Inspection and rebuilding

THE engine in this Td5 Discovery had given trouble-free motoring for over 240,000 miles, until it had begun to overheat and pressurise the cooling system. We decided to take the cylinder head off to investigate what had gone wrong, fix the problem and get the Discovery back into full service. Last month, in the first part of this two-part feature, we removed the cylinder head and saw, as expected, that the plastic dowels that help locate the head in position on the engine block had failed. The resulting head gasket leaks led to warping of the cylinder head – here, we fit the replacement head and build up the engine.

NEED TO KNOW

CONTRIBUTOR TREVOR CUTHBERT

COST: £1332.50

TIME: 7 hours

DIFFICULTY

MODELS: Defender 90, 110, 130 Discovery 2

TOOLS: General workshop tools, breaker bar, timing pin set, injector puller, torque wrench, angle gauge

PARTS & COSTS: Reconditioned Td5 cylinder head, £1050; Set of cylinder head bolts (ERR5384), £40; Set of four glow plugs (OEM), £16; Td5 head set (misc gaskets) (Britpart, DA2112), £43.50; Td5 head gasket (Britpart LVB000260), £25; Fuel pressure regulator (Britpart), £89; Extended manifold studs (Allisport), £69. All supplied by BLRC Ltd.

WORK SAFELY:

• Wear protective gloves

• Wear safety boots

• Ensure correct lifting techniques are