Aaron's 90 rebuild (round 3)

The shells were certainly ready to change, but I don't see any serious grooves or roughness,.
Looking at them and , the bores this looks like a well use engine with honest wear and tear..
What about the crank shaft journals are thet OK do you have a way to measure the to check if they are still nice and round?

Al2O3 said:

The shells are worn, all right. How many miles did it have on the clock?
Looking forward to watching the rebuild

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Good to hear it, should be plenty of pictures as usual
And mileage, the clock shows 80k or something silly, not sure what the real mileage is, but quite high one would guess

raywin said:

The shells were certainly ready to change, but I don't see any serious grooves or roughness,.
Looking at them and , the bores this looks like a well use engine with honest wear and tear..
What about the crank shaft journals are thet OK do you have a way to measure the to check if they are still nice and round?

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Thankyou for your thoughts Ray, you have much more experience in these type of things than me.
The crankshaft journals I have a micrometer to check them with, but I haven't gotten as far as that yet.

You might be pleasantly surprised when you mic the bores , have seen big mileages without much wear in bores

Just been looking at your engine stand Aaron. I've got the same one myself but I haven't dared put the engine on it yet. I don't need to yet but the thought of the weight of the engine hanging off 4 bolts is freaking me out. Mines a series 3 petrol so I don't know how engine weights compare.

tacr2man said:

You might be pleasantly surprised when you mic the bores , have seen big mileages without much wear in bores

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Fair comment I have heard similar quite a few times, only time will tell for me, hopefully get on with it at the weekend.

LincolnSteve said:

Just been looking at your engine stand Aaron. I've got the same one myself but I haven't dared put the engine on it yet. I don't need to yet but the thought of the weight of the engine hanging off 4 bolts is freaking me out. Mines a series 3 petrol so I don't know how engine weights compare.

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Ah, yes, I would agree with you their Steve, I thought the same thing, seems solid enough once bolted too it, rolls around nice and easy etc..
Stand is rated to 450kg, don't think the engine fully assembled weighs that, so should be fine in theory, might just be us being slightly cautious having not used them before.
Doubt their is much between the two engines either bud, the petrol might be a nacker lighter than the doozle, but still well within limits of the stand

Slightly cautious or slightly sensible. Doubt your feet or lower legs would make a very effective engine stand. Safety first!

I don't think a 200tdi is as heavy as a 2.25 petrol. a 2.25's cylinder head is bloody heavy!

Well it doesn't much look like I will be getting anything done on the LR this weekend
On garden projects for at least the next couple of weeks, the plan, a new patio, well extend the existing one.
So I had 4T of stone delivered on Friday ready for the weekend, it wasn't even dug out yet
Had a decent day at it yesterday, mostly dug out, just got to work out where the path off it is going and dig that out, but by the end of today I should have it all dug out, stoned up and wackered ready for the slabs next weekend.
The quicker I get this done the better really, mind you, their is loads that we need/want to do before the end of summer

That's frustrating, but a good job done at home. It's nice to do stuff for your parents.
I'm not getting anything done for a better reason. The Mrs has booked a holiday in Rome, so we are off in an hour. I'm feeling a bit guilty cos all I can think about are the jobs I want to do on the Landy. It's so close to being ready for the MOT I reckon. Crazy thoughts, I know. If it was in the middle of the project I'm sure these thoughts would't be in my head. Just want to get it on the road I think. Big kid really!

Well your lucky to be having a holiday that you can be keen to get back to something when it's finished.

Looks like you've been busy the last few weeks bud, I've not even thought about mine. Just getting back into it now at last. I have a question about your engine crane. It looks similar to those on ebay that claim to lift 2 tonne and are about £130 delivered to your door. If so, are they any good? Yours seems to have done it's fair share of work, and if it's good enough to hang a 6bt off then I may invest.

If you've nowt to check the bores with, I used a new piston ring and feeler gauges, you can check 'ovalness' by trying to insert gauges between the ring and the bore at various depths and points on the circumference. Can also check wear by seeing if the ring gap changes at different depths... Probably not very scientific but it will give an indication.

Al2O3 said:

That's frustrating, but a good job done at home. It's nice to do stuff for your parents.
I'm not getting anything done for a better reason. The Mrs has booked a holiday in Rome, so we are off in an hour. I'm feeling a bit guilty cos all I can think about are the jobs I want to do on the Landy. It's so close to being ready for the MOT I reckon. Crazy thoughts, I know. If it was in the middle of the project I'm sure these thoughts would't be in my head. Just want to get it on the road I think. Big kid really!

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I don't mind doing it to be fair, I'd just rather be spending the time elsewhere for obvious reasons
I'm sure we're all the same and wanting to get them back on the road mate, and I'm sure it will pass the MOT with flying colours.

Discokids said:

Looks like you've been busy the last few weeks bud, I've not even thought about mine. Just getting back into it now at last. I have a question about your engine crane. It looks similar to those on ebay that claim to lift 2 tonne and are about £130 delivered to your door. If so, are they any good? Yours seems to have done it's fair share of work, and if it's good enough to hang a 6bt off then I may invest.

