Thread: Restarting Dormant TD5 – Advice Wanted

Almost two years ago we removed the transfer case and gearbox from my son’s 2003 Defender TD5 to overhaul the transfer case and replace the clutch. While everything was out and access was good, we drained the oil and removed the sump to inspect the million dollar bolt (oil pump sprocket bolt) which was worthwhile as wasn’t very tight with no sign of any Loctite. A whole bunch of other stuff was done as well.
To cut a long story short for the last two years or so the engine was “stored” with intakes and outlets covered but no oil in the sump and was left leaning back at the gearbox withdrawal angle. It is finally back together and the time has come to fire up the beastie but not sure what the best start-up procedure is, particularly in terms of getting up oil pressure before firing.

Particular areas of concern are:

1. Cam shaft - not sure if flooding the rocker cover with oil while filling the sump (i.e. pouring in quickly) will succeed in lubricating the upper vitals, especially the high load points of the injectors on the cam shaft.
2. Turbo bearings, although turbo was not removed.
3. Cylinder bores – should we try to get oil on to the pistons? How? Not keen on pulling the injectors and there are only four glow plugs to remove (i.e. no access to cylinder No. 5)
4. Residual fuel in the injectors - I believe that there will still be a film of oil in all the bearings so turning the engine over on the starter motor with the fuel pump and glow plug relays removed should get oil pressure up before firing provided that the engine doesn't initially fire on residual fuel.

Any advice gratefully received. Any admonishment for the poor storage condition accepted.

Originally Posted by oldyella 76

What we do if an engine has been reco'ed is to prime the oil galleries by forcing oil in from the oil sender unit....

Thanks Lindsay. I had considered pulling the oil pressure switch and connecting an external pressurised oil supply but not sure how to achieve this.

1. What do you use as an adaptor to connect the external supply to the pressure switch port?
2. The pressure switch port is after the full flow filter so is there a risk of unfiltered oil damaging the bearing surfaces? I am not sure I trust “new” oil to be filtered to 15 microns or that I can ensure the external supply system is 100% clean.
3. What would be the best way to pressurise the external system? A reservoir raised about two and half metres above the engine should give a head pressure greater than 1.5 bar, allowing for some friction losses. This is the lower bound of specified operating oil pressure.
4. Do you leave the system pressurised to prime the galleries before you crank the engine over (with injectors & fuel pump disabled). Then how long do I crank the engine over to ensure the oil pump and lower galleries are primed given that the oil pressure switch isn't there to let me know?
5. Am I over thinking this?

How do you do this in the industry?