Engine change and chassis cleanup.

Projects and discussions on ‘how to’ and your Discovery 3 and 4
User avatar
Bodsy
Chairman
Posts: 12031
Joined: Mon Feb 15, 2010 1:37 pm
Winner: Technical Post 2012, 2013
Comedian of the Year 2014
Car Details: 2007 HSE
Member Since: 15 Feb 2010
Location: Sunny Shropshire!

Re: Engine change and chassis cleanup.

Post by Bodsy » Wed Mar 07, 2018 8:32 pm

So, Monday came and went, but we managed to get the body back on and bolted back up.

To make it easier to line back up as the chassis had been rolled in and out that many times, it was never going to be exactly in the right spot.

A couple of people had suggested a plumb line to get it ‘about right’ and someone else suggested some cut off bolts at the corners to slot into the body mounts.

This worked really well, along with four wheel dolleys meant we could easily manoeuvre it into the right place.

Some slight adjustment and tweaking as it got closer and slotted back on without much of a problem.
Caught the gearselector cable on the fuel tank but managed to free it up easily enough.

Decided to leave the electrics connecting for that night until Thursday as I had a couple of full days of paying work already booked in.

So we left it at that and James carried on Tuesday and Wednesday with the additional wax cavity spraying https://www.arc-rite.co.uk/corroless-cc ... biting-wax as well as surprising me by fitting the centre silencer delete pipes I had from Griffin and connecting up replacement brake pipes where needed and bleeding through

The ‘wax’ has a 4 year life, goes on clear and dries to a tough clear finish.
Much cleaner and easier to apply than the dreadful waxoyl.


So Thursday We got the car started, which was a tremendous relief!

Sounds lovely, runs lovely and injector values were great.
Up to temperature ok, bled through water etc and then set about reconnecting wheel arches.
There was a suspension fault, that I put down to the fact it was still in the air, so knew it would be either one of the valve blocks that I’d rebuilt or a connector or a chaffed wire.

One of the rear bolts that holds the bumper on, the factory rivnut was turning, so we replaced that and a few other little bits and pieces.

Was getting late Thursday and I didn’t have the connector info I needed to see where the wires terminated to be able to check out the suspension faults in more detail.

Drive home in some pretty bad snow on the m54, saw at least 12 other cars that had either hit someone else or hit the barrier or just spun down off the hard shoulder. This was in the T6, so a bit of cautious driving saw me home ok.

Back to it on the Friday and my iPad wouldn’t allow me to see the topix connector information, so some additional pics and pdfs from Clive Symons and Allan Thrower helped to quickly identify the right connector. Not surprisingly, all the faults connected back to one connector and after double checking, realised that the connector wasn’t quite fully clicked in place. Easily solved in the end.
Except another suspension fault popped up for the front valve block.

We’d had trouble getting this connector to click, but it did succumb the day before.
But somehow it had popped off and so once re clicked into place, some judicial use of cable ties to keep it there for the moment. And suddenly all of the suspension faults disappeared! So no broken wires or fault rebuilt valve blocks, just simple connectors!

A couple of test drives to double check for temperature and air and leaks etc, managed to identify a small diesel leak from the leak off pipe. One seal replaced again as it had a little nick in it.
Seemed to do the job.

Then the excitement of the drive home!
What a great drive, felt great t be back behind the wheel. I needed to get it back on Friday as the mot runs out at the end of the day!

So currently it’s sat back on the drive, MOT supposed to be Monday, but the diesel leak has re appeared, so I’ll just replace the leak off pipe completely which I’m hoping will cure it before having its MOT later in the week.

So, what next....?

Well, there’s still the underside of the chassis to clean up and protect as we’d concentrated on the tops and sides of the chassis whilst it was on the floor. I think I’ll need to order some more 2k paint for that.
Will also need to put the winch tray back on after another cleanup and fix the winch of course.

As a celebration, after it’s passed it’s mot, I’ll be getting someone to give the beast a proper deep clean.

The ride is a little unsettled, but I put that down to being off the body and I’ve changed the most worn body mounts as well as the rear complete ARB bar so I’d expect it to sit a little different to before.

Once the mot sorted, will calibrate the suspension and get the wheel alignment checked.

