 | Home > My Defender > Time to get round to the rebuild....open diary with pics. |
 
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| Jimb1978 Member Since: 05 Sep 2012 Location: Huddersfield Posts: 808   
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Got to love a good rebuild thread
 2002 110 td5 |
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21st Nov 2015 10:55pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49  
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Managed to get a couple of cheeky hours in the workshop this morning, between phone calls.
I took some pictures for Shaggydog whilst my hands were clean. I finally managed to get the rest of the engine in pieces and realised I forgot a few parts, the camshaft bearings and the conrod bearings. and whatever that semi-circle rubber thingy is called at each end of the rocker arm. The thick gloop in the bottom of the sump isn't very impressive, the oil pump pickup is clogged with it too. Next job is to clean up the block and get it ready to receive the parts, I'll probably get as much oil off things as I can, to help keep the workspace clean(ish). The broken glow plug and the seized injector.  Click image to enlarge Coking in the manifold too. Click image to enlarge Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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23rd Nov 2015 3:31pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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I haven't forgotten you all, I've been too busy. The storms meant I had to do lots of tree work, then the festive season suddenly jumped out on me Argh!!
Anyway, Merry Christmas and a happy new year to you all. See you in the New Year with some new posts and pictures HB Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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19th Dec 2015 7:43pm |
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| CarMan Member Since: 29 Nov 2010 Location: Cotswolds Posts: 1853
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Pictures please  |
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19th Dec 2015 9:06pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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I'm back!
The time has come for me to get my hands dirty again. I started by removing the seized timing belt housing bolt that had sheered off. I heated it up to soften it, then bent it over by gently tapping it. It was then easily removed by tapping again anticlockwise. Click image to enlarge After that it felt like I did a lot, but didn't achieve much. I spent 2 sessions (yesterday and today) cleaning up the block and preparing it of painting. Before Click image to enlarge Despite a good blast with the jet washer, it was still quite dirty (this is the cleaner of the two sides). A series of wire wheels were used to remove the 23 years of baked on dirt and grime and the original gold paint, to expose the bare metal. I'm quite pleased with the result and if I hadn't already got the VHT paint, I would have seriously considered just clear lacquer as a finish. Click image to enlarge Care was taken not to score or mark any of the gasket faces, a scraper and a polishing wheel was used to clean them effectively. My next stage is to clean up the bores. There is about 1/3" of coke at the top, which I intend to remove and then give them a quick hone. Just enough to mark them, but not to take any metal away. After that I'll clear out the oil ways, blow through the dust and bits a final de-grease and then paint. A quick question, does anyone have any experience or suggestions on de-coking the pistons? Thanks, HB Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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3rd Jan 2016 7:59pm |
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| calum Member Since: 05 Dec 2014 Location: Aberdeen Posts: 46 
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To de-coke pistons I just left them standing crown down in some degreaser (I used astonish degreaser). Then any of the methods you've used to clean up the block will work equally well on the top. I used scotchbrite.
To clean out ring grooves, break one of the old piston rings in half and use the end where the split is to shift the worst of the crap then just use regular cleaning methods. Scotchbrite OK for outside of pistons too. I'd be surprised if your little ends need doing - mine didn't and the bottom end was ruined. Also worth considering carefully if you really need to do camshaft journals - inspect carefully first. Are you doing all the core plugs while you're in this far? I busted the glaze off the piston bores using a honing tool that fits to a hand drill. Gave excellent results. I used Millers engine building oil on all mains, big ends, journals and cam followers when assembling. It's like a syrup. Make sure you do the o-rings on the oil pump to vacuum pump shaft as they get old and brittle. A bit of disassembly worth doing while you're in there anyway. Also worth checking vacuum pump and cleaning up with very fine sandpaper. Fix wet and dry to a board and rub flat faces on it to tidy these up. The biggest problem I had with my whole rebuild was I did not use a new tensioner bolt and did not add thread sealant. I had a wading plug in and oil filled the timing case! Make sure you use thread sealant on the timing belt tensioner or idler bolts! I had all the structural alloy parts (not anything with moving parts like the fuel pump) shot blasted at a local coating place and they came up great. http://1drv.ms/1JskAD1 I fitted a complete new cartridge to the turbo. I bought new firenze nozzles for the injectors and had the pressures set up by the local diesel experts. Engine was absolutely fantastic after the rebuild, and once I sussed the oil leak it was also dry! Shame the same couldn't be said for steering box, gearbox or transfer box! Cheers Calum |
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5th Jan 2016 11:08pm |
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| calum Member Since: 05 Dec 2014 Location: Aberdeen Posts: 46
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Nearly forgot - biggest job was busting all the oil and coke deposits off of the back side of the valves! I also lapped the valves in manually but to be honest they were pretty good anyway and didn't take much doing.
Have you bought a full gasket kit? I guess you're doing valve stem seals too? If not I would definitely consider it at this stage. One other thing = when restarting leave the fuel solenoid disconnected at first. Wind over on starter until oil pressure light goes out. Then reconnect fuel solenoid and start up. Even after reconnecting the fuel solenoid it can take a while to start the first time: https://www.youtube.com/watch?v=cZqwHSmx9rU I shut it down straight away as my 1/4" socket set was about to vibrate off the wing and onto the road! Second attempt: https://www.youtube.com/watch?v=zSDosiNrJ4o Cheers Calum |
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5th Jan 2016 11:12pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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Thanks for that calum, quite a comprehensive bit of advice there.
