Discovery II head gaskets

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DiscoSlice · #26 Post by **DiscoSlice** » Fri Feb 14, 2020 2:46 pm

Look forward to hearing about your completion! Just wrapped mine up, was a long battle but sooooooo worth it.

rgallant · #27 Post by **rgallant** » Sat Feb 15, 2020 10:49 pm

Well Saturday went to hell in a handbasket, 11:00 to 7:00 pm Clean gasket material from block, all but 1.5 hours of that time,many many bad words were used. Last hour was cleaning bolt holes, that at least was the expected time frame.
I also cleaned up some wiring loom while I waited for the Gasket cleaner to "work"

Used gasket removal spray
Hard plastic scrapers
Next to zero effect after 2 hours - ok I killed 3 scrapers

Then I did a bit of research and found a resin based scraper for gas stove tops and granite countertops popped down the hardware store and progress began ! it is called a Skraper Skraper
Before - Note carb clean works really well on piston heads

A few images

Block Before

https://i.imgur.com/OdRBAbm.jpg

https://i.imgur.com/4o1GpKs.jpg

Left side after 1.5 hours

https://i.imgur.com/hngY0SU.jpg

At 7:00 pm finished

https://i.imgur.com/DFjMsv9.jpg

https://i.imgur.com/ieN7iED.jpg

rgallant · #28 Post by **rgallant** » Sat Feb 15, 2020 10:53 pm

Wiring loom fix was pretty easy

Low tack cloth wiring tape
Braided loom

MAF Sensor wire Before

https://i.imgur.com/QcoVkdA.jpg

Taped

https://i.imgur.com/1m1v2j8.jpg

Loom in place just needed zip ties on each end

https://i.imgur.com/TSKhFSP.jpg

ANDYD · #29 Post by **ANDYD** » Mon Feb 17, 2020 7:55 pm

Good work Richard, its all down hill from here .................

rgallant · #30 Post by **rgallant** » Tue Feb 18, 2020 8:12 am

GRRRR 3 days and all I got done was get the heads on, right side is torqued down and good the left side is started, I can not finish that side. I need a torque wrench with a small head, extensions and wobbles do not work. One stupid bolt on the bottom of the head.

I did get some more bits degreased and de-varnished so things are proceeding.

I found a torque wrench that should work,with luck :)

swamijake · #31 Post by **swamijake** » Tue Feb 18, 2020 12:15 pm

Are you doing that with the block in the car? Ouch!

rgallant · #32 Post by **rgallant** » Tue Feb 18, 2020 3:47 pm

@swamjake yup found all kinds of muscles I have not used in years and they are all complaining :)

rgallant · #33 Post by **rgallant** » Fri Feb 21, 2020 11:32 am

Success, kinda of found a "wobble" extension that worked. The problem is the bolt appears to have 70 Lbs of torque on it, it should not. After a ton of reading I am going to loosen it off and re-torque, it is the last one in the chain.

The extensions : note angle is exaggerated for th photo

https://i.imgur.com/mCOj31J.jpg

Everything in place :

https://i.imgur.com/C0EYABr.jpg

Looking down to bolt location

https://i.imgur.com/XwFcMYy.jpg

rgallant · #34 Post by **rgallant** » Fri Feb 21, 2020 1:23 pm

Done and finished my shoulder hurts but I have it sorted out.

After reading a lot on several hot rod forums I went with removing that nut & washer re-lubing and reseating. It just made me feel better.

It took 45 minutes start to finish and the booster heat guard bracket had to be removed, but I got it torqued correctly.

A quick double check on both heads torque in the am and I can get back in the assembly groove

rgallant · #35 Post by **rgallant** » Sun Feb 23, 2020 1:02 pm

Now this looks a bit better

https://i.imgur.com/JUYbnht.jpg

https://i.imgur.com/XSGWC9M.jpg

swamijake · #36 Post by **swamijake** » Sun Feb 23, 2020 6:28 pm

Shiny!

rgallant · #37 Post by **rgallant** » Mon Feb 24, 2020 9:37 am

The valley pan gasket is a pain to get set just right, it takes a lot of fiddling to seat correctly - in my case the left side was great the right side took some work,the right rear was great the right front was low a bit. If you do this read a lot and dry fit a few times.

I suspect a lot of the issues around leaks in this area are related to fitting issues.

https://i.imgur.com/ipbhIZx.jpg

Bolt cleaning took a lot of the day, turns out the old intake bolts had plumbers paste on them, that is just weird as the bolt do not enter the cooling jacket.
After 5 days of soaking in gasoline that stuff was still hard as rock. As luck would have it the only thread chasing kit to rent was out.

In the end I used my old warped head as a chase and used this process:

hit the bolt with gasket remover spray
Screw the bolt into the head
Let sit for 15 minutes
Pull it and rinse (hot water)
Scrub with a bristle brush
Clean grooves with an exacto knife and jewelers screwdriver - this stuff is hard
Run into a second block hole with degreaser
rinise again
Run into the block in a 3rd hold dry
Repeat if required

I generally had one soaking in gasket remover while I cleaned the next one.

