Restoration

Technical questions and answers
disco2hse
Posts: 1559
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse »

It is an absolute pleasure seeing the application of old school techniques on an engine.

You can come and clean my engine anytime, I wish it looked like yours! :lol:
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Excited! 🤗
The goodies have arrived

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The refresh and upgrade is about to commence.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Today's mission was refit the cylinder heads. First I had to refit the valves in the LH head.

Smear valve stem with some Graphene...

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... insert valve through guide...

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... locate valve spring...

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... locate cap and compress the spring...

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... Insert split collet into groove...

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... and repeat

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That's the valves back in place

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Next up, check rocker arms are all aligned correctly and test fit.

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All looks good to go, so next step is refit the head. First off, fit new ARP head studs

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The advantage of the studs is that I will be able to remove the head if needed without having to replace the stretch bolts. Also, I can get rid of the outside 4 bolts that can be a cause of problems. The old bolts will be used to fill the bolt holes but only 20lbft (and loctite so they don't come out).

New composite head gasket...

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... Head on and torque up

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Now repeat for the RH head.

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And that's the heads back in place.

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I've got the new cam followers (Tappets) soaking in oil so will have to leave it for now. New camshaft, etc. tomorrow.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Got stuck straight back in today and fitted the new camshaft: Piper Torquemax.

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After smearing it with graphene assembly grease, slipped it in gently (phnarr phnarr) and checked turned nice and smooth. Fitted perfectly.

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Then put the new tappets in, all coated in assembly lube first. Then inserted the push rods.

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With the tappets and push rods in place, the rockers went on

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Of course, I forgot to line up the cam for timing first, so rockers back off and rotated cam to the correct position, I already had no1 piston at TDC, it was just the camshaft I forgot to rotate so no big deal.

New duplex timing chain and sprocket set on next

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Now the new Valley gasket and end seals...

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...and the new Edelbrock inlet manifold bolted on

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And left it there while I work out what to do next. Put the rocker covers on loose to keep the dust out.

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I did fit new crank oil seal in the timing chain cover as that will be going back on next.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Fish
Posts: 38
Joined: Fri Dec 28, 2018 7:35 pm

Re: Restoration

Post by Fish »

Making great progress there..

Finished the chassi fully just moved it asside and starting to clean my axles today for stripping down.. Just noticed the one of the front brake drums has bits missing and cracked.. will be checking out the disc brakes..

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

L. O. F Power spec clutch kit arrived.

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Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

More bits

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Waiting on one more delivery then should be able to finish off and put it back in.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Progress is not as fast as some seem to manage but nethertheless, progress there is.
Having received last few bits needed, back to work. Refitted the oil pickup strainer (was waiting on gasket) and put the sump back on.

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New oil pump gears in, packed with petroleum jelly and fitted new gasket prior to refitting oil pump

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Pump bolted on

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Now for water pump

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Water pump on

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I now had to wheel the engine on the stand out to the vehicle ready to put it back in. This was a sight harder than it sounds as it's rather heavy. I also had to negotiate workshop step and clear a path through to front of the 109. Tool cabinet and parts washer in the way so a lot of work. But to cut a long and quite boring story short, here's the V8 up front where I want it.

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Bolted the engine mounting brackets back on.

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The V8 now needs to come off the stand. I also have the rear crank seal to fit and the new LOF Power spec clutch.
Got the crane set up and bolted the leveller on.

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Took the flywheel off (don't know why I left it on in the first place) and gave it a scrub. There was oil contamination which presumably was the source of the bell housing contamination. Not clear if old and the crank seal had already been replaced or if the seal has been leaking. It may well have been the sump gasket leaking at the front. We'll find out when it's back on the road if I've cured the leak or not.

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Removed the old seal

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... and fit the new one

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Replace flywheel

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... and fit the clutch

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What do you think of my clutch alignment tool 😂

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So it's now all set to go back in. Beer time now though and I don't work on Sundays, so Monday job.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Milestone day today; the V8 is back in.

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Had to get help guiding it in place but managed to do it without too much problem, just a bit of wiggling to locate the primary input shaft splines in the clutch plate.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

User avatar
Geoff
Posts: 563
Joined: Sat Oct 29, 2011 2:21 am
Location: Leicester UK

Re: Restoration

Post by Geoff »

"A thing of beauty is a joy forever" !! :D
2 1981 Stage One 109 V8 SWs
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User avatar
Mik
Posts: 189
Joined: Wed Sep 20, 2006 10:25 am
Location: Denmark

Re: Restoration

Post by Mik »

Wow, that looks fantastic!
Michael
109" 1982 SIII CSW Stage 1 V8
109" 1957 SI Truck Cab
1991 RRC Vogue SE

Cliff4WD
Posts: 189
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

I've not been able to do much since putting the engine back in (ongoing chronic health issues). I did though spend a bit of time today making up some new brake lines.
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Off to London tomorrow for some long awaited covid interrupted, delayed tests, so hopefully I'll be able to crack on again next week.

I've missed this year's painting window so bodywork will be next year now, but plenty of mechanical and welding jobs to keep me busy
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

disco2hse
Posts: 1559
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse »

Super impressed with your work. Good luck with the tests. This virus has sure been an annoying interruption, but it is what it is. We have to adjust to stay safe, especially when we are unwell (me too by the way) :roll:
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5

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