So that’s it for now anyway, I’ll change the oil/filter in 1,000 miles or so and take it easy for a while.

I’ll let you know when leak sorted and passed the MOT!

Got to put a lot of credit for this to James as without his expertise in getting the fiddly little fecking bits and expertise in broken bolt removal 😂 it would have been a very different story! Many late nights and horribly grubby rust removal work on top of the engine swap. I realise than most wont go to this extent, but hopefully it will go on to last me a few more years yet!

For those that don’t know James, he has a small garage in Bedworth and takes his time to make sure the jobs are done right rather than just rushing jobs through the door.
He also has a D3 and a petrol RRS, so know his way around.
You may also have seen the series LR that has been rebuilt in one of the popular Lr mags, that’s his handiwork as well.
24848116-2ECB-4CC0-BF7F-3C12EC5B7B58.jpeg
FA157E4F-8341-441D-B9AC-E0E20163855D.jpeg
27412A26-381B-4ABB-8CB2-AD5610D22A1C.jpeg
E2D73B1C-3ACC-4AA9-B270-C479AA2F9B65.jpeg
A96B9613-E48D-4C21-9E9C-BD0A8C493A3B.png
A7394164-E001-4793-87D2-C7851AE74440.jpeg
8E30D726-75D0-48CC-B8DE-C99A62E25C61.jpeg
9C3CC01F-9893-4353-B912-48C3142401D6.jpeg
EF52C4B2-A1A9-4FB8-8381-2DB4FA3DC89F.jpeg
F707084F-B75C-4860-A4FA-1CEB763D2024.jpeg


Check http://tinyurl.com/brakebible
Here for How to change your Brake Pads, Disks, EPB Shoes Adjust, removal, cleaning & fitting Guide.

IID Pro Multivehicle. D3, D4, RRSport pre and post 2010, FFRR.
Gearbox Transmission Flushes and much more

Disco3Club Chairman

User avatar
Bodsy
Chairman
Posts: 12031
Joined: Mon Feb 15, 2010 1:37 pm
Winner: Technical Post 2012, 2013
Comedian of the Year 2014
Car Details: 2007 HSE
Member Since: 15 Feb 2010
Location: Sunny Shropshire!

Re: Engine change and chassis cleanup.

Post by Bodsy » Wed Mar 07, 2018 8:43 pm

So managed to get the leak off pipe leak fixed, by putting another £100 in the bill for a new pipe!

What a pita to change! But all working well.

Some people wanted to know what the exhaust now sounds like....




Now got to try to get it in again for MOT which I think they can squeeze me in on Friday.


Check http://tinyurl.com/brakebible
Here for How to change your Brake Pads, Disks, EPB Shoes Adjust, removal, cleaning & fitting Guide.

IID Pro Multivehicle. D3, D4, RRSport pre and post 2010, FFRR.
Gearbox Transmission Flushes and much more

Disco3Club Chairman

User avatar
anglefire
Site Admin
Posts: 18878
Joined: Sat May 15, 2010 8:01 pm
Winner: Club Member of Year 2012 & 13
Car Details: BMW 530d M Sport
Member Since: 17 May 2010
Location: Solihull, West Midlands
Contact:

Re: Engine change and chassis cleanup.

Post by anglefire » Wed Mar 07, 2018 8:48 pm

Does sound nice. 👍

Should have a mids meet and hear it in the flesh.


Mark

Waeco CFX 40
2006 disco3 SE. Gone but not forgotten.
Member of Admin team and :ugeek:
Disco3Club Photos: Here

User avatar
Bodsy
Chairman
Posts: 12031
Joined: Mon Feb 15, 2010 1:37 pm
Winner: Technical Post 2012, 2013
Comedian of the Year 2014
Car Details: 2007 HSE
Member Since: 15 Feb 2010
Location: Sunny Shropshire!

Re: Engine change and chassis cleanup.

Post by Bodsy » Wed Mar 07, 2018 8:51 pm

That sounds like a plan. Monday 12th?


Check http://tinyurl.com/brakebible
Here for How to change your Brake Pads, Disks, EPB Shoes Adjust, removal, cleaning & fitting Guide.