After on top, before below

https://i.imgur.com/smjas63.jpg

State of the bolts overall

https://i.imgur.com/Dr1NgAP.jpg

Final job was replacing the throttle body heater, mine leaked and has been bypassed but as long as everything was apart, I figure replace it.
It is very easy:

pull the old one
Clean the mating surface,used 2000 grit sandpaper and steel bar
Copper gasket spray on both sides of the gasket
Set the gasket in place
Put the manifold in place
Bolt it down

https://i.imgur.com/XrrmzQj.jpg

https://i.imgur.com/NX6KLVR.jpg

https://i.imgur.com/GTKK2U6.jpg

Final job on the day was to install the SAI tubes into the Block, just some copper anti seize and 18 mm open end wrench. nice an easy with exhaust off

DiscoSlice · #38 Post by **DiscoSlice** » Tue Feb 25, 2020 10:53 am

Almost there! I bypassed my throttle body heater... I warped three new ones before I just simply had enough.

Have had enough run time on mine to speak very highly of the NGK double platinum plugs I installed. Major improvement over the Bosch platinums that were in there.

rgallant · #39 Post by **rgallant** » Tue Feb 25, 2020 11:01 am

@discoslice mine will likely stay bypassed too, I am going to route the cooling line directly back to the expansion tank. Then just block the heater ports. It will be a lot cleaner setup.

red90 · #40 Post by **red90** » Tue Feb 25, 2020 11:56 am

DiscoSlice wrote: Tue Feb 25, 2020 10:53 am I bypassed my throttle body heater... I warped three new ones before I just simply had enough.

There is a solution for you. Only one province to the right.
https://www.sportscarcentre.ca/MGM000010K?mid=948

Good to get this as well. https://www.sportscarcentre.ca/aluminiu ... -s?mid=948

DiscoSlice · #41 Post by **DiscoSlice** » Tue Feb 25, 2020 4:42 pm

red90 wrote: Tue Feb 25, 2020 11:56 am
DiscoSlice wrote: Tue Feb 25, 2020 10:53 am I bypassed my throttle body heater... I warped three new ones before I just simply had enough.
There is a solution for you. Only one province to the right.
https://www.sportscarcentre.ca/MGM000010K?mid=948

Good to get this as well. https://www.sportscarcentre.ca/aluminiu ... -s?mid=948

Whoa! Of all the mods and parts I’ve seen in my time I’ve never come across an upgraded throttle body heater. Those are rad. If I thought I needed that heater for any purpose at all I’d be all over that. Nice looking bleeder upgrade too. I’ve been meaning to get the one from carrs4x4 for a while now.

red90 · #42 Post by **red90** » Tue Feb 25, 2020 6:17 pm

You need one. Your throttle will ice up without one.

rgallant · #43 Post by **rgallant** » Tue Feb 25, 2020 7:38 pm

Well as of today I will lots of time to get her sorted out just got laid off, sucks but the wife says I can mostly retire

Tony4921 · #44 Post by **Tony4921** » Tue Feb 25, 2020 8:06 pm

I have been running a 4.0L D2 with no TBH for the last 5 years, no problem at all.

rgallant · #45 Post by **rgallant** » Tue Feb 25, 2020 10:28 pm

It is pretty rare to getting icing down here,up around Dawson Creek I would be way more concerned. I have a few ideas around a controllable bypass, I will post up if any comes of it

red90 · #46 Post by **red90** » Wed Feb 26, 2020 1:50 am

Or you could spent $75 and fix it properly forever.

DiscoSlice · #47 Post by **DiscoSlice** » Wed Feb 26, 2020 8:38 am

Sorry to hear about the lay-off. That is not good news but if retirements on the table than enjoy the hell outta that!!

I ran without a heater in -30 Calgary weather for about 2 years and never once had an issue. Or at least not one that I noticed...

bsa_m21 · #48 Post by **bsa_m21** » Wed Feb 26, 2020 2:53 pm

Hey Richard,

Sorry to hear about your "forced" retirement. Just means you'll have lots more time to keep the D2 running. :toothy7:

Regards,

rgallant · #49 Post by **rgallant** » Thu Feb 27, 2020 7:16 pm

Well solid days work today, I will have more of a write up but here is the end of day pic. Pretty sure I messed up the firing rider so that needs to be reviewed in the AM.

Got tired of whacking my knuckles on the lifting eye so it is a nice "see I am right here red" now

https://i.imgur.com/PmPZKu9.jpg

rgallant · #50 Post by **rgallant** » Fri Feb 28, 2020 10:23 pm

Long day today not much progress a lot of wiring to re-wrap.

Upper Intake manifold on and off 3 times and 1 more time to go

Missed SAI pipes of all things
Dropped a nut - it lodged in a bad place
Dropped and lost an coil bracket bolt
Noticed I had not checked off verify the valve covers are tight on my check list

Kind of frustrating day - taking a break Saturday back at it Sunday

The Rover-Landers of BC

The Rover-Landers of BC

Discovery II head gaskets

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