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BaronDefenders



Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 899

United Kingdom 2004 Defender 90 Td5 CSW Santorini Black
Overhaul
Just wondering if people can give me some advice please? I’m planning on doing a rebuild of my 90 in the summer and part of that will be overhauling the engine. Everything is running perfectly but by then it’ll probably be on around 160k and I think it’s worth doing whilst the engine is out. At the minute I’m planning to do: seals/gaskets top to bottom; oil cooler kit; water pump; starter motor; oil pump sprocket bolt; GORE coolant housing; FPR; injector harness; and maybe an AMC head. I don’t think the head has ever been off and the exhaust manifold has never warped. I’ll be getting a new turbo from CR Turbos eventually and I’ll sort an AlliSport manifold as well. Is there anything else you think is worth doing? And is it actually worth upgrading the head to an AMC one? Cheers! Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders
Post #815364 16th Feb 2020 11:02am
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Mash



Member Since: 09 Feb 2015
Location: Guernsey
Posts: 1674

Guernsey 1998 Defender 90 300 Tdi HT Nato Green
If it’s that apart, check the dual mass and possibly replace, new clutch obviously, the removal will give you access to the rear crank seal so you can do that. You really can go mental but if it isn’t broke why spend the time and money, some things like clutch etc do make sense but pulling a head off if it has no problems ? I would leave it and just do it if something happens.

When Buggsy had an engine swap I did the oil pump sprocket bolt, rear crank seal, clutch pack, new loom, and that was about it, when she started to be difficult to start I did the injector seals with the engine fitted no problems and when she sprang a leak I could do the fuel rail pipe easily enough also. 90 wolf - Jasmin http://www.defender2.net/forum/topic39408.html
90 V8 - Maggie http://www.defender2.net/forum/topic42564.html
110 TD5 - Buggsy http://www.defender2.net/forum/topic59029.html
52HG25 lightweight https://www.defender2.net/forum/topic72342.html
D3 Hse - Fiona
Capri 2l S - Anna

Think I might have a problem............
Post #815369 16th Feb 2020 11:12am
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BaronDefenders



Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 899

United Kingdom 2004 Defender 90 Td5 CSW Santorini Black
Yes clutch and flywheel are definitely on the list. I don’t think they’ve ever been changed.

I do agree with the “if it ain’t broke don’t fix it” mentality. It just seems like a good opportunity to replace anything that is easy to get to. The head is the main thing I’m 50/50 about. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders
Post #815370 16th Feb 2020 11:18am
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Retroanaconda



Member Since: 04 Jan 2012
Location: Scotland
Posts: 2656

Scotland 
It’s all fairly easy to get to even when the car is built up, so I wouldn’t do anything that doesn’t need doing. At only 160k it shouldn’t be anywhere near worn out unless it’s been abused.
Post #815372 16th Feb 2020 11:33am
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2181

2004 Defender 110 Td5 DCPU Epsom Green
Be interesting to hear from those that have an AMC head, see if its worth it. Instagram @defender_ventures
Empire Tuning - Agent
Post #815397 16th Feb 2020 12:57pm
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htb2



Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 532

Wales 
Mine was as only paid £100 for it including injectors, taken off one with knackered bottom end. Have had the landrover one crack twice, welded once and then replaced with the AMC one, due to diesel in the oil trick.
Post #815401 16th Feb 2020 1:11pm
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BaronDefenders



Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 899

United Kingdom 2004 Defender 90 Td5 CSW Santorini Black
I’d be interested to know what the likelihood of a standard LR head cracking is. You hear about it enough but obviously you don’t hear about the ones that haven’t cracked. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders
Post #815425 16th Feb 2020 2:38pm
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Fatboy Slim



Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

Wales 
Honestly, I've seen Td5s do 300k without the head ever being touched. If it was mine I'd stick a clutch,flywheel, water pump, injector seals and harness in it, change a few gaskets that are a pain in the butt to do when it's in and keep it going. You could spend thousands on it only for some kind of mishap to happen to it 100 miles afterwards......
Post #816590 23rd Feb 2020 4:49pm
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Fatboy Slim



Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

Wales 
160k is absolutely nothing on those engines
Post #816592 23rd Feb 2020 4:50pm
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Tommo



Member Since: 19 Dec 2013
Location: Leicestershire
Posts: 830

United Kingdom 2006 Defender 90 Td5 Black LE Java Black
As said above don't over think problems.
Post #816611 23rd Feb 2020 6:39pm
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BaronDefenders



Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 899

United Kingdom 2004 Defender 90 Td5 CSW Santorini Black
Thanks Fatboy & Tommo! I am cautious about removing the head and, as you say, it easy to go down the road of trying to plan for every possible failure, even if they never happen. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders
Post #816626 23rd Feb 2020 7:49pm
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othorton



Member Since: 22 Jul 2019
Location: London
Posts: 104

United Kingdom 2005 Defender 90 Td5 CSW Java Black
I'd do your clutch spigot bearing if the engine is out. TD5s are notorious for them whining and as a really cheap part it makes sense to replace.
Post #816848 25th Feb 2020 9:25am
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BaronDefenders



Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 899

United Kingdom 2004 Defender 90 Td5 CSW Santorini Black
Yes that’s on the list. Has been making a noise for a while. Whistle Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders
Post #816849 25th Feb 2020 9:34am
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