BennehBoy's D2 adventure

Engine stand turned up.

Engine rebuild in the house, Brave

It's the only way to be sure.

Bennehboy said:

Engine stand turned up.

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well that is big enough to hold the cyl head,when is the big one arriving.

Parts arrived from Turners, will hopefully get cracked on a bit later.

Bennehboy said:

Google so I don't incriminate myself in front of SWMBO

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This rebuild is very interesting, I do like that manifold but I do lknow the price butI will not tell Mrs Bennehboy

OK so got cracked on today with the strip down....

Took the weight of the engine with the crane and undid the passenger side engine mount completely, lift the engine up until I could pull that mount out, then jacked the gearbox up to support so I could wiggle the engine forward extracting the gearbox input pinion from the back of the crank. Then just a case of lifting the engine out, it only just cleared the skuttle panel with some persuassion - going to have to think hard about how to lift it back in with the head on....


Here's the hole it left, some oil in the bell housing:


Clutch cover and plate off the back of the engine:


Flywheel looks good still:


Flywheel off:


Mating gasket off:


Onto the engine stand, bolts where a bit too long so I put some oversize nuts at the back side


OS engine mount bracket and belt tensioner removed:



NS mount bracket and rotary oil housing removed:


Fixed guide off:


Stiffener plate and pump off:


Loads of crap in the pickup :/


One of the torx bolts rounded


Revealing the crank:


Wonder if a Cummins will fit in here.....

Some photos missing will upload later, but it's beer o'clock now.

First coat of red on DS of the block:


Probably needed a better clean down first, ah well.

did you replace core plugs whilst its out ,i would , you could fit engine back in without head and fit that once its in

jamesmartin said:

did you replace core plugs whilst its out ,i would , you could fit engine back in without head and fit that once its in

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No, the bottom end kit from Turners didn't come with any James - I'll order some in.

2nd coat - had a break between to go watch the tour de france pass through Hudders.

Bennehboy said:

It's the only way to be sure.

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sure thing ripley

back on topic-and what a great thread- what sealant will you be using on the core plugs?

hopefully only loctite

I'm not pulling the pistons out so not sure I'll change them tbh.

PS painted, first coat:

Earlier I mentioned that one of the torx screws had rounded which holds the oil pickup to the stiffener plate.

These are M6x20mm (Part no LYP101160 ) - is there any reason why I couldn't/shouldn't just replace these with hex bolts?

Main crank seal off, doesn't look like it had failed:

no but you can see where the seal has worn a ring on the crank,so possibly just a slight weep etc.

gemsdad said:

no but you can see where the seal has worn a ring on the crank,so possibly just a slight weep etc.

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Yeah good point.