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2004 Disco 2 Engine Rebuild

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  #131  
Old 10-09-2019, 07:42 PM
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Originally Posted by cvhyatt
Working out the gremlins in the new engine. Getting a P0441 error so will replace the PCV tomorrow. New fan comes on Tuesday. Oil drip is fixed. now I am trying to understand why this thing sounds like a diesel when I accelerate.

I have attached a sound file. As I accelerate (stationary or not) you can hear a high pitched rattle. Any thoughts on what this is?
Tough to hear, but sounds like maybe something rattling/vibrating?
 
  #132  
Old 10-11-2019, 10:24 PM
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Originally Posted by Jason_B
Your temps still seem like you dont' have a low temp thermostat. I had the exact same temps when I got my new Turner engine. Around 220 at idle and 200 cruising or something like that. I made a thread about it. Once I got the Grey 180 stat or the black one, my temps are now 188-193 moving and never higher than 206 when idling. Still a little hot at idle but I gave up chasing it for now. Going to install the inline mod pretty soon I think.

I replaced my fan but it didn't help. New genuine thermostat on the way!
 
  #133  
Old 10-11-2019, 10:28 PM
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Also mounted my over sized spare and put my running boards back on. Heading to the beach tomorrow!


Running boards coated with Durabak.


 
  #134  
Old 10-11-2019, 11:01 PM
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Originally Posted by cvhyatt
Thanks - I am not as "handy" as most on these boards so I would prefer getting a complete kit that I can drop in versus pulling something from another vehicle, fabricating brackets and modifying the shroud. I am in awe of people who can do this kind of thing - I'm just not one of them! Any suggestions on a drop in kit that only requires basic automotive ability?
It’s not hard. Take your time, read instructions, be creative and buy cool tools.

also, I recommend hitting your fender flares and trim with some UV resistant clear as well. The liner will fade over time.
 
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  #135  
Old 10-15-2019, 06:33 PM
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Default Victory!

Pulled the stat and put in a genuine 180 stat. Flushed all the coolant out. Running with water and purple ice - no coolant.

Before

idle - 210 to 215
1500 rpms - 210 to 224
2000+ rpms. - 204 to 212

After

idle - 194
1500 rpms - 183 to 188
2000+ rpms - 179 to 18

Fixing the exhaust leaks tomorrow!
 
  #136  
Old 10-16-2019, 06:51 PM
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So with the cooling issues behind me, I wanted to next tackle the exhaust leaks. With a blower attached to the exhaust and some soap and water, I narrowed down my leaks. One was an SAI connector that was loose so I just tightened it down. The big leaks were with the exhaust manifold to exhaust which I attribute to gaskets. I have two that will be here tomorrow. I did find a couple of leaks on the driver side flange and the connection to the exhaust. I reversed the air so it was sucking instead of blowing and slathered on some JB ExtremeHeat. Will wait 24 hours for that to cure.

Next I took on the SAI pump which has been throwing errors and screaming at me for the past couple of days. Turns out it ate part of the filter. I cleaned it out with a vacuum cleaner and am waiting on a filter which I will attach tomorrow.





 
  #137  
Old 10-16-2019, 08:59 PM
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Hello - nice job on tackling all this. My compliments for your willingness to dive in to unfamiliar waters.

For your SIA pump filter... I used this little K&N filter to replace the stock one. Hope this helps. You have to chip away a little of the flange to fit it but was a 5 minute job.

$20 on Amazon: K&N 62-1370 Vent Air Filter / Breather: Vent Air Filter/ Breather; 1 in (25 mm) Flange ID; 1.5 in (38 mm) Height; 2 in (51 mm) Base; 2 in (51 mm) Top


 
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  #138  
Old 10-17-2019, 05:11 AM
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Originally Posted by gmuiter
Hello - nice job on tackling all this. My compliments for your willingness to dive in to unfamiliar waters.

For your SIA pump filter... I used this little K&N filter to replace the stock one. Hope this helps. You have to chip away a little of the flange to fit it but was a 5 minute job.

$20 on Amazon: K&N 62-1370 Vent Air Filter / Breather: Vent Air Filter/ Breather; 1 in (25 mm) Flange ID; 1.5 in (38 mm) Height; 2 in (51 mm) Base; 2 in (51 mm) Top


Thanks! That is the mod I will be doing! You had a great write up!
 
  #139  
Old 10-17-2019, 05:37 PM
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Got the new gaskets in, the extremeheat is cured and I reinstalled the SAI pump with the filter mod. The engine is a little bit quieter but I still think I have a few more leaks to track down. Will check and retorque the exhaust again this weekend.


Installing the gaskets

SAI pump assembled

SAI pump installed
 
  #140  
Old 10-21-2019, 06:39 PM
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Default 10-21 Update

Waiting on a new idler pulley to come in. While I’m waiting, I thought I’d tear out the rear bumper to get it ready for the one from Dark Crow Designs.



 
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