Defender 90 300tdi strip down and rebuild

Time for another update. Well was working with the roof to windscreen as it would not sit right. After looking at it for a long time and trying to sort the gap on the offside between the screen and door it finally clicked i was using m8 bolts and nuts along the front of the screen when i should have been using the m6 with the special nuts :doh: a couple of mm makes all the differance.

So today have fitted new timing belt and all the other bits that go with it. Had to borrow a dial torque wrench to set the tensioner. Lot of other jobs done as well and have got the nearside wing on aswell. So tomorrow Will be starting to install the roll cage to chasiss bits.

Only one pic lol need to use the camera more will take some more tomorrow.

This is a pic of the old timing belt. Could not understand why i had so much fluff inside turns out whoever changed it last time had dammaged the guides trying to take off the pulley on the crankshaft. So i straightened it and filed the edges so it should be good but will keep an eye on it.

Just notest looking at the last pic that the belt apperes to run totaly on the guide roller above the crank whereas with the new one fitted it was running approx 3mm off the roller.......James? lol

Here is apic with the new belt fitted.

And the engine has been through tdc five times.

was there a washer on rear of idler ,so that tensioner isnt trapped by idler

jamesmartin said:

was there a washer on rear of idler ,so that tensioner isnt trapped by idler

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No there was no washer. The only thing i can think of ... i spoke to the guy supplying it and he said he had a problem with getting the guide roller and it would be with me soon. Going to take the roller off and mesure it to the old one. Back in a bit.

on the back of roller is a machined step looks like a washer tensioner arm sits over it so when idlers tight tensioner is still free ,did you retension after 2 engine turns,was idler decent make

jamesmartin said:

on the back of roller is a machined step looks like a washer tensioner arm sits over it so when idlers tight tensioner is still free ,did you retension after 2 engine turns,was idler decent make

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Yae James it has a step on the back so the tensioner can rotate. i have just pulled it back off and found it is 1.5mm shorter than the old one.

Yes the engine was turned over and retensioned.

It all came from a company
who do not supply britpart that was wh i went to them.

Bloody Hell not updated this in a while. It is mostley back together now and working on the electrics trying to get the lights working etc.

Looking very smart mate. Love the cage.

absolutely lovely !!! better than new

thats sweet mate makes me want to respray my truck happy days!!

Thanks for the replys guys but i have run into a problem with the lights indicators in fact. When i put the right indicator on the trailer light on the dash flashes along with it. When i put the left one on the trailer light flashes once and stays off. So far i have changed the indicator switch and the hazzard switch both made no differance to the problem. The indicator switch was changed for another fault but rules this out anyway.

New bulbs all round as well 21w from Halfords.

Has anyone had this or similar problems. One thing when i took it apart i thought there was earthing to the body at the back lights as well but at the mo i don't have any.

Can't belive it just gone and passed the MOT with no advisorys. Will tax it at the end of the month. That will give me time to finish of a couple of wee jobs..

One the road again...with new wheels...

Very nice mate!
Love the cage - looks brilliant!!

Daz

just read this Well done it is better than new , now i will have to sort my 300Tdi .

puffin1 said:

just read this Well done it is better than new , now i will have to sort my 300Tdi .

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+1 really nice paint job! just read the whole thing and totally know the ebay thing god only knows how the second 90 I bought passed its test the battery was held in by the cables!!!

Just a wee update it,s been on the road for 1500 miles now aqnd the only prob has been the windscreen wipers. Motor has burnd out twice now so will need to look into this,,, Apart from that it has done the job,,

Eventually got to the problem with the wipers and it turns out the cable was broken also the drivers spindle is quite stiff to turn. So ordered new cable and will strip out spindle and free it off.
In addition to this i lost the keys for it so have had to buy new locks all round and new fuel cap lucky i have a spare key for the cubby box.

So looking forward to spring have got a better bonnet and am looking for a set of doors to work on while still keeping the landy on the road..

Well done mate looking to do mine this year