Not bad for a days work...

[Veryan]

Finally managed to get round to swapping the engine out my Defender at the weekend.

So, floor out...would have been easier if the panels were not silkaflex'd in, but then I am strong and brut force prevailed...along with a screwdriver

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Detach all the ancillaries, oil cooler, fuel lines and electrics, ready to lift out...there is a spare bit of space in the front of these machines....

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The out came the old engine...looks like the defender has wet itself in excitement of getting a "new engine"

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The replacement unit of the left in this picture...new clutch fitted, found a suitable broom in the cupboard to use as a alignment tool. Its alittle shorter now Looks like the original had recently had a new clutch fitted. changed the thrust bearing, not that the old one need replacing, but I had the part and the fork was new so did not bother with this.

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This replacement unit came out of my flatmates SI, which came out of a SIIa, which was born into a Sherpa Van (in the UK) Basically the same engine a few minor differences...had to swap over the inlet/exhaust manifold, starter, engine mounts and vac pump.

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Those with a keen eye will also notice that the timing cover is different which means that the original accelerator linkage will not fit...so going to have to make up a custom job.

[Veryan]

So that was the morning...and this was the afternoon:

Drill out the exhaust manifold studs, re-tap with a M10 tap and then refit:

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Put all those bits I had taken off onto the donor engine - should be able to spot the difference in this picture

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And then drop the "new" unit back in, bolted up and reconnect all the bits and bobs, bleeding the fuel lines etc...taht was the easy bit

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But he big question is? Did it start? Err...Nope...I think it had something to do missing the pulse box for the special glow plugs, which, being from the "Freight Rover" group, part of Rover or British Leyland seem to be unique. Typical. Well I dug it out the shed:

The pulse box (front)

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And Back

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Just have to figure out which way all the wires go...I see one side is the high ampage side, and one the ignition side.

Anyone seen one of these magical Lucas boxes of electrical trickery before?

I also found out that having sat for 6 months the water pump seal has a leak, when filled up with coolant...lucky I have a spare to fit.

So, the saga continues...I hope to get this running so al least I have a truck that drives and can save for something with a little more grunt...got to be due some good luck at some point, right?

[Veryan]

Well, curiosity got the better of me and I'm not sure this is what I wanted to see when I opened up the little blue box with the words "Lucas" written on the front

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Plain Lucas wiring makes me scared....this makes me shake with fear!

Back in the day (1983), this was cutting edge stuff:

Popular Science - Google Books

Although I do seem to have found a wiring diagram....which does help matters.

[Sue]

Phew.. I got tired just reading that!

[kentkal]

Ahh, electrickery, the curr of a good vehicle

[newhue]

Veryan,
had a chance to fire it up. Hopefully smoke out the back and no smoke up the front.

[Veryan]

Well after a week of conferences, it was time to give the liver a rest and the brain a hard time with some thought of Land Rovers.

I managed to get it started, but alias, the replacement unit still breathers a little, so still get some smoke out the front, but most is all out the back It was pretty smokey, but then the motor has been sat for 8 months.


It might have taken a day to swap the engine, but it has taken a couple of weekends to fix the slight differences between the two engines:

1) Accelerator Linkage - had a make up a new bell crank as the pump sits in a slightly different place:

IMG_1629.jpg

IMG_1631.jpg

2) Fan hits shroud. The fan sits slightly further forward on the 2.5D for land rovers, so I am waiting on a tool to arrive so I can take the fan and spacer off the 2.5D and fit it too the BN52, it fouls at the moment on the nuts and brackets that hold it in place.

IMG_1633.jpg

3) It still breaths some, so I rigged up this oil catcher and re-breather system

IMG_1632.jpg

If you were quick you might have seen me take it for a spin round the block in Subi, no bonnet and all. They get hot pretty quickly without a effect shroud in place - even when going forward....! Hopefully some point this week the magical viscous fan tool should arrive and I can swap round the fan, pulley and spacer and take it for a few runs to work. I hope thats all it is and I dont have to swap round the entire pump....grrrr