The saga of the copart range rover sport - Page 2
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Thread: The saga of the copart range rover sport

  1. #16
    FRESHMAN ROVER BostonRover7's Avatar
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    February 1st, 2018
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    Re: The saga of the copart range rover sport

    Now for the meat of the post... the engine swap.

    Done in about 18 continuous hours of work (24 if you include sleep) - we are amateurs after all.

    I'll let the pictures speak for themselves, but here's a general overview:

    The old engine was totally seized, so we couldn't rotate the crank to release the flexplate to torque converter bolts. We stripped down the old engine as best as we could to see if we could figure out what was causing it to seize. Note the headbolts are T60. Landrover sells a special tool (of course) but we got a set of extra long Torx sockets on Amazon ($16). You can see the epic carnage from cylinder 7 detonating in the block. I wonder what that must have sounded like while driving!

    With the engine totally stripped, and new parts transferred over to our donor Jag block, we took the engine/transmission out as one unit. When it was out, it was clear to see the problem - the connecting rod in cylinder 7 had actually impacted through the side of the block (I didn't get a good picture of this). Some short work with a drill and chisel, and we had a very destroyed, but freely-spinning, engine block. Flexbplate bolts came off next, and then we put the transmission back in the car.

    After building up the new engine on the stand, we realized that the Jag and Land Rover engines actually have two different sump designs. So we had to switch the oil sumps between engines. The only part that needed to be swapped over was the pickup tube - the sump otherwise bolts up. We did have to clean out the bits of piston chunks from the sump first, and the destroyed oil level sensor too...

    The last challenge we faced was swapping the exhaust manifolds, because they are different between the Jag and Land Rover engines as well. It looks like they are mounted with a Torx bit, but it's in between T50 and T55. We thought we were stumped, but turns out an 8MM hex socket works just as well

    I don't have any pics, because we were both pretty tired at this point, but we installed the new engine in the bay, mounted it to the trans, and starting hooking everything back up.


    The saga of the copart range rover sport-head-damage.jpgThe saga of the copart range rover sport-destroyed_cylinder.jpgThe saga of the copart range rover sport-destroyed_engine_in_situ.jpgThe saga of the copart range rover sport-engine_removal_0.jpgThe saga of the copart range rover sport-engine_removal_1.jpgThe saga of the copart range rover sport-replacing_trans.jpgThe saga of the copart range rover sport-trans_insitu.jpgThe saga of the copart range rover sport-oil_sump_old.jpgThe saga of the copart range rover sport-new_engine_complete.jpg
    1995 Range Rover County SWB (sold)
    1995 Range Rover County LWB
    2005 Land Rover LR3 (sold)
    2011 Range Rover Sport S/C

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  3. #17
    FRESHMAN ROVER
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    Lake Elsinore,Ca
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    Re: The saga of the copart range rover sport

    Im just still impressed at how you got the body off the frame. Good job!

  4. #18
    FRESHMAN ROVER
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    Marshall, VA
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    Re: The saga of the copart range rover sport

    Any updates?

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  6. #19
    FRESHMAN ROVER BostonRover7's Avatar
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    Re: The saga of the copart range rover sport

    Sadly, yes....I'll tell the fun part before the sad part.

    The fun stuff:

    Put the body back on. Couldn't get the engine to crank though, feared the worst.
    Determined with some real "backyard mechanicing" that by jumping the starter relay, we could get a crank. So for a while we had a sequence where one of us would hold down the start button, the other would jump the starter, and we'd actually get ignition for a few seconds. If you let go of the button it died immediately.

    Turns out the brake switch was not picking up the non-pressurized brakes. This was a wild guess, but after plugging in the GAP tool and activating the bleeding protocol, and bleeding all the brakes, the pedal felt much firmer. Engine started up instantly. Whoa.

    Had a few problem codes: intermittent misfires on 2,4,6,8. Fairly continuous misfires on cylinder 4. After a few seconds of idling, check engine light and "restricted performance" warning chime on the dash.

    Replaced the coil on cylinder 4, still misfiring. Checked that the plug sparked on the block - it did. So misfire could be due to fuel or air issues. Seemed like air was getting to all the other cylinders ok.

    Drove to get fresh gas to rule out the "bad gas" excuse. Car handled fine over 20 mph, but at idle it was clearly misfiring, and stumbling. New gas did nothing.

    The whole time I monitored coolant temps through the GAP tool. temperature rose normally, thermostat opened at 89C and then it held perfectly. Think we got most of the air out of the system, nice.

    So..injectors?
    1995 Range Rover County SWB (sold)
    1995 Range Rover County LWB
    2005 Land Rover LR3 (sold)
    2011 Range Rover Sport S/C

  7. #20
    FRESHMAN ROVER BostonRover7's Avatar
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    Re: The saga of the copart range rover sport

    The sad stuff:

    Decided to drive it to a local shop to get the injectors properly diagnosed (60 miles). Drove it slowly on the highway. Again, shuddering at idle and "restricted performance" warning on the dash. I kept it around 55 mph, monitored coolant and oil temps the whole time - perfectly in line.

    Parked for about 20 minutes. Got in to drive the last few miles. All symptoms as previously described. Then, at a red light, the engine gently died. No explosion, no drama, just idle rpms and then nothing. Engaging the starter did nothing.

    Got out and looked around. hitting the start button produced a "click" but nothing. All sorts of codes showing, but seemed like they were more related to the engine not running (open circuits, etc). Nothing about camshaft timing.

    Got it towed to a friendly shop - too far from my garage. See sad picture of Range Rover on a flatbed!

    Shop says he thinks the engine is seized. Cannot turn it over by hand. Pulled the plugs, and one is slightly bent. This was cylinder 4, the one with the continuous misfire. Not catastrophic damage, just looks like it was "bumped" closed a bit. Boroscope down the spark plug holes reveals that this cylinder hit a valve. Others all look ok.

    The saga of the copart range rover sport-towtruck.jpgThe saga of the copart range rover sport-plugs.jpgThe saga of the copart range rover sport-valvedamage.jpgThe saga of the copart range rover sport-valvedamage2.jpgThe saga of the copart range rover sport-okcylinder.jpg
    1995 Range Rover County SWB (sold)
    1995 Range Rover County LWB
    2005 Land Rover LR3 (sold)
    2011 Range Rover Sport S/C

  8. #21
    FRESHMAN ROVER BostonRover7's Avatar
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    Re: The saga of the copart range rover sport

    So what could have happened here?

    Misfiring due to a leaky injector diluted the oil and caused the piston to seize in the cylinder? Possible, but how would that explain the valve/piston collision?

    Jumped timing the old fashioned way? But how would that affect only one cylinder?


    And what's seized? There is still plenty of space left between the piston and cylinder head (enough to fit a boroscope in there) so it's not wedged up in there against the valve still.
    1995 Range Rover County SWB (sold)
    1995 Range Rover County LWB
    2005 Land Rover LR3 (sold)
    2011 Range Rover Sport S/C

  9. #22
    FRESHMAN ROVER
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    March 10th, 2019
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    Holmdel, NJ
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    Re: The saga of the copart range rover sport

    Oh wow... this is so sad. so much effort.
    2013 RRS SC, Fuji White with Almond/Mocha int. 80K ml

  10. #23
    FRESHMAN ROVER BostonRover7's Avatar
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    Re: The saga of the copart range rover sport

    Any guesses to what failed? I think that if it were timing, we'd see marks on more than 1 cylinder. Open to any thoughts here?
    1995 Range Rover County SWB (sold)
    1995 Range Rover County LWB
    2005 Land Rover LR3 (sold)
    2011 Range Rover Sport S/C

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