Discovery 3 Engine re-build

gstuart · Oct 6, 2022

tyregeezer said:
Hi all crankshaft passed its crack/straightness check all good, journals just lapped still standard mains and big ends all in £130. Valve seats all now lapped will clean them today waiting for valve guide seals and gaskets so going to catch up with checking, cleaning and maybe fitting other parts

great news and bet ur well pleased u don’t have to replace the crank

massive credit to u my friend and can feel ur pain after lapping all those valves , indeed does seem to take a lifetime when having to clean everything up in the rebuild preparation

as a side note always remember when I rebuilt a few engines with the help of my dad , best one I enjoyed the most was on my old 2500 straight 6 triumph vitesse , my dad sent the crank and clutch to all be balanced , then fitted a full janspeed exhaust , was amazed how smooth it was on tick over and acceleration

other triumph we had was a 2500 Pi , what a bloody nightmare that was to get right

tyregeezer · Oct 6, 2022

Hi all yes happy lapping done (easier with tiny valves) waiting for valve stem seals and gaskets most parts now cleaned. Next tricky job is fitting collets I can't get on with those tools, found the easiest way is with a screwdriver using oil to create some suction to hold collets on valve. Started re-assembly of parts not in way, also started stripping turbo ready for new cartridge, vane all free the rings and vane are what seizes these are free more cleaning and sorting parts tomorrow work this evening

tyregeezer · Oct 7, 2022

Started re assembly today put one set of inlets in very fiddly valves quite deep will take some pics found best method is tiny bit of grease on a small screwdriver stick the collet on and fiddle it on. Gaskets and head bolts turned up today fia hope to finish heads over weekend fit Monday

gstuart · Oct 7, 2022

Great job mate and indeed found getting the collets back in very fiddly , use to use a magnet and screw driver, then after they were all refitted would tap each valve with my face out the way and sure as sure some of the collets would spring out, lol

don’t know if u do the same but I’d then tip the head up and pour some fuel down each port to see if any would come out of the inlet / exhaust valves , might have to re grind a couple after seeing a few drops of fuel pass the valve seat

talking of cyl heads saw this video the other day ref BMW heads , omg looks a nightmare

great u can just replace the cartridge , will u fit a new actuator and then send it away to be calibrated or just the cartridge plse

Thks again for sharing the progress mate as it’s most appreciated

gstuart · Oct 7, 2022

Plus forgot to ask, ref new hydraulic lifters, do u squeeze the oil out and allow the engine to refill them or leave it in there please

hope u didn’t mind me asking as was just curious, many thks

tyregeezer · Oct 7, 2022

Hi mate I use brake cleaner to check valves it finds any little gap but usually before lapping take your time you can kind of tell with your eyes. the turbo cartridge will just be switched, original actuator, have done this before with no issues so far surprisingly d3s seem to come to life even after standing for a year or more when the battery is connected it won't know anything has ever changed if you see what I mean. I pump up my lifters with my fingers in oil they should go solid, or I replace you can press a little oil out carefully in a vice protected with ali leaving a little movement you can't overcome the motor with your fingers, check before by compressing feeling for stickiness or gritty feeling this is how I do it you get a 3-5 second tickety tic on first start up so I stuck with this method

gstuart · Oct 8, 2022

tyregeezer said:
Hi mate I use brake cleaner to check valves it finds any little gap but usually before lapping take your time you can kind of tell with your eyes. the turbo cartridge will just be switched, original actuator, have done this before with no issues so far surprisingly d3s seem to come to life even after standing for a year or more when the battery is connected it won't know anything has ever changed if you see what I mean. I pump up my lifters with my fingers in oil they should go solid, or I replace you can press a little oil out carefully in a vice protected with ali leaving a little movement you can't overcome the motor with your fingers, check before by compressing feeling for stickiness or gritty feeling this is how I do it you get a 3-5 second tickety tic on first start up so I stuck with this method

thanks mate for the great explanation, alas I think the first time I heard about the hydraulic was in an old rover V8 , think it was that engine ??

know what u mean ref the valve seats , trying to remember what my dad used before installing the valves, wonder if it was the blue paste that he smeared on the valve seats, apologises as was a few years ago, lol

u saying that my disco wasn’t started for over 5-6 x months due to me having it in bits when I was trying to find all the turbo intake errors , fixed one air leak then found another , that’s when I decided to buy all new silicone intercooler hoses and T bolt clamps , certainly resolved the air leaks that’s for sure but my god that plastic air inlet pipe was a complete and utter basterward , along with the short turbo hose

went up the road yesterday and gave it a short burst if acceleration, omg the thing was like s**t off a shovel, the improvement was quite dramatic of how it use to be , assume that’s because I now resolved the intercooler air leaks,

plus I fitted the D4 Map sensor , noticed it has a large hole which I’m wondering if that’s to reduce them blocking up

shame ur not closer as would have really liked to have popped in to see the engine out etc

thks again mate for the continued pictures , keep up the awesome work and have a great weekend

tyregeezer · Oct 8, 2022

Yes I'm not sure that must fit a battery within five mins is true had several been flat for a year before i got them and they all came back to life. Ha Ha takes off like a scalded cat that is what attracted me and made me buy one 2.7 t and almost does wheelies, maybe this adds to crank issues? especially if not serviced but am finding a few myths about this motor too I try to keep it simple, happy to see your back on the road and having fun.

