1985 BJ70 CND refubishing and modifications

[crushers]

install the timing gears, i like to highlight the numbers on the gears for easy location.
clean and assemble and install the oil cooler, DO NOT forget those pesky rubber Orings.
clean and test the relief valve and install the oil filter mount.

clean clean and check again.

 

[lowenbrau]

clean and assemble the oil pump, use plenty of lube again ...

NOTHING that rubs on something else should be dry installed. seals front and rear, bearings, rings, anything that moves gets lubed.

Nothing? How about the flywheel and pressure plate?

I agree with your ring positioning but wonder if properly gapped rings leak much in the first 300,000km.

 

[crushers]

<where is that 'stick my tongue out' icon>
good point, no idea how much leakage would happen, i am sure there is some engineer out that has it all figured.
i was just passing on what an old school engine rebuilder taught me ... before i forget myself.

 

[tmarx]

Awesome work Wayne !

 

[crushers]

the 4 core rad showed up today ...

 

[crushers]

the bottom end oilers, inspected, tested and the rubber on one was ... well ... interesting. might have been part of the leak on that side of the block?

cleaned, new rubbers and ready to install.

 

[crushers]

bottom end oiler location on the block
injection pump was delivered to a specialist who inspected, replaced the hand pump as it was worn, did his stuff inside and back. not rebuilt as he stated that the pump is fine as is.
installed ...

 

[crushers]

i decided to pull the old water pump apart to show how just using water causes rust in the cooling system.
as you can see the rust particles are definately there and that is after a bunch loosened and fell out while banging on the cover plate to loosen the rusted bolts.
the back plate is pitted and corroded.
the fins were covered with corrosion and none of this is conductive to good water flow.

just thought you might like to see...

 

[crushers]

more pics of guts of the pump ...

 

[crushers]

installing the clutch
turned flywheel installed bolts torqued to 130 ft/lbs
new pilot bearing
new disc
new pressure plate
don't over tighten the small retaining bolts...

 

[crushers]

common mistake that kills the release bearing in short order is putting pressue on the outside of the bearing when installing it.
you should only put pressure on the inside race and press it straight onto the holder.
if the fork has excellent spring pressure then you need to insert a "wedge" under the spring to hold it out so you don't damage the spring as you insert it over the retaining ball.
a light dab of grease on the fork so the bearing can rotate easily ...

 

[ForealBoreal]

I always knew cookie monster was a rebel.

 

[crushers]

i fill the oil filter with oil on a rebuild to help prevent oil starvation on fireup ... you can also turn the engine over with the fuel shut off and the glow plugs out. either way works fine.
i also use cheap filters for the first 2 runs, the first run is usually about 5-10 min, shut down, drain, fill with cheap oil again and replace the filter with the 2nd cheap unit. then take it for a drive for about 500 km, drain, change and fill with good quality oil and a quality filter...

since we are not using the factory vacumm pump alternator combo this made for a perfect spot for the after market oil sender unit.

tap and plug the return location.

 

[crushers]

the water pump is installed using temp bolts, these will be replaced with SS.
the York in installed

 

[crushers]

the huge alternator bracket and unit is installed.
the tranny is now installed

moving along

 

[crushers]

i lube all the surfaces where the bearings ride or gears rub and the seals to ease the initial run in.
i also use a TINY bit of silicone to hold the brass bushings in place while installing the back half. i have never had much luck using grease to hold them in place.

 

[crushers]

the t/case almost complete, sadly the 4wd indicator switch is buggered so it needs replacing and waiting for a few bolts for the bell housing.
the assembly is coming together nicely, still waiting on those gosh darn springs from OZ.
the inlet for the York created, the hose will lead to the airbox as suggested by a member on the forum.

 

[crushers]

fuel tank ready for install ...

 

[crushers]

fittings for the air feed, the large unit will go to the air line manifold and the small one will go to the dash mounted air pressure gauge.

the thermostate housing before tear down and sand blasting and paint ...

 

[crushers]

so the springs FINALLY arrived from Oz
the head taped off for paint
etching primered ...