Hi Peter , well done on a great imformative detailed issue . great pictures as you go along with continuous dialogue of descriptions of what your doing !!!!!! wonderful nice looking p38 with low mileage ,,, will follow this post avidly thru to completion and wish you well and every success in your project .... kind regards Mozz
 
mozz smith said:
Hi Peter , well done on a great imformative detailed issue . great pictures as you go along with continuous dialogue of descriptions of what your doing !!!!!! wonderful nice looking p38 with low mileage ,,, will follow this post avidly thru to completion and wish you well and every success in your project .... kind regards Mozz
Click to expand...

Thanks for that, but let's wait until it is running before we get too excited :) :)

Peter
 
+1
Regards the different colour rocker assemblies, my guess is one is not native to that engine?
The N/S bank has the colour of the later M62b44, which I think operates at a higher temp.

My second guess is it's aftermarket, therefore metalurgically contrary t'other side.
 
Yes, a Cuckoo in the nest is a possibility, but I've looked back through the big stack of bills, the last time the heads were touched was at 66k miles, we are at 115k now, so I'd have thought that any colouring would have been masked by now?

Difficult to tell, but a few months on diesel engine oil will clean that off.

Our Discovery V8 runs on 10W-40 semi-synthetic diesel oil and has done since we put the short motor in it during 2009.

After 45k miles it was as clean as a whistle inside:

HeadGasket3.jpg
HeadGasket4 (1).jpg
HeadGasket5.jpg


Peter
 
Another day dodging the rain:

One part we were waiting for was wrongly picked by LR Parts Centre. Dealer's label had the right number but the part label was totally different!

Marshalls were very good about it, wasn't their fault, replacement will be here tomorrow.

The recalcitrant exhaust manifold bolt on the driver's side rear, the last one at the back finally gave up and went in. Was being very careful not to get that cross-threaded!

Almost all of the water hose replacements are here, if we can get a full day on it we should be close to running tomorrow.

I spoke with Turner Engineering to see what the block requirement was for exchange, seems OK, just has to be a Thor block.

Peter
 
GEMS block has crankshaft pickup in a slightly different position to the THOR block. We fitted a GEMS block to our D2 in 2009, found out at the assembly stage that they were different.

The small alloy housing is/was available to convert, I have a new THOR housing but don't know if the GEMS one is still available.

Peter
 
listerdiesel said:
Always working to a factory time for the job, no allowances for cleaning of parts or investigating other issues,

Factory times are based on work carried out on new cars, no time for corroded fasteners!

Peter
Click to expand...
But no pride in doing a proper job,how long does it take to use a greaseater. Had one come back from a main agent because itwouldnt pass the emmision test, so it was our fault ??? Turned out the fitter/mech ??had left half of the old inlet manifold gasket on.
 
Here is the Thor crankshaft pickup housing, EIQ100020.

Rangie43.jpg


It locates on a roll pin through the hole on the edge, and is TIG welded in one spot to hold it in place.

Peter
 
tomcat59alan said:
But no pride in doing a proper job,how long does it take to use a greaseater. Had one come back from a main agent because itwouldnt pass the emmision test, so it was our fault ??? Turned out the fitter/mech ??had left half of the old inlet manifold gasket on.
Click to expand...

We took pride in our work when I was working on trucks, plus you were working on rather bigger and more expensive lumps, the DS14 Scania V8 diesel for example. You couldn't send out a heavy truck that was going to drive to the Middle East without being sure it was safe. Scania and Volvo were the most popular trucks for that run, LBT110 or LBT140, double drive rears and DS11 or DS14 engines. They were just changing to the GR860 range-change box when I was out there, the GS750 splitter box couldn't handle the torque of the V8.

Those of us who showed that we could be trusted to do a job properly were assigned the trainees, so we could pass it on. I went to Sweden for the Scania training, but I don't think the UK manufacturers were as interested, although Vauxhall Bedford did have a training school in Luton.

Long time ago!

Peter
 
Everyone wanted Scania once upon a time. They were the bees-knees. @tomcat59alan probably left half his DNA around the cab of one or another. :-/
 
Rain again!

Got out later in the day and started on getting some work done at last.

The wrong water pipe that goes into the lower inlet manifold had been delivered, and once that was fitted I could get the power steering and aircon pumps bracket fitted up.

The idlers were pretty good so I've left them for now, I've got bearings on the shelf, the earlier ones can be changed, later ones are moulded into a ribbed pulley.

There's a bit of work needed on the engine loom, mainly brittle sleeving and wrapping that has come adrift. The start cable needs a new ribbed sleeve as well, the existing one is well broken.

Peter

Rangie44.jpg
Rangie45.jpg
 
We actually have two!

Trouble is that they block access through the factory yard when they are erected.

We did use one extensively when we did Rob's 109" Safari chassis, but that wasn't as big or as bulky as the Rangie.

Peter
 
Lots of bits and pieces today, nothing worthy of a shot, got both rocker covers set up with the new gaskets tacked on with a bit of RTV and left overnight with some weight on them, gaskets were slightly small through shrinkage of the material, and springing off the covers at a touch.

Checked both idler pulleys, bearings sweet enough but I took note of the numbers in case I need to carry spares, I think they are the same as the Discovery version. 6203DDU and 6304DDU, both shielded:

https://simplybearings.co.uk/shop/p...ove-Ball-Bearing-20x52x15mm/product_info.html

https://simplybearings.co.uk/shop/p...ove-Ball-Bearing-17x40x12mm/product_info.html

Coil pack in place but not tightened down as it needs the upper inlet manifold in place first. Two bottom bolts in place. On the Discovery they are almost buried, but a bit more room at the back of the Rangie engine bay.

Saturday looks like a good day, rain in the evening.

Got one rocker cover screw missing, which corresponds to a misplaced rocker gasket spacer and damaged gasket. Might have one in the spares box.

Peter
 
More work done today, rocker covers fitted, new plastic water pipes from header to radiator and to throttle body heater.

Throttle body heater is a new one, waiting for the throttle body istself to come back from being skimmed.

Upper inlet manifold is on, got to hook up the plug leads in place and finish tightening the coil pack bolts. The cross-threaded lower bolt on the coil pack has been rectified, and the small M6 stud that carries the metal water pipes on the offside of the inlet manifold has been removed, cleaned up and refitted the right way around with a spot of Loctite.

New belt tensioner fitted yesterday, genuine Dayco at a very good price on fleabay.

Got to get underneath and fit new lower hoses and new thermostat tomorrow.

Looking OK, nothing in the way of a showstopper so far.

Progress is not as quick as I'd like, but weather and medications conspire against me :(

Peter
 
Last edited:
On the case....

Decided to change both idler pulley bearings, we had new ones on the shelf for the Discoveries, one benefit of running the same engine.

Next job is to pull the thermostat and old hoses out, then once the new stuff is in place I can refit the pulleys and fan etc.

Then the top front inlet manifold after it has had a clean up, then the throttle body.

Peter
 
Last edited:
Rain again, but carrying on between the showers.

Lost one of the new hoses somewhere, but good progress otherwise.

Peter
 
'Lost' hose wasn't ordered! my bad.

Mind you, £60+ for a composite heater hose is going some: PCH000910.

Ordered that this morning, sun is out so hopefully can get some time in today, in between work calls.

Peter
 
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