I have acquired my parts truck to steal the engine out of, and am planning on pulling the engine to rebuild it and put it back in my 01 (maybe swap parts to the 02 since I like the color). I have done head gaskets before, but that's really the extent of my engine work experience. I have an idea of what needs to be done, but while I spend some time accumulating parts and such, I wanted to see if you all had any advice to offer me. Anything you wish you knew before you did one, parts to stay away from, must have tools or upgrades, etc. Only thing I am pretty dead set on is going to a flow kooler water pump, and using head bolts not studs.

I am trying not to spend a ton of money, so I would like to reuse pistons, rods, crank etc. but I also and willing to do whatever I need to to keep this engine solid for a long time. I am working on a spreadsheet with all the parts, links, and prices on it separated by what's absolutely needed, what would be ideal to have, and what I just want so I can get a good estimate on cost.


Here is the parts truck in question. I knew it had been painted due to the hood emblem being painted over, but I read to Vin, and the truck was red stock. Whoever painted it went all out, there door jams and engine bay are all blue to match. I am not currently parting it out as I may be keeping it, but I am waiting on a few things to make that call. The front bumper will definitely go though. It has two small cracks in it, but it has fog lights. If anyone near upstate SC wants it let me know.


And here is why I am doing a new motor. Several threads felt weak, and this thread fully let go.

 

There was a guy here who had a whole spreadsheet on the costs of his repairs/maintenance, can't remember the username though.

Be careful of Britpart, the quality is hit or miss. I received a broken motor mount from the get go. If you wheel often you will likely break 1-2. Some people use engine mounts for a 300tdi if I remember correctly.

The big issue I had with my rebuild was the headgaskets came in bent... from the LR dealership near me.....

 

flat tappet Small Block Chevy lifters will work vs spending the money on Rover branded lifters....it's what I put in mine when I rebuilt it (I think I used oil restricting ones, but I did other mods as well). The Buick 215 cam bearings work as well...I used them too. Cam itself is unique to rover as are the main bearings I believe.

 

I rebuilt my 4.0 years ago. From what I remember, I would consider stud kits to replace the head bolts and crank bearings. I also recall reading about oil pressure relief valves getting stuck, I cleaned my passages, plug, and spring well.
After I rebuilt mine, a friend of mine who is the service manager at a boat shop told me that he was talking to an outfit in California, the guy he was talking to claimed that they made the top hat pistons that go in the AB rebuilds. Maybe some internet searching would come up with the name of the piston makers. I like the idea of top hat pistons, if I lived close to an AB facility I might consider just buying a rebuilt engine from them
Choose a good machine shop. I had a problem with the machine work, I don't recall now what the problem was, but they fixed the problem. The machine shop put in new freeze plugs, at least a couple of them seep. I never felt that they seeped enough to warrant the trouble of fixing them.
Pressure test your engine before you disassemble it to check for cracks.

 

Recommend a HD flex plate, stock ones are prone to cracking. Check the rear cam plug for evidence of leaks, sometimes the cam plug is leaking and people think it is the rear main. Per your previous experience, be sure to chase all the head bolt holes with a tap.

 

Do you have any links on where to buy the HD flex plate?

 

https://ashcroft-transmissions.co.uk...uty-flexplate/

I need one myself; haven't ordered it yet though.