Outer Limits 4x4 Board

Been pretty quiet in here........

My latest project, A NZ new wagon. Pretty rare with a manual trans, being NZ new it has factory diff lock and manual fuel pump. Its a 1998 NL model.

Got it, it was filthy inside, so much dust and it has been run out of water. SO hot the top tank on the radiator was melted. Some pics.











Started yesterday morning, I pulled the engine out...



The 2.8's and 3.5's have a pull clutch which is a sod of a thing to get out, there is a pin with a bolt in it inside the bellhousing. I have two special tools for the job, I made one up when I took the clutch out of the 3.5 a few years ago. this time the pin wouldn't slide out so needed tool number two.

bellhousing showing pull clutch




To get the top bellhousing bolts I gave big black a body lift

4 lumps of 4x2 did the job


Stripped interior (found some money!!!)


Vacuumed it




Pulled windows out and waterblasted them



Waterblasted all the pastics inside the vehicle also then started on the carpets.




Got most of the dust and dog hair out I think, I sure hope so anyway. Started reassebling, as much as I can until carpets dry.

Pulled turbo off manifold ready to drill for a exhaust temp gauge.


Cleaned the inlet manifold and rocker cover to within an inch of its life, this thing was rather full of gunk.



Thats it for now.
Glen

Manifold looks new! what's the plan? Just a tidy up and flick, or a keeper? body mods?

[quoteThe 2.8's and 3.5's have a pull clutch which is a sod of a thing to get out, there is a pin with a bolt in it inside the bellhousing. I have two special tools for the job, I made one up when I took the clutch out of the 3.5 a few years ago. this time the pin wouldn't slide out so needed tool number two.][/quote]

Mate I thought you had to knock that big pin out initailly too. But there is an easier way. The circlip that retains the clutch fork and throwout bearing into the centre of the pressure plate can be accessed through the square rubber inspection bung in the bellhousing. If you get a long flat bladed screwdriver and lever the circlip the opposite way to which it locks the gearbox and engine separate easily.

Have a play with it when it is pulled apart and you will see how it works.

Does that mean I can assemble the pin and everything with the throwout bearing before I put it back in and then it'll just 'snap' into place?

SO I pulled the sump.... All good still, no filings at all, actually it was nice and clean, but the oil level sensor plastic bit had gone brittle and was sitting in the sump



Finally found the injector pump timing mark...



Lots of gears in there.



Then got it out for a measure up and the light revealed...



Some marks in the bores and signs of it having almost seized due to heat. SO... I now have another dilemma, where to from here. The bores are no longer fully round. Depending on price for pistons I may re bore or get another motor, proving to be easier said than done to get another motor. Despite what I have seen on there most Delica ones are quite different and are not interchangeable.

Glen

NJV6 wrote:Does that mean I can assemble the pin and everything with the throwout bearing before I put it back in and then it'll just 'snap' into place?

Yep sure will, just look through inspection hole and work clutch fork onto circlip. Its a pretty good design. It had me stuffed to start with my brother and I replaced a transfer case chain on his NM pajero, got stretched using a air locker. Same clutch setup on it.

MAn those bores are ugly. Hopefully the over-bore doesn't hurt $ too much.