Going back in....
IMG_20140715_194017.jpg


And back out... used a socket to align the clutch and well erm it was a pants alignment, rembered I had the perfect tool in the shed.... (engine has grown legs)
IMG_20140715_201634.jpg


And it's in, YAY!
IMG_20140715_202149.jpg

Splendid work mate.
Have a 3.5 V8 in the shed looking for love.... If only I could spare the time...and money
 
So, slowish day so far - I've had to do some running about....

First job was turning the DS engine mount bracket the right way up, doh!

Refitted the PAS/water pump assembly - new o-ring used:
IMG_20140716_100410.jpg


Refitted the alternator and it's drain pipe:
IMG_20140716_100418.jpg


Some accumulated scrap:
IMG_20140716_101030.jpg


Moved onto the head, and fitted new stem seals after giving the head a bath in clean paraffin:
IMG_20140716_102622.jpg


Fitted new o-rings and copper washers to the injectors:
IMG_20140716_111733.jpg


Refitted the valve springs - if I never see another collet I'll be a happy man:
IMG_20140716_120036.jpg


New injector pedestals in:
IMG_20140716_120333.jpg


Lash adjusters refitted:
IMG_20140716_120752.jpg


Valve followers in:
IMG_20140716_121127.jpg


At this point I had applied hylosil 2000 to the cam carrier and fitted it to the head, but guess what, the last bolt to go in wouldn't grip - looks like I must've pulled the threads out of the rear right bolt hole when disassembling, the real bugger is I couldn't do a nice thread repair with my time sert kit because this hole sits inside a steel dowel. Fortunately a slighter longer bolt grabbed the threads!
IMG_20140716_164827.jpg


And hylosil on for a second time - bloody horrid stuff! I masked off near the cam journals so no sealant would squeeze into them:
IMG_20140716_170948.jpg


And it's on:
IMG_20140716_171959.jpg


Next I got the injectors fitted and the rocker on:
IMG_20140716_174652.jpg


Followed by the glow plugs:
IMG_20140716_175355.jpg


And the rear cam seal:
IMG_20140716_173235.jpg


FPR to fit shortly, had to do a 2 hr drive to pick up the 'correct' gasket and the oil strainer o-ring, tuners sent the wrong gasket, and they dont include the o-ring which I'd thrown away.

Once the FPR is on the next job is fitting the head to the block - I'm undecided about fitted the manifolds first, it will probably be easier to lift in but might make locating the head on the dowels a pain...
 
Tis a thing of true beauty Benneh. Why are you slinging it in an old Disco? It should be in an art gallery somewhere, or a posh blokes front room.

Others may disagree here, but I would be tempted to put the inlet manifold on the head before fitting it, as I don't have hands like Jimmy Savile.
 
Tis a thing of true beauty Benneh. Why are you slinging it in an old Disco? It should be in an art gallery somewhere, or a posh blokes front room.

Others may disagree here, but I would be tempted to put the inlet manifold on the head before fitting it, as I don't have hands like Jimmy Savile.

Too late, the head is on, piccies just coming....
 
My erstwhile helper couldn't get out from SWMBO's thumb so I had to crack on fitting the head single handed, bit of a fiddle but got there in the end....

Lowering on, gasket and dowels in place:
IMG_20140716_201258.jpg


ker plunk:
IMG_20140716_203421.jpg


Cam sprocket attached but not tightened, needed to just slightly fettle the bottom end to TDC and get the flywheel timing pin in place:
IMG_20140716_204447.jpg


Little bit of tooing and froing to get the timing recess lined up, but pin in job done - look how mucky that bell housing is!!!!:
IMG_20140716_205634.jpg


Head bolts in and oiled, ready to progressively torque up, 30nm, 65nm, 90deg, 180deg, 45deg:
IMG_20140716_211042.jpg


Head bolts torqued, no point showing a pic, head to timing cover bolt & nut on, and the fixed timing guide hex pin threadlocked and torqued.
IMG_20140716_214608.jpg


That's it for today, it's now beer'o'clock.
 
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Back at work today so won't get much done until the evening, put new quality (Mahl) filters in first thing, and might get the manifolds fitted at lunch time.

Hoping to start it up tonight.

IMG_20140717_100804.jpg
 
FPR on:
IMG_20140717_122000.jpg


Tensioner retaining bolt in:
IMG_20140717_122007.jpg


Cam sprocket bolts torqued up:
IMG_20140717_122010.jpg


New front cam seal on:
IMG_20140717_122140.jpg


New o-ring on vac pump oil feed, and the feed connected up after:
IMG_20140717_122204.jpg


Some new hoses:
IMG_20140717_124628.jpg

IMG_20140717_124634.jpg


Inlet manifold on, glow plugs connected, MAP connected, engine loom fed through:
IMG_20140717_140336.jpg


Loom connected to front of block:
IMG_20140717_140343.jpg


Crank pulley on with 'the big one':
IMG_20140717_142824.jpg


Exhaust gasket on:
IMG_20140717_144448.jpg


And the new manifold on:
IMG_20140717_144838.jpg


Turbo on:
IMG_20140717_152044.jpg


Aux belt on:
IMG_20140717_153640.jpg


Header tank on:
IMG_20140717_155021.jpg


Rad & IC back in and all hoses connected (flushed the IC, provent, and hoses with white spirit):
IMG_20140717_183938.jpg


Timing pins out, and the injector clearances set.... screw fully in then back off one turn and lock the nuts:
IMG_20140717_183946.jpg


You can tell when each cylinder is TDC by looking at these timing marks on the cam just behind the sprocket, when the lines line up with the lobe on the head you're at highest lift:
IMG_20140717_184236.jpg


Starter back on:
IMG_20140717_185241.jpg


Oil in and cam cover on. Coolant in..... to the car, and the owner...
IMG_20140717_194134.jpg


reaping the rewards of a **** part top hose - luckily I had the old bleed screw from the previous hose so drilled out the broken bit and refitted:
IMG_20140717_193236.jpg


And she's running:
https://www.youtube.com/watch?v=lrS5zA3_i8Y&list=UUXNbwoJBaP-xZGcQF4L0Pew
 
fantastic mate,well done for doing all the work correctly and letting us all view the re build pics.;):):)
 
Cheers fella, had some great advice from the folks on here, I'm much obliged.

Special thanks to Aaron for the loan of his engine crane,
Maaaargghhhk! for his valve spring compressor,
Sabredylan (from the D2 Boys Club) for his fancy torque wrench, ring compressors and flex hone.
JamesMartin for phone support :D

I'm really chuffed that I managed to get it done :)
 
Great to see it running. You must be chuffed!

Now you need to find another job to keep us hooked on this thread ;)
 
I have followed this thread with interest. Well done, a great story and very good to see the clip of the engine running at the end.
 
Thanks for a great re-build guide Benneh as well as a "music" video to go with it - sounds lovely.

I think there would be a good case for extracting the engine build from the rest of the thread and using it as a "sticky". A great source of reference for anyone wanting to re-build their TD5.

Well done!:praise:
 

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