4.2 engine build

[skippy3k]

I got the engine back in today. No exciting pictures to post this time. Removing the engine mounts and letting it rest on the frame made a huge difference in accessing all 8 bell housing bolts. I guess these are the tricks you sometimes learn the hard way. Also having the intake off made things a lot easier. (Thanks Chris.) Looking at it now, it's pretty obvious to remove the intake before removing the bell housing bolts. I don't know why that didn't occur to me when I first was pulling the engine out.

Next weekend I will be able to pull everything back together, assuming the weather holds out. I'm getting closer to turning that key for the first time in months.

 

[skippy3k]

The beast is alive. I finally was able to reconnect everything the other weekend, and turned the key. It's funny, because we were talking about "that moment" when you are about to turn the key for the first time, and how nerve-wracking it is. In my case, I was too busy talking to my neighbor that I didn't even think about it. I cranked it many times with the coil unplugged to get the oil moving. Then came the moment of truth; I hooked up the coil and turned the key.

No start.

After cranking it endlessly, we decided that the timing must be waaay off. After fiddling around, it finally started and ran. But I could smell fuel and I couldn't time it for the life of me. I finally tracked the fuel smell down to a leaking fuel pressure regulator. I replaced it and it ran much better and allowed me to time it correctly.

Then I decided to go for broke and pull the stock manifolds off and install the headers. Talk about tight tolerances. If things were 1/2" closer together, those headers wouldn't fit. After much encouragement with a rubber mallet, they finally slid into place.Tomorrow I will take it in to the shop to get the exhaust welded back up and quieten the thing down. Then back to the smog shop, which is what started this whole project in the first place!

 

[skippy3k]

So everything is pretty much done. Even though the headers extended back further, I didn't have to extend the O2 sensors wires to reach the holes. So that was good. I did have to re-route the starter cable so that they didn't touch the headers. The cats needed to be relocated behind the front crossmember. In the future, I probably would have just replaced them with smaller Catco's. I don't know if that would have prevented them from needing to be relocated, but they would tuck up under a bit better. As it is, I am happy with the placement.

The headers definitely change the sound. It has a rumble to it, more like a V8. I honestly can't say I feel a difference with the headers and new cam because I didn't know what a 4.2 felt like before. (If you remember, I was only running on 7 cylinders and a slipped liner.) It doesn't throw you back into the seat, but I wasn't expecting that anyway.

I am curious about my advance on my distributor after reading what TigerDan posted. I might take mine apart just for the heck of it and see if anything is stuck. I don't quite know what the symptoms are of stuck mechanism...who knows, maybe there is a lot more power just waiting for me to unleash it.

I did jack up the dipstick tube when I was trying to get it back into the block, so I will need to buy another one. But that was the only damage so far.

Next up is some fun work. I will be installing the auxiliary fuse block, wiring the Engel, installing a second battery, and most importantly, figuring out what is wrong with the stereo. But all of that is for another thread.

 

[rover4x4]

BTT. Any updates?

 

[crown14]

Ive built a few engines, done a LOT of head jobs, and broken in camshafts both ways. First startup never bothers me, in fact kind of the opposite. If you start to focus every little noise you hear then you are much more likely to forget to look at that oil pressure or water temp. Also maybe it is just me but I can't wait to find out if everything is fully driven, seated and not stripped.
I do admit I get a little obsessive over the checking the oil on a fresh motor though, and I keep a speaker magnet on the bottom of a steel oil pan during cam break-in.

 

[skippy3k]

No update really. Everything works. My only problem now is the dipstick tube; I can't get the new one in either. I also have a slight oil pan leak, so I think I will drop the pan and clean out the dipstick hole with a small bottle brush or something. There could be some gunk or buildup in there preventing the new tube from going in. (I got this block without a dipstick tube, so who knows what got trapped in there.)

The honeycomb in one of my cats broke loose and is rattling around. I suspect the extra heat from the headers was the final straw. So I am ordering some Catco's and will replace both while I am at it.

The stereo had a bad ground back by the amp, so that felt good to fix. I installed the second fuse block at the base of the steering wheel and wired it up.

But believe it or not, I am already thinking about a second engine build. I still want to do it proper and build up a 4.6. Enough time has elapsed that I am already forgetting the pain and frustration of this build!

 

[ptschram]

The dipstick tube may have been broken off in the block. If this is the case, it will be easiest to rectify with the pan off so you can drive the stub out from beneath-if that's the case.

Cats are supposed to run hot, they are more efficient when hot. It is unlikely that heat caused the failure.

 

[grtdivide302]

I used a punch from a set of center or transfer punches, the set I have must have 20 different sizes and one of them fits perfectly. It let me just tap the old one right out.

al

 

[skippy3k]

I don't think the old tube is broken off. I can only get the new one in about 4 inches, and there is nothing obstructing its path. It is just a very, very tight fit. I tried light oil, heat, everything. It will twist in with some effort then just stop. Anymore force begins to bend the tube.

Good point about the cats. My brain wasn't engaged before coming up with my theory.

 

[MUSKYMAN]

there are 2 different diameter dipstick tubes that I know of, the larger size will only go about 4" .

I dealt with the same issue when I put the defender V belt engine into my serpentine disco.

I just went ahead and used the smaller dipstick tube and stick from the defender.

 

[ptschram]

there are 2 different diameter dipstick tubes that I know of, the larger size will only go about 4" .

I dealt with the same issue when I put the defender V belt engine into my serpentine disco.

I just went ahead and used the smaller dipstick tube and stick from the defender.

Weird, I have found the break point to be that where they dropped the lower row of bolts in the heads. The dipsticks with the plastic handle are the larger ones, I've found.

(I hadn't even thought about this Thom, thanx!)

 

[rover4x4]

awesome thread, getting me motivated to dig out my 4.2 Ive had almost 2 years.

 

[skippy3k]

Since you resurrected this thread, I had to go through and re-read it. Funny, I don't even remember writing most of it, but I remember the project well. Definitely one of the best projects I've done, the engine has ran flawlessly since then. I am very glad I did it. Not to mention since I did it from the ground up, I feel like I know every inch of that engine and am prepared for any failure.

Of course, now I'm putting the truck up for sale and moving on to something else. Keep an eye out in the For Sale section for a white LWB with a rebuilt 4.2!

 

[rover4x4]

How does it run?

 

[skippy3k]

Runs great. Never had an engine problem since the rebuild. It was the first time with any of my Rovers that I had peace of mind that it wouldn't leave me on the side of the road.

 

[pdxrovermech]

if its nice shape i think i may have a buyer for you. one of our customers wants to buy 3 classics.

 

[skippy3k]

It's not in bad shape...no sagging headliner, slight wear in the seats, etc. But it's set up for "expedition" trips. Brownchurch rack, 3 lockable ExPo jerry can holders, 3 Wedco water cans, etc. I'm waiting delivery on my new vehicle this weekend, so I'll know then if I can put the For Sale sign on the Rover. I'll post back.

 

[pdxrovermech]

sounds good. this guy wants one for the wife, one to haul the kids around, and one for tooling around the mountain by himself. we built from the ground up, a 109 hybrid for him, but I think he decided it was a little too utilitarian. its basically a 110, coils, chipped 4.6, R380, rack, rear tire carrier, sliders, great sound system, custom dog guard, etc. its for sale for about $45K if anyone's interested.