After fetching the replacement engine, I had little time to phaff around getting it installed, so I started on the job the very next day.
The engine came out pretty easily since the head was already off and things were easy to get to. Disconnect the myriad of hoses and wires to the inlet manifold was a bit of a job, and can somebody tell me why Volvo had to use 18mm bolts on the bell housing! If I ever have to take engine/gearbox out again (and I sincerely hope not!), I'll buy myself an 18mm spanner first!
Next challenge was to get the engine out the Landrover and up to the middle barn, I didn't do the job in the normal garage as I decided the extra space and height up there would be an advantage. Now, the easiest would have been to ask the Neighbours to come round with one of their tractors with a pallet forks on the front. The would have happily done that, but it was only 3 days earlier that I had borrow one of their vehicles to fetch a plough so I felt I needed to manage myself this time.
So with the David Brown, a few ropes, some help, a little risk, a wing and a prayer we got it out the back of the car.
It was given a quick scrub down and driven up to the middle barn.
The only things we did in preparation were to swap over the clutch that I had changed late last year, swap the water pump which was pretty new and even Kid sister, visiting from Ireland, gave a hand changing the engine moutning rubbers (I figured it was a good time to replace them).
So, new engine, old engine, all one needed to do was get one out the way and the other in the car.
I had been very lucky in acquiring an old 1/2 ton electric hoist from work. It was one that they didn't have use for and since it hadn't been tested by the people that test lifting things couldn't use if they wanted too. It's even got 2 speeds so it's really controlable, way better than a hydraulic engine crane. The David Brown could have done the job, but the risk of disaster would have been high. The only downside was the the hoist was fixed to the steel beam above so to get the engine onto the hoist meant moving the engine and to adjust the relative position of car and engine meant moving the car. I'll invest in one of those upside down trolleys one day.
The David Brown, and a few bits of rope were just the job to get the engine onto the hoist. Just like this...
One
two
Three
T'was the usual hassle getting the input shaft to engage with the clutch and the spigot bearing, but I've had much worse! The only unexpected hitch I hit was when I found out that the inlet manifold had a bigger butterfly and my airhose was too small. Bit of a pain but it didn't take too long to get the manifolds swapped over. By early Sunday afternoon the engine was in and running. The block mounted engine heater, which had been butchered when the took the engine out leaked water. A quick session with a hacksaw, blow torch and some solder sorted this out, much easier than putting a new core plug back in!
The only issue left now is the Lamba warning light is on. However, despite this, it passed it's emissions test and got a 2 year ticket so it can't be anything to serious. I've installed a new Lamba sensor, that didn't help, soon I'll start swapping sensors over from the old engine to see if one of them fixes it.