Hi there all,
Landie newbie here looking for some advice and guidance from the experts amongst you! I've done some cruising around the forum but can't get all the definitive advice I'm looking for (that I can find anyway!).
I've got a 1999 Defender 110 hardtop TD5 (ex electric board) and I've got to do an engine out job. It's done 136k miles and thrown a bid end in number 2 pot
. To save time and reduce the risks, I've decided to go for a short motor from Turner Engineering (they're only 20 mins away from me, and Richard was very helpful with advice on initial diagnosis which at first I thought was a dropped valve). Also the clutch is starting to slip as well as a grumbling release bearing so time to get it all fixed in one go! Bearing in mind I'll be doing this on my driveway with limited shelter, I would be grateful for some hints and tips.
1. Is this a viable one man job, or is it really best with two? I'm an experienced DIY mechanic and have all the necessary tools (I think!). I've done a couple of engine out jobs in the dim and distant past (including a Jag XJ6).
2. I'm probably going to hire (rather than buy) an engine hoist - do I need a 1 tonne version or will a 500kg do the job?
3. From reading it seems it's best to separate & drop the gearbox first with the engine still in situ. Obviously it's heavy so should I do this from inside the cab maybe using the engine hoist through the passenger door?
4. Once I drop the gearbox, will the handbrake be out of action? My drive has a slight slope away so don't want it rolling away into the neighbour's TD5 90! I'll obviously be chocking it anyway.
5. As well as the short motor I'll be replacing clutch plate, pressure plate, release bearing, spigot bush, plus all gaskets, head bolts, injector wiring loom, and hoses. I'll check out the flywheel once it's out in the open and replace if necessary. The top end seems to be in good shape so don't plan on doing anything there - or should I?. Is there anything else I should do/replace while I have the engine out? Funds are fairly limited, hence the decision to do the job myself but don't want to cut corners if it risks future failures.
6. I already have the head off. It's obviously now easier to remove the bottom end without the cylinder head (I assume) but should I fit the head to the new short motor before putting back in the vehicle, or doesn't it matter?
7. Any things/tricks/gremlins to look out for when doing the lift/replace of the engine and/or gearbox?
Thanks in advance for your help - it'll be much appreciated!!