Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21361
New engine time!
Mmmm...... might have had a busy day today.....
Some of you may know, that last March, I had a month of a nightmare car after 10 years of being a nice car, I had wiring issues, changed gearbox/TC/transfer box (just proactively), then the turbo went, replaced it then 1,000 miles later, big ends went... been a driveway ornamental storage area since end of March!
Recovery truck was an hour late grrrr!
Got it to James Holmes place in Bedworth for around 11ish, unloaded and in the workshop ready for a brew for 12.
Decided after taking the bumpers and arches off, that there was just too much crap from off road remnants, so we rolled it outside and gave it a good steam clean.
Bit of Pyrenees, Wales, England, Belgium, Germany, Luxembourg mud was deposited!
Rolled it back in and then methodically went through the bits that needed to be removed and disconnected. A few troublesome bits, like brake pipe and a body mount bolt that LR had used super torque on!
A bit of bolt head welding managed to transform the 15mm into a 23mm and provided enough grip to release the pesky blighter!
Once the body was separated, a little nervous to say the least!
We marked the floor where the tyres are and the tyres so we can hopefully align it back up again.
Rolled the now separated chassis out for another steam clean of the chassis. And it needed it!
So, that’s where we’ve left it after airing out as much of the water as possible.
Instalment 2 tomorrow.
This pic, is behind the rear wheel arch, signs of corrosion as this is where the mud builds up.
So engine off tomorrow and the cleanup of the chassis begins!!Bodsys Brake Bible
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20th Feb 2018 1:48 am
defector
Member Since: 23 Feb 2009
Location: Greater Manchester
Posts: 1420
I used a string / plumb-bob from one of the body fixing bolt holes to line up body with chassis fixing bracket.
Take lots and lots of pictures from every angle (Reminds me of Father Dougal with the camera), helped me loads when it came to put everything back in the right place - having said that i marked a lot of items with tippex i.e NSF turbo h/s etc. There are a lot of brackets
Sorry if i am preaching to the experienced.
Good luck with it.
20th Feb 2018 2:32 am
DSL Keeper of the wheelie bin
Member Since: 11 May 2006
Location: Off again! :-)
Posts: 72790
New "new" engine? Enjoy getting it fitted, just don't break this one.
20th Feb 2018 8:38 am
Bodsy Site Sponsor
Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21361
New service exchange engine from LR 👍
I won’t be doing the same mileage in it that I had done before, so hopefully last me a good many more years!Bodsys Brake Bible
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20th Feb 2018 8:43 am
Gareth Site Moderator
Member Since: 07 Dec 2004
Location: Bramhall
Posts: 26702
Crikey Bodsy, it’s another Triggers Broom! I admire your persistence with it!
That corrosion is interesting, is it behind the plastic wheel arch liner?
It’s getting to the point where older D3’s might start rusting away, might be a good opportunity to have a good look at her underpinnings and see what’s looking flaky so others know where to look.
20th Feb 2018 10:34 am
Philip1972
Member Since: 10 Mar 2017
Location: Gloucestershire
Posts: 1072
Bodsy wrote:
New service exchange engine from LR 👍
I won’t be doing the same mileage in it that I had done before, so hopefully last me a good many more years!
I love my D3 and as you know have spent a fortune on it, I think I too would be tempted to go down this route should my engine expire. It would still be cheaper than a D4 (which incidentally as you all well know could do the same )The happiest of people don't necessarily have the best of everything;
They just make the best of everything they have.
20th Feb 2018 4:57 pm
DSL Keeper of the wheelie bin
Member Since: 11 May 2006
Location: Off again! :-)
Posts: 72790
I was kind of lucky with the economic argument. Her dying so far from home, with the costs of getting her home plus what little she was worth, it was a done deal, she was going to make Norwegian Coke cans. Plus I brought back enough stuff from her to take the sting away. I wasn't going to fall into the trap of pouring good money after bad.
Had she died on the drive would I have done the same? Yes. Several thousand pounds to put an engine into a car worth only ~£3k would have been madness.
20th Feb 2018 5:05 pm
Bodsy Site Sponsor
Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21361
Day2 in the big brother house.....
Ok, Day2 in the engine swap process.
Engine out this morning, went all very well.
