My 04 D2 rebuild adventure by knightmetro

4 minute(s) of a 35 minute read

Forgot to update for a while.

Well I pinned all the liners. Easier than I thought. Drill. Tap. Had to grind down each bolt to size, which was the only real time consuming part. The walls on the part of the block are pretty thin. Drill goes through the liner nize and clean.

Looks good.

All the parts for the bottom end came in from Turner. FAST. Sad how $40 can get me a big box from the UK here in 2 days, but I can't get a box the size of an iPhone from Cali for the same price in a week.

I dropped the crank off at the machine shop and we decided to grind all down to fit .010 bearings. I'll be picking it back up today.

So, this weekend the whole bottom end goes back together. Heads go to the shop next week. So I should have the long block all back up in the next 3 weeks and then back into the car.

2nd update..

I may be taking delivery of a 06 LR3 SE fully loaded in the next week for about $8k. So, if that works out, I may be selling the freshly restored(when done) Disco II to my folks to pay off the LR3.

They could use a second car, something that can tow far more than their Element, and I want the LR3 a bit more than the Disco. But this isn't set in stone yet.

5-27-2014

OK. UPDATE.

Bottom end is all back together.
New piston rings, crank and cam gears, new timing chain, all new seals, new main and conrod bearings, crank ground and polished to .010 sizes, tappets inspected and primed, etc etc. New rear core plug. Threw in a block heater while I was at it since this will be in Alaska for a while. Of course all the liners are now pinned as well. Much easier than I thought it would be.

I've also put in a new oil pump, and the water pump was already very new. Threw on a new gasket though. Cleaned up all the pistons.

Everything from the oil pan up is back together. A good dose of oil and assembly lube on everything. Wrapped it all up in a garbage bag to keep FOD out until I get the heads back.

Heads were sent off to the shop to be rebuilt last week. Upon inspection, they found a circle hammered into the deck caused by the slipped liner. Must have been 1/32" deep. You could get a whole fingernail in there. So, it's being sent out to be welded, and then the head will be decked smooth. Then both will be rebuilt. I should have these back in a week or two. Then buy a new flexplate, and an ARP stud kit, then slip this back into the engine bay  My nice freshly cleaned engine bay. Then, as I am not the one who took the whole top end apart, I'll have to piece this puzzle back together. See what needs replaced as I go. I'll be putting in all new coolant hoses and a new radiator and t-stat. I figure I'll just get any cooling related possibilities solved before they ever happen with putting in all new from the start.