BennehBoy's D2 adventure

Made a mistake, drivers side engine mount is on upside down LOL!

Hope that's the only one.

Bennehboy said:

Going back in....

And back out... used a socket to align the clutch and well erm it was a pants alignment, rembered I had the perfect tool in the shed.... (engine has grown legs)

And it's in, YAY!

Click to expand...

Splendid work mate.
Have a 3.5 V8 in the shed looking for love.... If only I could spare the time...and money

ifloochies said:

Splendid work mate.
Have a 3.5 V8 in the shed looking for love.... If only I could spare the time...and money

Click to expand...

Cheers, I foresee a V8 RRC project in my future

So, slowish day so far - I've had to do some running about....

First job was turning the DS engine mount bracket the right way up, doh!

Refitted the PAS/water pump assembly - new o-ring used:


Refitted the alternator and it's drain pipe:


Some accumulated scrap:


Moved onto the head, and fitted new stem seals after giving the head a bath in clean paraffin:


Fitted new o-rings and copper washers to the injectors:


Refitted the valve springs - if I never see another collet I'll be a happy man:


New injector pedestals in:


Lash adjusters refitted:


Valve followers in:


At this point I had applied hylosil 2000 to the cam carrier and fitted it to the head, but guess what, the last bolt to go in wouldn't grip - looks like I must've pulled the threads out of the rear right bolt hole when disassembling, the real bugger is I couldn't do a nice thread repair with my time sert kit because this hole sits inside a steel dowel. Fortunately a slighter longer bolt grabbed the threads!


And hylosil on for a second time - bloody horrid stuff! I masked off near the cam journals so no sealant would squeeze into them:


And it's on:


Next I got the injectors fitted and the rocker on:


Followed by the glow plugs:


And the rear cam seal:


FPR to fit shortly, had to do a 2 hr drive to pick up the 'correct' gasket and the oil strainer o-ring, tuners sent the wrong gasket, and they dont include the o-ring which I'd thrown away.

Once the FPR is on the next job is fitting the head to the block - I'm undecided about fitted the manifolds first, it will probably be easier to lift in but might make locating the head on the dowels a pain...

nom nom nom :behindsofa:

Tis a thing of true beauty Benneh. Why are you slinging it in an old Disco? It should be in an art gallery somewhere, or a posh blokes front room.

Others may disagree here, but I would be tempted to put the inlet manifold on the head before fitting it, as I don't have hands like Jimmy Savile.

Maaarrghk said:

Tis a thing of true beauty Benneh. Why are you slinging it in an old Disco? It should be in an art gallery somewhere, or a posh blokes front room.

Others may disagree here, but I would be tempted to put the inlet manifold on the head before fitting it, as I don't have hands like Jimmy Savile.

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Too late, the head is on, piccies just coming....

My erstwhile helper couldn't get out from SWMBO's thumb so I had to crack on fitting the head single handed, bit of a fiddle but got there in the end....

Lowering on, gasket and dowels in place:


ker plunk:


Cam sprocket attached but not tightened, needed to just slightly fettle the bottom end to TDC and get the flywheel timing pin in place:


Little bit of tooing and froing to get the timing recess lined up, but pin in job done - look how mucky that bell housing is!!!!:


Head bolts in and oiled, ready to progressively torque up, 30nm, 65nm, 90deg, 180deg, 45deg:


Head bolts torqued, no point showing a pic, head to timing cover bolt & nut on, and the fixed timing guide hex pin threadlocked and torqued.


That's it for today, it's now beer'o'clock.

Back at work today so won't get much done until the evening, put new quality (Mahl) filters in first thing, and might get the manifolds fitted at lunch time.

Hoping to start it up tonight.

FPR on:


Tensioner retaining bolt in:


Cam sprocket bolts torqued up:


New front cam seal on:


New o-ring on vac pump oil feed, and the feed connected up after:


Some new hoses:



Inlet manifold on, glow plugs connected, MAP connected, engine loom fed through:


Loom connected to front of block:


Crank pulley on with 'the big one':


Exhaust gasket on:


And the new manifold on:


Turbo on:


Aux belt on:


Header tank on:


Rad & IC back in and all hoses connected (flushed the IC, provent, and hoses with white spirit):


Timing pins out, and the injector clearances set.... screw fully in then back off one turn and lock the nuts:


You can tell when each cylinder is TDC by looking at these timing marks on the cam just behind the sprocket, when the lines line up with the lobe on the head you're at highest lift:


Starter back on:


Oil in and cam cover on. Coolant in..... to the car, and the owner...


reaping the rewards of a **** part top hose - luckily I had the old bleed screw from the previous hose so drilled out the broken bit and refitted:


And she's running:
https://www.youtube.com/watch?v=lrS5zA3_i8Y&list=UUXNbwoJBaP-xZGcQF4L0Pew

fantastic mate,well done for doing all the work correctly and letting us all view the re build pics.

Cheers fella, had some great advice from the folks on here, I'm much obliged.

Special thanks to Aaron for the loan of his engine crane,
Maaaargghhhk! for his valve spring compressor,
Sabredylan (from the D2 Boys Club) for his fancy torque wrench, ring compressors and flex hone.
JamesMartin for phone support

I'm really chuffed that I managed to get it done

Awesome, props to you, sorted td5 is mustard

Been following with interest and amazed!!!!!

Great to see it running. You must be chuffed!

Now you need to find another job to keep us hooked on this thread

phil540uk said:

Great to see it running. You must be chuffed!

Now you need to find another job to keep us hooked on this thread

Click to expand...

Still got my gearbox and lt230 overhaul to crack on with

Top work Ben, Good to see it's running again.

Great job Ben

Very good thread

I have followed this thread with interest. Well done, a great story and very good to see the clip of the engine running at the end.

Thanks for a great re-build guide Benneh as well as a "music" video to go with it - sounds lovely.

I think there would be a good case for extracting the engine build from the rest of the thread and using it as a "sticky". A great source of reference for anyone wanting to re-build their TD5.

Well done!raise: