Engine Fire Up

Setting the clutch pedal - 140mm from floor plate to bottom of pedal (no rubber).

Had to grind down a spanner to work in the limited space in the clutch pedal box.

Fitted some heat shrink wrap to the battery cable on the starter motor.

Inlet manifold.

Bled the power steering box.

Intercooler and radiator fitted.

A late night session with Christopher fitting the propshafts.

Connected the fuel lines, starter electrics and fuel pump relay. Once we managed to get the fuel pump to prime (long story) it fired it first time.

Then we took it out for a test drive. Happy days.

Engine and Gearbox Refit

It's going to be a long day!!

Lined up nicely - taking time and being very careful. Much up/down/angle/shift/squirm/etc...

Oh yes!

Yes. Yes. And Yes!

Engine Bay Ancillaries

Coolant tank refitted.

 

Clutch pedal box fitted as well as air intake hose.

Fitted new pipes for the power steering and clipped across the front chassis with new bolts, rivnuts and brackets. 

Protected all the fixings. 

Cleaning up the UJs on the steering column and greased up. Replaced the copper seals to the fuel filter. Stripped the EGR circuit from the wire loom back to bulkhead. Replaced all the insulation tape and conduit on the loom. Cleaned up all the earth points and connectors. Fitted the exhaust hangers and rubbers.

Exposed the metal surface of the gearbox cross member as it is used as an earth connection to the chassis.

More Corrosion Protection

Protected the gearbox and engine mount brackets.

Decided to mask off and protect all of the inside of the bulk head. 

 

Clutch Fitted

New bolts on the flywheel all torqued up.

New HD clutch.

New clutch cover.

Corrosion Protection

Spent a bit of time going round the engine bay using "BlackIt" spray on the chassis, bulkhead where the clutch box is going to be fitted and then all the seams around the bulkhead tunnel arch.

There were a few old screw holds in the back of the bulkhead. Filled these and rounded off with SikaFlex. Once set, I'll spray over with BlackIt.

Flywheel Housing

Bolted on the flywheel housing.

Hylomar sealant applied.

All torqued up and off the stand.

Took the copper main shaft bearing out from the crank shaft. Filled the end with heavy duty grease and drove in the clutch alignment tool. Hydraulic pressure from the grease pushed the bearing out. Crazy pressure generated for sure. New bearing is soaking in engine oil overnight and will fit

Made up a tool to gently drift in the new copper bush back into the crank shaft. Put a bolt into a socket whose outer diameter matched the inner diameter of the bush, washers tightened up with a nut to socket head and then lock nuts on the end to protect the thread. Gently tap into place.

Cylinder Head

Engine block all cleaned up ready to fit the cylinder head.

Check the raise of the cylinders above the cylinder block. Validating the correct thickness of the new head gasket.

All confirming that a 2 hole gasket is required.

Cylinder 1 - Front 65, Rear 60

Cylinder 2 - Front 65, Rear 63

Cylinder 3 - Front 64, Rear 64

Cylinder 4 - Front 61, Rear 52

Nice and shinny.

Dowels, gasket, thermostat and coolant elbow fitted. 

New head gasket.

There are 4 sequences in total. Torque and 3 sets of angles on specific bolts in each sequence. 

Fitted the vacuum pump, oil filter housing, manual fuel lift pump and oil breather. All these parts were cleaned up prior to fitting with new gaskets. New washers for the sump and coolant plugs too. New injectors, fuel lines and spill returns fitted, glow plugs and push rods. All new copper seals as necessary.

Fitting the rocket shaft.

Valve clearances setup.

Loaded up with air intake brackets, engine breather, coolant pipes, fan, brake vacuum hose, new spill hoses. 

Transmission Rebuilding

 Order a new heavy duty clutch release bearing mount.

Heavy Duty clutch 

Clutch release bearing is on hold due to new clutch fork hole for push rod clamp not being in exactly the correct location causing issues. Will send back and get another. Rebuilt the transfer box and main gearbox selectors and attached to gearboxes. 

Rebuilt transfer box selector.

Main gearbox selector.

All the linkages attached and tested.

Fitted the new rear shock absorber mounts to the chassis.

Heavy duty clutch fork and heavy duty release bearing fitted.