Thread: Looking for Backyard Mechanic - Engine Change - Northern Rivers NSW

Originally Posted by jboot51

Accessing the bell housing bolts on a disco is the biggest hassle. In the past it has taken 6hrs to undo them.

I assume it's not too different to a V8, remove the front engine mounts entirely and lower the engine to get better access. About 3-4ft of extension bars lets you operate a ratchet from behind the hand brake drum.

Originally Posted by bee utey

I assume it's not too different to a V8, remove the front engine mounts entirely and lower the engine to get better access. About 3-4ft of extension bars lets you operate a ratchet from behind the hand brake drum.

Tried that last time.
The engine does not drop as the itiming chest fouls on the power steering box.

Originally Posted by Vern

I have a cheapy engine crane, lifts my 4bd1, msa gearbox and tcase no worries.

I have a hafco crane.
At full extension, which is required for me to lift the donk out of a defender, the capacity is down to 250kg.

I will have a look and put some more thought into it.

Originally Posted by jboot51

I have a hafco crane.
At full extension, which is required for me to lift the donk out of a defender, the capacity is down to 250kg.

I will have a look and put some more thought into it.

Mines the same, actually it came from Hare and Forbes so is probably the same unit.

Righto. Here is where we are at.
I've been down to baz's place and pulled the head off to find a melted piston on #2 cylinder and the head gasket blown through between #2 and #3.
Curious as to what caused the piston to melt.
Obviously high egts would cause this, but this is an unmolested, stock standard disco.
Maybe a faulty injector on #2 let too much fuel in on #2.

Prior to melting, the disco was travelling at highway speeds on the M1. A noise/bang was heard and the driver (mrs baz) backed off the go pedal, but everything seemed ok. A minute or two later smoke,steam and associated noises brought it to a stop.

Along with the head and block, the turbo is shot as aluminium has been sprayed through the manifold and made it to the down pipe.

The engine is all unbolted waiting on the arrival of its replacement.

The dreaded bell housing bolts weren't so bad.
We removed the sound proofing on the firewall, which is retained by 4 plastic threaded discs. Increased access from zero to 50mm.

Attached photo of block for you all to ponder.
And that half moon object at the top is melted aluminium.
20181223_110125.jpg

Im guessing just cooked caused by the blown H/G . It is common for Tdi`s to a grab piston when ran with out coolant
Lack of coolant causes heat

Donor motor has been given new bearings, head, head gasket, rearmain, timing belt, and all seal/gaskets replaced.
Going down on saturday 5th january for the reinstall.
If anyone is local to Byron Bay, I could use a hand to get the engine into the engine bay saturday morning.

Update from Baz & Mon:


Thanks to everyone who got involved in the convo here on aulro, we appreciate all your help and knowledge.


A HUUUUUGE thanks to Tony. Everything that he has done is way beyond what we were ever expecting, he's an absolute legend and we can't thank him enough. And a big thanks to Rick for helping out on engine morning.


Tony will be able to fill you in with more specifics, but from our side, the receivers of Tony's generosity - things couldn't be better.


Glad to be a part of this community, what a bunch of good people.