I couldn’t for the life of me work out why LR tell you to remove the front upper wishbone... engine is out and I still can’t work out why they tell you to remove it.
Glad I didn’t blindly follow the LR instructions! Would have taken longer I’m sure!
Anyway, old and new engines together, just the ancillaries and bits to swap over. Note the latest oil pump on as expected.
Oil dipstick pipe has a little kink in it, so the dipstick doesn’t come in and out easily. So on the lookout for another if I can in time.
James started on transferring the ancillaries this afternoon whilst I got busy with my new bestest friend, the Needle gun!
Made short work of the multitude of rust spots (mainly on the welds) around the engine Bay Area. More prep tomorrow and then get some paint on!
Air compressor tank should have been with the engine, but alas it didn’t make it! So supplier ordered another one and should be here tomorrow.
Today’s cash eater was the turbo, you can see some movement on the video, so thanks to Pete Bell @ Bell Autos (BAS) for supplying a new turbo en route for Thursday.
Probably won’t see that much difference tomorrow as most of the day will be spent on Chassis and body rust prep and cleaning. Resulting in the first coat of some new black stuff to help it last a few more years!
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21st Feb 2018 9:29 am
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15214
Good read, looking forward to tracking its progress.
Sounds like you'll have a 'nearly new' D3 by the end of it.
Fingers crossed you don't get any additional 'surprises' I was a normal heterosexual chap, but in these new woke awakenings I now identify as a Wardrobe.
21st Feb 2018 9:44 am
rockcrawler
Member Since: 31 Oct 2012
Location: Ferring
Posts: 2884
Hats off to you Bodsy, at least your car's getting younger as the years go on D3 Metropolis Bonatti Grey-Alpaca Leather-adaptive headlights-fridge-EGR blanking kit-Harmen Karden-Cruise-4x4 info enabled-Tinted Windows-Heated F&R Seats-Rosen rear Entertainment-LED'S everywhere -Smoked Side Repeaters-Rear Aircon-Vredestein Wintrac 4 Extreme-Puddle and Footwell Lamps-Stainless Steel Side Protection Tubes- NEW ASHTRAY ( thanks to dsd1036 )
Club BAS Remote FBH
Club MXS10 Ctek
Club Beanie Grill
Rear D4 Lamps
Geoff Gearbox Flush
BAS Remap
21st Feb 2018 9:53 am
stew 46
Member Since: 01 Dec 2011
Location: cornwall
Posts: 10146
Brings back some memories , good luck -------------------------------------------------
if you cant hold on dont let go , it ill come in handy for something even if you never use it.
D3 SE 05,
110 s wagon 300 tdi SOLD
h top transit
crew cab transit
transit connect
ausa dumper, muck truck .
peljob 2.5 digger
06 L 200 crew cab
21st Feb 2018 9:53 am
kevin-t
Member Since: 12 Nov 2007
Location: sheffield
Posts: 680
This is making an interesting write -up.
Cant wait to see the final bill. (for reference, for the future of the rest of us unlucky sods)
You said 3500 + vat for engine
???? ............ Turbo
?????............. ancillaries
??????........... Labour
Total??
Where do you source the engine? what if any warranty? ( I'me sure this will help some of us in the near future)
Good luck with it, you doing a good job.
21st Feb 2018 10:29 am
comedyharvey
Member Since: 04 Jul 2010
Location: Gloucestershire
Posts: 1727
Looking forward to ‘Bodsy’s Engine Swap Bible’, then we can all have a go
Amazing work, watching slack jawed just out of interest.
.Arthur.
Comedy was a horse, Harvey a dog, both sadly gone. Thought I was choosing a password!
Currently;
Discovery 3 HSE 2009
101" Fwd. Control 1976
Nuffield 10/90 Tractor (10/60 with 6 cylinder conversion) 1964
Previously;
Series III Lightweight. 1976.
21st Feb 2018 11:24 am
rrhool
Member Since: 28 Aug 2014
Location: Norfolk
Posts: 4400
Get that chassis galvanised while you can!Richard
D3 SE 2007. Triumph 2.5Pi 1973. Ferguson TEA20 1948.
Discovery 2 4.0 ES 2001- Gone
Discovery 1 300Tdi ES '95 - Gone
Range Rover Classic '79 - Gone
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