IID Pro Multivehicle. D3, D4, RRSport pre and post 2010, FFRR.
Gearbox Transmission Flushes and much more

Disco3Club Chairman

User avatar
anglefire
Site Admin
Posts: 18878
Joined: Sat May 15, 2010 8:01 pm
Winner: Club Member of Year 2012 & 13
Car Details: BMW 530d M Sport
Member Since: 17 May 2010
Location: Solihull, West Midlands
Contact:

Re: Engine change and chassis cleanup.

Post by anglefire » Wed Mar 07, 2018 9:23 pm

Ah. I have a rally meeting on Monday. Forgot that. 😳


Mark

Waeco CFX 40
2006 disco3 SE. Gone but not forgotten.
Member of Admin team and :ugeek:
Disco3Club Photos: Here

User avatar
Bodsy
Chairman
Posts: 12031
Joined: Mon Feb 15, 2010 1:37 pm
Winner: Technical Post 2012, 2013
Comedian of the Year 2014
Car Details: 2007 HSE
Member Since: 15 Feb 2010
Location: Sunny Shropshire!

Re: Engine change and chassis cleanup.

Post by Bodsy » Fri Mar 09, 2018 7:20 pm

And today it now has an MOT!
Result, :mrgreen: :mrgreen:


Check http://tinyurl.com/brakebible
Here for How to change your Brake Pads, Disks, EPB Shoes Adjust, removal, cleaning & fitting Guide.

IID Pro Multivehicle. D3, D4, RRSport pre and post 2010, FFRR.
Gearbox Transmission Flushes and much more

Disco3Club Chairman

User avatar
anglefire
Site Admin
Posts: 18878
Joined: Sat May 15, 2010 8:01 pm
Winner: Club Member of Year 2012 & 13
Car Details: BMW 530d M Sport
Member Since: 17 May 2010
Location: Solihull, West Midlands
Contact:

Re: Engine change and chassis cleanup.

Post by anglefire » Fri Mar 09, 2018 7:26 pm

How's it running now Ian? Not that I guess you've had chance to really drive it much!


Mark

Waeco CFX 40
2006 disco3 SE. Gone but not forgotten.
Member of Admin team and :ugeek:
Disco3Club Photos: Here

DSL
Forum Contributor
Posts: 11064
Joined: Sun Apr 18, 2010 8:58 pm
Car Details: The old muddy banger
Location: Can't make my mind up!! :-)

Re: Engine change and chassis cleanup.

Post by DSL » Fri Mar 09, 2018 8:41 pm

:popcorn:


If only I could think of something useful to type here!! :(

User avatar
Bodsy
Chairman
Posts: 12031
Joined: Mon Feb 15, 2010 1:37 pm
Winner: Technical Post 2012, 2013
Comedian of the Year 2014
Car Details: 2007 HSE
Member Since: 15 Feb 2010
Location: Sunny Shropshire!

Re: Engine change and chassis cleanup.

Post by Bodsy » Sun Mar 11, 2018 4:29 pm

Took it to Shrewsbury today, attingham park to have a little run out. I’ve not given it good beans yet as thought I’d better let the engine settle in a bit first.
Have to tow the caravan to Pembroke in three weeks time, so hoping to get a few miles on it and then change the oil possibly before going.

Checked fluid levels when I got back just as I’m paranoid, but all ok so far.


Check http://tinyurl.com/brakebible
Here for How to change your Brake Pads, Disks, EPB Shoes Adjust, removal, cleaning & fitting Guide.

IID Pro Multivehicle. D3, D4, RRSport pre and post 2010, FFRR.
Gearbox Transmission Flushes and much more

Disco3Club Chairman

User avatar
anglefire
Site Admin
Posts: 18878
Joined: Sat May 15, 2010 8:01 pm
Winner: Club Member of Year 2012 & 13
Car Details: BMW 530d M Sport
Member Since: 17 May 2010
Location: Solihull, West Midlands
Contact:

Re: Engine change and chassis cleanup.

Post by anglefire » Sun Mar 11, 2018 4:38 pm

I'm pretty sure that there is no need for a particularly early oil change - its only got dye in it. I can ask though!


Mark

Waeco CFX 40
2006 disco3 SE. Gone but not forgotten.
Member of Admin team and :ugeek:
Disco3Club Photos: Here

Post Reply