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That is exactly what mine is bud, a cheap ebay jobber, bought it 5 years ago and has done me well since, including the 6bt swinging off it more than once, which if I'm honest I didn't have much faith in it the first time I lifted one, but it managed it with ease.
Would definitely buy another if this ever broke.

Bennehboy said:

If you've nowt to check the bores with, I used a new piston ring and feeler gauges, you can check 'ovalness' by trying to insert gauges between the ring and the bore at various depths and points on the circumference. Can also check wear by seeing if the ring gap changes at different depths... Probably not very scientific but it will give an indication.

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This is indeed what I ended up doing I was going to buy a bore gauge but after much thinking I couldn't really justify.

Well it's probably about time I updated this thread, I have been doing bits and bobs over the last couple of weeks, I just haven't been able to upload the photo's as I had reached the photobucket storage limit, and have only just got round to opening another (I already had 3 )

First up I cleaned and painted the block..



And my parts washer turned up, it does a good job of cleaning stuff up and a damn sight quicker than my usual method, I just wish I had bought a bigger one.
I bought a little one for ease of storage, as I haven't room in the shed/garage to fit a floor standing one, but isn't really big enough for a lot of stuff, so I guess I can't really win either way.









Cleaned the pistons up with it.





And pistons back in the block, did as Ben described above and decided not to go down the re-bore route, whether I have made the right decision or not time will only tell.



Cleaned and painted a few brackets and what have you.





Yesterday I finished up cleaning all the ali engine parts, cylinder head went in the parts washer (well the best it could)



And then stripped of valves, injectors etc..



I then spent several hours sat masking parts for paint.







So this morning I got up early doors to get them all in paint, I had wanted to get them done Saturday evening, but people where still in their garden at 9pm so I thought best not too.
Would have looked alright just left as they was really, but I dunno... something came across me to say bugger it and paint it all..










And a few more bits and bobs that where cleaned/painted today.







And that's it, all upto date, might have some progress next week, but maybe not, still got this patio to do.
Was going to do it this weekend, but I just never got organized as I'd been feeling terrible all week and never sorted a mixer out.
But I did organize the stuff to be here, and that was one of todays jobs and got it all loaded up ready to go for when I do actually do it.

You're on to your 4th photobucket account! Mines only 14% full. I estimate about 1300-1400 pictures and some short videos.
Anyway, the engine is looking great. Well done, mate.
When I see your engine builds it does make me wonder if I should have stripped and painted my engine. Something for the future, perhaps.

Well a little bit more progress was to be had on Sunday, and got the paving finished up on Saturday, although tonight's conversation was about a path down the garden, so I guess the job just got bigger once again..

First job was to get the ladder frame, oil pump and sump back on.



Got a couple more bits and bobs bolted on.



And then moved onto the cylinder head.
New valve seals being installed, I found a gentle tap with an 11mm socket worked well..



Head on and torqued/angled down, thermostat housing fitted along with timing case.



Manifolds, push-rods/rocker assembly, fuel pump and a few other bits and bobs fitted.
And that is where I am upto and where I called it a day, not sure what the plan is this weekend is, if it's raining I'll be hiding in the garage finishing the engine, if not I'll likely be digging.. Boo!

WOW. It's a thing of beauty, Aaron.

Al2O3 said:

You're on to your 4th photobucket account! Mines only 14% full. I estimate about 1300-1400 pictures and some short videos.
Anyway, the engine is looking great. Well done, mate.
When I see your engine builds it does make me wonder if I should have stripped and painted my engine. Something for the future, perhaps.

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Could be your next project, a spare engine
And the photobucket thing is likely because I use the free space up and then don't want to pay the subscription to get more storage. It says you get some more if you download the mobile app, but I don't do any of that fandangled stuff on my phone

Al2O3 said:

WOW. It's a thing of beauty, Aaron.

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Cheers mate It certainly looks better than it did.

aaronmorris said:

Could be your next project, a spare engine
And the photobucket thing is likely because I use the free space up and then don't want to pay the subscription to get more storage. It says you get some more if you download the mobile app, but I don't do any of that fandangled stuff on my phone



Cheers mate It certainly looks better than it did.

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You should put the app on your phone mate, It's great for getting your photos up without fannying about with leads and such, Best not auto uploading as you have no control where they go that way.

Had another couple of hours in the garage tonight, the first job was to get the engine off the stand, I didn't much like it sat on their the more I was bolting stuff too it, and no need to turn it over now, so off it came.
Got the glow plugs, injectors and lines back on, drilled the holes out on the engine mounts and got them bolted on too.



Pressed a new rear crank oil seal in using the water pump pulley to get it started, flywheel housing fitted, flywheel/clutch and starter motor and that was it for the night.
More tomorrow if I've got the energy, I couldn't tonight after concreting this morning , but I need to get things flowing again.