gstuart · Oct 8, 2022

tyregeezer said:
Yes I'm not sure that must fit a battery within five mins is true had several been flat for a year before i got them and they all came back to life. Ha Ha takes off like a scalded cat that is what attracted me and made me buy one 2.7 t and almost does wheelies, maybe this adds to crank issues? especially if not serviced but am finding a few myths about this motor too I try to keep it simple, happy to see your back on the road and having fun.

cheers buddy and indeed really pleased it’s back on the road, don’t mind admitting there’s a few times I seriously struggled, but just had to take my time by chipping away at it in small doses

plus think ur exactly the same in being ur own worst enemy with regards to ensuring things are just so , i even went to the length of getting a wider stainless steel genuine jubilee clip on the air intake pipe , as when I removed it I had noticed traces of oil in that area which indeed indicated it was leaking air , plus that short turbo hose, hardest bit was doing the clip up, was an excuse to get a cordless ratchet, lol, got the long neck one , wow that seriously made life a lot easier as just used some long extensions , also really like the slow speed ,

plus got some UJ crow’s feet and some insulation for the underside of the plastic engine cover, convinced it’s made it quieter , have enough left to do under the bonnet

also found refitting the egr pipe clips a lot easier using the pliers in the picture , left the pipes on for the mot but fitted blanks on the other end

did have a result in finding a deep centre console tray , funny how the simple things make u happy , lol

hope ur getting on ok mate and have a good weekend

tyregeezer · Oct 8, 2022

You have lots of nice things top of my list is a degreasing tank would like one of those cabinet type pressure jet thingies but their quite expensive. dropped off the block this morning and picked up the crank, finished assembling one head but then had a bad evening escorting drunken people out of a supermarket (work) quite a busy evening must be a full moon. Been looking at shells today going to ask your opinion as there seem to be a few differences going to crack on over weekend

gstuart · Oct 9, 2022

tyregeezer said:
You have lots of nice things top of my list is a degreasing tank would like one of those cabinet type pressure jet thingies but their quite expensive. dropped off the block this morning and picked up the crank, finished assembling one head but then had a bad evening escorting drunken people out of a supermarket (work) quite a busy evening must be a full moon. Been looking at shells today going to ask your opinion as there seem to be a few differences going to crack on over weekend

many thks, I do try and buy the best I can afford

must confess looked at the degreasing tanks from machine mart , did think about getting one a while back but to be honest couldn’t really warrant one for the amount of times I would use it

these guys are very good regarding parts , plus very helpful on the phone as well , assume ur just need STD shells

https://www.advancedfactors.co.uk/crankshaft-pistons--rings-1613-c.asp

or there’s turner engineering who are reknowned engine builders who have an excellent reputation

https://www.turnerengineering.co.uk/land-rover-27-tdv6-engine-parts-c102x3005712

if I remember rightly King shells are supposed to be decent, both companies sell them, others I’ve heard of are timpkin, or do u have other makes in mind plse as of course know ur extremely knowledgeable

Oh wow that sounds a lot of fun, NOT, lol

hope all goes well my friend and the above is useful to u

gstuart · Oct 9, 2022

Funny u talking about the full moons, there’s one today the 9th called hunters moon

https://www.sciencefocus.com/space/hunters-moon/

The virtually-full Hunter's Moon will rise in the east at 6:28pm, on Sunday 9 October (as seen from London, UK – times will vary depending on location). The Sun will set around 10 minutes earlier at 6:20pm, meaning the Moon will rise into a gradually darkening sky. The full Hunter's Moon will set in the west at 7:43am the following morning, 10 October.

tyregeezer · Oct 9, 2022

Hi mate from what i have been reading king brand are rated the highest but after watching an utube or two and doing a bit of research there is a significant difference in the oil hole between brands fia being smaller for example but same size as oem I just wondered why really? bought mains cap bolts from turners will have a look see what they have, there's definitely something in the full moon thing nutter central last night. Back to sanity now more valve assembly today and cleaning rocker boxes will post some pics later

tyregeezer · Oct 9, 2022

Hi all built up l/h head today valves in and head on also new cams that were fitted to the original head all gone quite well, used Loctite flange sealant on outer cam caps (I did smooth with a brush after picture) also cleaning gunge out of rocker covers and other bits @gstuart explained slightly wrong last night sorry relaxed to quickly after a bad night, ( wild turkey 101) when they come new, they are solid this is when I give them a squeeze if an old one is solid give it a squeeze its either seized or moves nice and free as long as it's not gritty once the rockers are fitted I give the a press like to feel a little movement they pump up in seconds sorry mate, r/h head tomorrow and more cleaning