I have got a full top and bottom gasket set, and will be adopting the 'while it's out have a look' policy. I decided before I started that this project was going to be all or nothing on the different vehicle systems. It was suggested to use a soda bath to de-coke the pistons, and I was very surprised at how effective it was at doing the job Click image to enlarge Most of the carbon deposits have now been removed, today I'll be finishing off the swirl chambers and then polishing. Once completed, I'll be turning my attentions to the head. I have a few problems with injectors sticking and glow plugs breaking up. Still, better than watching TV in the evenings... Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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7th Jan 2016 10:18am |
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| calum Member Since: 05 Dec 2014 Location: Aberdeen Posts: 46
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Good stuff. Full gasket kits don't normally come with one or two of the o-rings needed for the oil pump shaft. Not replacing this o-ring can lead to low oil pressure.
Top O ring ERR531 Skew O ring ERR532 Look 2/3rds the way down this page, or search for 'skew' for detailed pictures. http://seriouslyseries.createaforum.com/th.../mandy/15/ Cheers Calum |
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7th Jan 2016 7:31pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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Wow, one thing that I didn't anticipate was how long it would actually take to clean up the parts. It's tedious, boring and laboursome. But now that they're on the way, they are looking good.
I was advised to soak the pistons on soda water to loosen off the carbon, it was a lot more effective than I thought it would be. Click image to enlarge(sorry for the wrong angle) I left them in a pan and boiled them on the workshop burner whilst cleaning up the head. I carefully scraped the deposits off and used a couple of snapped piston rings to clean out the channels. The Head was causing me hassle, there were injectors stuck and a couple of glow plugs had broken off at the element. Click image to enlarge It took a long soak (weeks) and persistent wiggling to get the injectors out, one of them tried to unscrew itself in the process. I tried to tap out the glow plug, but it just collapsed. So I file the tip off, and drilled the core out. This was to give the metal somewhere to go as it crumples, and not to cause it to jam in the head. I used another glow plug as a drift, and it was successful. The amount of carbon built up in the ports, especially the exhaust was surprising. I didn't have somewhere big enough to soak it all in, so I made a strong solution of soda water, blocked the valve holes with bluetac and poured it into the ports. it loosened it off a bit, and the rest was done by scraping and many hours with the Dremel. 
I moved on to porting and polishing, it's not finished yet but I'm pleased with the progress so far. Click image to enlarge I plan to skim the head once completed. The block was ready to paint before xmas, so I got on with it to protect the exposed faces. The red engine paint actually dried as orange, I was disappointed. I ordered some new paint (in Ferrari red) it may not be to everyone's liking, but that's why this build is described as 'personal spec'. A Defender Autobiography as it were. Click image to enlarge I have also done the exhaust manifold. The textured surface is difficult to clean, even with a sand blaster (could probably do with a better setup than what Ive got), so I found that it was quicker to just smooth it off with the grinder and some different grades of sanding discs instead. Click image to enlarge Click image to enlarge It was finished off with silver VHT paint and lacquer, looking much better than factory finish. Then it was cured using the trusty workshop burner. Click image to enlarge I might start rebuilding soon, I cant wait to finish it and get on with the next part; The gearbox(s) -although it is snowing right now, and the sledge needs 'testing' before the boys injure themselves on it..... HB Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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16th Jan 2016 9:37pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10728
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Great work HB, think its time you 'tested' the sledge out now
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16th Jan 2016 9:49pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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Thanks for the advice L110,
In the end, I managed to play in the snow and with land rovers! Click image to enlarge I'm not sure whether to call it mini me, or Land Snover.... 
Some may say I'm obsessed, I say it's the Wilkes brothers fault... HB Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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17th Jan 2016 5:03pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10728
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lol nice one HB
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17th Jan 2016 9:15pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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Hi all,
just a quick update. The head is just about done. It's been cleaned, injector and glow plug ports cleared, valves seals fitted skimmed and painted. The kitchen table was essential for the success of the valve lapping  , a job which takes much longer than you think!
I put tape on the newly skimmed face to protect it from paint and scratches until its ready to be fitted. Click image to enlarge Click image to enlarge At this stage, I had a real urge to paint the valve springs too. Luckily sense prevailed, no-one would see it and there would probably be bits flaking off and blocking essential oil ways and jets.... The block has had the camshaft bearing fitted and is at the motor engineers waiting to be line bored. I'd like to get on with other things, but my workshop has limited available space and I have already filled it with bits of engine! I can do some more cleaning and probably will, but the items on the 'get round to it' list seem more interesting at the minute! As soon as the block comes back, I'll be starting to put it back together. HB Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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3rd Feb 2016 11:19am |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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It's back! The block has been at the Motor engineers having the camshaft bearings line bored. They took pictures of it on the machine for me too. Tomorrows weather has meant that work has been postponed, so I plan to grab a session in the workshop and start putting it back together again. Yay!
Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first!
http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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5th Feb 2016 9:56am |
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