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Hi Guys. This will probably be the final update for this rebuild thread. Mark, What you said about the plating makes perfect sense. I will test it out when I have a few moments, also glad to hear that your Td5 is running again. The 300tdi is a great engine, you are lucky that in the UK you are...

I think 6 in total. Part number is ERC4996GEN

Thanks for all the nice replies guys. A lot happened since the last update so without further delay herewith the detail. The head was all torqued up and the time arrived to fit the rocker shaft. Before any adjustments could be made to the tappets I had to fit the injection pump, pulleys and...

After a slight delay, 2 week holiday :-), the engine is back in the Landy. I will post a proper update sometime this week

I figured out the story behind the "Genius at work" notice my wife stuck on the Landy. It is to remind her why the car is not running yet.......it also loosely translates into "do not bring coffee if sign is visible" for the kids :-) On to the important bits. Cleaned, oiled and fitted the...

I had a plastic mushroom top Mantec snorkel fitted to my TD5 which I think was excellent. At some point I'm going to fit the same to my 300tdi, I just love the look of it.

So after the post from theflyingvegetable I removed the rear timing cover and took the oil pump cover for a surface grind. The shop I went to failed to assist me with a surface grinder but did assist none the less. According to them the plate was flat enough to be installed but they assisted in...

Thank you for the kind words. I already fitted the cover plate and the rear timing cover but you are correct thus I'm going to remove the oil pump cover plate again and ensure flatness by means of surface grinding. Progress.....some of which will be undone :) It is important to refit the oil...

An hour and half of lapping with medium paste and look at the difference (compared to last pic in previous post) I've got a bit more to go and will finish it up this evening.

My dad had exactly the same fault on his 2004 TD5. As suggested by arboorman it was a loose connection on one of the yellow relays under the drivers seat (assuming rhd). Before this was fixed his Defender would often fail to start and the temp will be at max as soon as you turn the ignition to...

Not a big update but something worth posting none the less. I re-checked piston heights. With this in mind I believe a 3-hole head gasket would be in order. Some individual cylinder pics just because. Piston 1: Piston 2: Piston 3: Piston 4: One thing I did manage to do was to figure...

Haha....I like your idea! It is his bday today and when I spoke to him earlier he asked me whether the engine is assembled and back in the car....

I had a terrible flu over the last week, I'm just starting to show signs of life..... The engine is back in my garage and I'm planning to start the assembly process over the weekend. It is also my dads 65 birthday this weekend so progress will be slooooow.

Yip. Drain oil, remove sump, clean mating surface on sump and block with thinners......to ensure it is free of oil, clean it again. Use Loctite 5699 and follow instructions, I think it is a 2mm bead on the sump mating surface. Fit sump and follow the tightening sequence as specified in the manual.

I do not know whether there is a sediment filter on the Disco, if there is make sure you clean that out.

At last a bit of an update for you. Just have a look at how shiny the block is now It does look nice painted like that. According to the engineer he managed to offset ream the little-ends by the same amount he skimmed the block face. I can't remember now how much he said it was, either 0.10mm...

Welcome to the forum guys. +1 on the head gasket. Unless you are going to do the job yourself I can suggest a couple of reasonable places to get this sorted for you, all depends where you are based in SA.

In order to get back to std pistons I've had new liners pressed in after which they need to skim the block deck. During disassembly I removed a 2 hole head gasket, counting from the thinnest I'm on the second one of the available 4. The difference in thickness between the gaskets are 0.09mm thus...

Hi Mark, Thanks for the positive input, much appreciated. I trust your TD5 is running better than new after your rebuild. I had the injection pump overhauled by Bosch probably 1000km back who also checked the injectors, they said the injectors are still in good shape. My engine is currently...

I enjoyed your thread on the rebuild. You've done a brilliant job.