An Engine Rebuild Thread for Beginners

[maxstu]

Still waiting faithfully.

[Stesaw]

Still waiting faithfully.

Im getting there, a visit to Aidan last year to collect my crown and pinion also meant I came away with a front diff that I wasn't expecting. .

Parts wise for the 4x4 stuff I only need tank straps, front driveshafts, bushes for diff, prop and a VC... oh and the gearbox rebuilding..

If I had space at the workshop I'd have done the basic conversion already..

[maxstu]

I know what you mean...here l have the following projects waiting for me.

* A small block DJ2.1 waiting my attention.
* A final drive check and change, from NH (?) to NJ to match above.
* Square headlights conversion.
* New auto box foot brake lever replacement.
* Wiring issues galores.
* Change cab windows to green tints and source matching windscreen.
* Towbar with full electrics to mount.
* Carb overall. Accelerator pump refuses to pump more fuel to match timing. Runs well on LPG, though.

Plus decorating our bungalow inside and outside.

Meanwhile, the rust slowly creeps along each panel seam and invades every window cut. Never, ever own a T25 and live near the coast!

This last couple of months, Maxine and l discussed giving up on T25's and moving to a more suitable and modern camper. We viewed a couple of T5/T6 and a 2008 Vito (spit). Souless and very sterile were the lasting impression. And very limited in habitation space compared to the T25. So, the adventure to financial ruin continues in a T25.

Just been quote 10-12k for a full body restore on the 1989 DJ. l've have the mechanical side covered. But l need to learn how to do basic panel welding.

That said, got a few long term personal obligations ending in a couple weeks. And the weather should start to improve, with longer daylight hour soon, too.

Time to 'get under'! And then go camping again.

Good luck, matey!

[Stesaw]

10k for a resto? Is it that bad??

[maxstu]

10k for a resto? Is it that bad??

Lots of small bits and front defamation panel needs looking at. Rust at bottom of both front door and hatch. Under panel for sliding door is rotten, coming up towards rear window now.
I thought maybe 7- 8k. That's south east prices for you. Around 80 quid an hour l suppose.

I guess we should start a new post instead of
hi-jacking an engine rebuild thread.

[300CE]

Have you tried for a quote from Tom at Eagle Autos Stu? I’m hoping to get a quote from him to do the whole nearside sometime this year.

[maxstu]

Hi J,

I have a few options to consider. But number one is the DJ up for sale locally come March. So unlikely worth paying for full renovation just it to sell on. Hoping for a figure around 6K plus for it... dream on l hear some say.

T25 prices are generally heading downwards, in my opinion, unless the van something uber special. But it is a rare DJ2.1 AUTO with PAS and ABS. Plus it sports a very rare rear weather-proof locking cabinet instead of open roof rack. Only ever seen one other, at T3BUSSTOP.

Engine performance, braking and handling are spot on. This camper rocks away from traffic lights, often surprising modern vehicles. And regularly return 24mpg (on E10) on long motorway journeys. It really is a joy to drive.

Money will go towards upgrading the Auto sleeper LPG camper. A DJ2.1 engine waits my attention after Silverbullet put together a shortblock, with new cam and customised oil pump.

New engine top end rebuild thread coming in mid Feb

[Snowmark]

Ok, so I’ve finally accepted what has been abundantly obvious to you all for months and months……..I’m never going to complete this engine rebuild.
Many reasons for this - primarily, I’ve sold my van and therefore don’t have anywhere to put a rebuilt 2.1DJ engine (not sure it’d be an ‘upgrade ‘ in the BMW E30 that I’m currently playing with).
So, the engine project will be up for sale. It is in exactly the same state as it was when I last posted about it. All pieces are present, labelled etc. I have everything required to finish it, including a brand new, unused complete Reinz Gasket set, Brand new Scat Pushrod tubes and lots of other bits.
I’ll dig everything out tomorrow and photograph it all and post properly. Thanks for all the advice and encouragement throughout the thread - it was most enjoyable.
Kindest regards, Mark


Sent from my iPhone using Tapatalk

[Rik]

Oh noooo!!

At least I heave really enjoyed reading about it. And learned something as well. Good luck with the sale

[1987Caravelle78PS]

Gutted. I've just joined the forum today as I've bought a 1987 1.9 Petrol, and it has no compression on two of the cylinders (one each side) and I want to attempt to strip it and rebuild it myself, and have been reading, with increased enthusiasm, your thread here.

So, at least I know now how to strip it all. I will be sending my heads away to have them machined and see if we can get a small performance upgrade from improved gas flow. 
Did you sell your engine?? is it still available??

[maxstu]

I think Snowmark sold engine.

[Snowmark]

Yep, sold the engine along with crates of parts I’d collected along the way. Ironically, now have the spare time wheee I could have feasibly finished the engine so get pangs of regret on a weekly basis……

Busy learning a new world of BMW E30s - no t dissimilar just more expensive.
Hope the early posts on here help a few people out - I genuinely had no idea about engines, mechanics etc before I had my T3….still don’t know much but more than I did.
And still keep looking at vans for sale

[maxstu]

I will add that rebuilds by non professionals are getting more difficult. And this forum has seen quite a few abandoned rebuilds recently. Not because of inadequancies of the individual or any doubts in their own abilities with measuring gauges or spannering.

Often they realise the complete package they hoped to rebuild is beyond redemption, as a good reusable pair of engine cases are rare nowadays. And this is crucial for oil pressure. Good cranks and camshafts are limited, too. And crank bearings are also limited and costly. So in the end an alternative engine seems more economical.

My last DJ rebuild in 2024 cost 3K. Previous DJ rebuild in 2022 (different engine for different van) cost 1000 to 1200 pounds (l'm not good at keeping fiscal accounts). Mostly because a custom camshaft was my only option as no one had a decent used one. Which in turn needed a reworked oil pump and new hydraulic lifters.

Fortunately Silverbullet answered my mayday with a short block rebuild including a custom camshaft/oil pump combo. Otherwise my last rebuild would have been a non starter too.