gstuart · Oct 10, 2022

Fantastic job there mate with the progress

must confess all I done today was put a new blanket into candy’s bed and tided up my desk , got one of those memory foam bedding for her , with her getting older thought it would make it more comfortable for her , plus found the dashboard panel that has the extra bottom bit , cleaned up some of the tools, a,img with getting some ew drawers which must confess really pleased with

bet u can’t walk to start in getting the timing belts on etc

once again thks so much for sharing such an interesting project

Few pics for u

tyregeezer · Oct 10, 2022

One day I hope to be that organised mate. Have one side of motor almost done and other side as far as I can go was missing a set of bolts on my order on way now, forgot to order conduit also cam bolts hoping to fit in a week or so

gstuart · Oct 11, 2022

tyregeezer said:
One day I hope to be that organised mate. Have one side of motor almost done and other side as far as I can go was missing a set of bolts on my order on way now, forgot to order conduit also cam bolts hoping to fit in a week or so

lol, alas though my spare bedroom looks like a bomb has gone off, want to build another shelving unit , pic of the one I built , must confess well pleased with the blue drawer units, got some of those stick on labels , once I build the other unit will get some more of them , they do all different sizes/ no of drawers so can then build them up, plus thinking I’ll add a board in order for me to secure the drawers to it

plus over the moon with the tool cabinet I got , to be honest really need another seeing I’ve virtually filled this one up, amazing how many tools etc to collect over the years , got it last year and since then has gone up by another £250 , some of the new ones have sockets fitted so really handy for recharging ur cordless batteries

this was the one I got

https://www.sgs-engineering.com/stc...e-might-also-like&tmty=w&tmcv=45&tmcs=go2yy1b

these drawer units bolt on the side but blimey there a lot of money @ £240 a pop but suppose a lot cheaper than another large cabinet

https://www.sgs-engineering.com/stc4200s-side-locker-cabinet

Sorry I’m waffling as per usual, lol, awesome mate , so ur 50% there , massive credit to u my friend as I wouldn’t do the belts , mainly because I’ve not got the experience like ur good self

really enjoying the thread and following with great interest , see u have the metal intercooler pipe already fitted , still can’t get over what a night mare it was getting the bolts back that secure the plastic air inlet pipe

will u fit all new silicone intercooler hoses plse , plus was surprised when I found air leaks on the egr pipes that secured to the throttle body

thks again for the updates and awesome project hopefully ur bolts will arrive sooner rather than later so I can make some more progress

hope all goes well mate

tyregeezer · Oct 11, 2022

Hi mate really jealous now mate did you do the woodwork yourself? I'm a total dunce where woodwork is involved, been looking at exactly your toolbox sds since I bought their engine stand, my workshop leaves a lot to be desired, this spring I hope to start an extension, no space is my issue. Guess what the block at the engineers, the one that had the broken crank it passed its crack test and mains check A ok bores also checked out and have been honed all in cost £100 going to use the jaguar crank, it seems a lot more can be done to a tdv6 than I thought and at a reasonable price, gaskets and seals have been a surprise to me £250 plus with all bolts. will do some pics tomorrow all the best

gstuart · Oct 11, 2022

tyregeezer said:
Hi mate really jealous now mate did you do the woodwork yourself? I'm a total dunce where woodwork is involved, been looking at exactly your toolbox sds since I bought their engine stand, my workshop leaves a lot to be desired, this spring I hope to start an extension, no space is my issue. Guess what the block at the engineers, the one that had the broken crank it passed its crack test and mains check A ok bores also checked out and have been honed all in cost £100 going to use the jaguar crank, it seems a lot more can be done to a tdv6 than I thought and at a reasonable price, gaskets and seals have been a surprise to me £250 plus with all bolts. will do some pics tomorrow all the best

hi buddy

Many thks , indeed I did build the workbench myself , must confess was the first one I had built and just made it up as I went along, had a good few bits leftover so made up the corner blocks , don’t mind admitting my woodworking skills are a lot to be desired as it takes ages for me to do something ,must have taken me well over a week to do that bench , is all in 3 x 2 as found that was a lot cheaper than 4x2 and felt that would be a serious overkill, 2 x 2 being too small , last year bought 20 x lengths of 3x2 x 3 m so should be enough to do another one, this time will do some upstands in order I can screw some ply onto the back to fit some bin plates to hang them on

thinking of buying some more of those blue drawers , spare bedroom indeed looks like a bomb has gone off and don’t know where to start , did get some of those 1 ton sand bags which I’ll throw all the rubbish in then get a company to come and clear them for me, just found it easier that way

really pleased with the SGS cabinet and made a lot of difference , just drives me nuts when trying to search for things , understand where ur coming from when u start a project and then realise u have tools everywhere

that’s fantastic news and well pleased for u mate , seems the main issues with these are the shells spinning , don’t know if the new shells have tabs on them to prevent any way of them spinning

bet ur well chuffed as indeed over the moon for u as that’s a great price

really grateful for the progress mate and going forward goes to plan, credit to u in remembering where everything goes

have a great week my friend and thks as always

gstuart · Oct 12, 2022

Also just remembered that some have used shells for a Ford F150 Lion engine , think they have to be bought in pairs

Discovery 3 Engine re-build

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