool Set | eBay

1x Puller (for pulling stuck radial seal rings). 7x Adapter Rings (for M8, M10, M12, M14, M16, M18, M20 central screws). To remove and install crank and cam seals. 1x Carry Case. Engine Timing Tool Kit For Panda Punto 500 Doblo Idea FOR Ford 1.2 1.4 VVT.

www.ebay.co.uk

gstuart · Aug 10, 2024

CRANKSHAFT OIL CRANK CAMSHAFT KIT SET SEAL REMOVAL TOOL INSTALLER TOOL SET UK | eBay

To remove and install crank and cam seals. Engine Oil Pump Pressure Detector Tester Gauge Tool Kit M14x1.5 M16x1.5. Tools Locking Wheel Nut Removal Sockets for Alloy Wheels Tire Screw Extractor. 9X 1/2" Drive 6 Point Axle Nut Hub Air Impact Deep Socket Set 29-38mm.

www.ebay.co.uk

gstuart · Aug 10, 2024

Blimey £70 from Amazon

Amazon product

gstuart · Aug 10, 2024

also found this which shows the measurements, of course assume you’ve got these already but just in case

gstuart · Aug 10, 2024

Just sent u a pm

tyregeezer · Aug 11, 2024

Been out for the day at the seaside and also picked up new puppy wife bought a puppy must be my turn to buy tdv8 Lol sent you pm mate

gstuart · Aug 12, 2024

tyregeezer said:
Been out for the day at the seaside and also picked up new puppy wife bought a puppy must be my turn to buy tdv8 Lol sent you pm mate

Oh bless , what breed please mate

Seeing those reminds me of my beloved candy as when I’ve got my landy done will get another dog

Indeed ref the Tdv8 or a supercharged version

tyregeezer · Aug 12, 2024

Hi mate it's a cocker poo cross terrier, missus been looking for sometime for a companion for our Jack Russell fell head over heels, surprisingly we also have a squirrel who I found as a baby and weened him from a couple of weeks on now had him about 8 years his names Cyril nutkin only in Norfolk mate will do a picture but he likes to bite phones also stole the enter key from my laptop

tyregeezer · Aug 16, 2024

Had couple of good days but forgot couple of bits namely rear oil seal, but there's going to be a few bits I forgot I'm sure. Did piston protrusions yesterday all between 0.541-0.590 but a couple are close so going for two notch 1.17 playing it safe, ordered gaskets and bolts and water pump and new lifters today also going to exchange the turbo for a reconditioned unit found a bit of oil in breather and intercooler, perhaps didn't clean it well enough first time, signs of oil in turbo too, everything now soaked or filled with gunk
Engine has a rotating resistance of about 18nm so seems ok happy at this point
Cleaned and fitted a few other parts today, cleaning is a good time to check stuff over

gstuart · Aug 17, 2024

1st rate work as always my friend , bet ur also pleased with the amount of money you’ve saved plus knowing they’ve been done correctly

Top work mate and fantastic thread and can be proud of what you’ve achieved

tyregeezer · Aug 21, 2024

Thanks mate, rebuild cost mounting though about £1500, rear seal came today fitted and shrinking as we speak, breather box first tab under seal housing and tube doesn't fit after head is on, found a piece of thick wall tubing machined at one end did the job fitting oil pump seal elring seal installation tool slips over crank beautiful tried a fia one as I had one here tool only butts up leaving a lip?
Fitted Sump ladder and sump little smear of dirko HD at the four joints, cleaned one cylinder head ready for new lifters, installed turbo filter (before I forget) heads on in next day or two

tyregeezer · Aug 23, 2024

Managed to fit left head today, complete with new litters well oiled and in place was going to do right but had other jobs pending so ran out of time, yes the dust plugs are McDonald's sauce tubs, shame you have to cover so much of this engine up as is fantastic looking engine.

tyregeezer · Aug 30, 2024

Fitted other head and turbo oil supply pipe, exhaust manifolds, made my own removable spacers, nipped up all other bolts and removed
Fitted crank pulley now bolts arrived (see picture of how quickly costs spiraling) spent ages cleaning oil residue from intercooler and breather pipework just intercooler itself to finish
Exchange Turbo on order, cams and timing belt next, then can prime the system, still mulling over fitting xf rocker covers identical apart from redundant gunge catching butterfly's but we'll see hopefully resume work on sunday as I have to take on a bit of work for my wallets sake have a good weekend

tyregeezer · Sep 3, 2024

Timing done, fitted vacuum pump, primed motor through oil filter until oil ran out of turbo feed, cam chain tensioners pumped up, put about 2L ish in, did fuel pump pulley and belt, and breather tube, turbo arrived now primed and fitted started fitting oil supply rocker covers tomorrow decided to use xf ones, just waiting for injector washers and egr valves had pre 07 fitted, now just remembering order and what needs to go in front and what behind

gstuart · Sep 5, 2024

Really coming along there nicely mate

In awe of how much is involved rebuilding an engine , my last rebuild was from a series 3 , even then I bought a short block and head was all done, then rebuilt it from there

Also saw some data the other day and pretty sure it said the 2.7 engine weighs 250kg , Christ a 1/4 of a ton, gulp

Bet ur getting itchy fingers to get on the D4 , also very jealous u have one

tyregeezer · Sep 6, 2024

Thanks mate, short block is the trickiest part to get right just take your time and be methodical
But I think doable for most people
Don't take notice of blogs that over complicate
That's what we have machine shops for
Yes mate with the box to lift in 300+kg
Wow D4 engine had a quote gulp , to dip block and clean, rebore, hone and meyle pistons-rings, crank test-polish £1200 can also say gaskets, seals and bolts round about £500 so not cheap to do but very satisfying and relaxing I find
As I said before get one and a stand and you have a great hobby mate all the best

tyregeezer · Sep 7, 2024

Copper injector seals came this morning so cracked on injectors in fuel system feeds then leak off pipes, started replacing wiring on left hand side, power steering, air conditioning, intercooler pipe work and a few other bits

tyregeezer · Sep 16, 2024

Done all auxiliaries bits and Bob's last weekend
Removed from stand fitted trigger wheel crank sensor and flywheel, fitted gearbox and turbo brackets, routing the wiring, last part was to fit cross over pipe
Grand tidy up next and get Discovery in refit within couple of weeks if work permits

gstuart · Sep 16, 2024

Looking good there mate and massive respect

bet u can’t wait to see all ur hard work come to fruition

tyregeezer · Sep 16, 2024

Thanks mate just tidying and finding all tools now Lol yes looking forward and as usual a little nervous but looking good

Discovery 3 Engine re-build

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