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Some of you may have read my thread on my DIY engine rebuild I posted earlier in March - CLICK HERE FOR THREAD. I bought a 2003 SE7 for $1,800 with a known blown head gasket. Unfortunately, during disassembly, I discovered the number 4 cylinder was steam-cleaned. After not wanting to believe what several forum members wanted to tell me - I finally came to grips with the fact I had a cracked block. I made some aluminum block-off plates and pressure tested the block up to 60 psi. No leaks - that was odd. Then I researched the core exchange programs out there for around $1,500. The problem was I am on a tight schedule and no shops had blocks ready to ship. So I looked into getting the sleeves and after calling both major sleeve suppliers in the US (Darton & LASleeves), and all the major parts suppliers & engine rebuilders - nobody had sleeves in stock with the bottom o-rings. I finally found them cheaper and faster from England (48 hr shipping) at Turner engineering (GREAT customer service, seriously, Frida is awesome).

Today I got my propane tank exchanged for a full one with the correct threads and readied my large propane torch. It was actually pretty easy and took less time than putting it in my oven (it did fit - I checked). The only liner that gave me trouble was #4, the one that ended up having a pin-hole leak.



After removing the liners, I pressure tested the block again with water and air up to 40 psi. Behold the 2 pin-hole leaks in cylinder #4:


The block goes tomorrow to the machine shop to be bored for a .003-.004 inch interference fit (basically .003-.004" smaller in diameter than the average outer diameter of the Darton sleeves) and have a lip cut for the top-hat liners. I will then heat up the block again with the propane torch, as Turner recommended, and drop in the new liners. Then I'll quickly bolt on the cylinder heads before the cooling aluminum block tries to squeeze the new TIGHT liners out. Then after waiting 4 hrs for cool-down, I'll drop it off at the machine shop again to get decked and the cylinders honed to each individual piston. I'll update tomorrow with more info and organize the post better.
 

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Updates???


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Finished the engine. Took High Definition video of ALL engine assembly. Will be uploading to YouTube soon. Lots of pics. Just stuck on where to buy 80mm driver's side idler pulley that the previous owner did not give me with all the parts. Expect more videos to be updated with this thread once I get it running, flush the transmission, and check for ABS codes (car was missing Hill Descent Control switch which leads me to believe the 3 amigos brake error codes were showing up).
 

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What was the cost of the sleeves and machine work ?


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Machine work - $520.
Sleeves from Turner Engineering - $626

Machine work included boring old cylinders to larger size for sleeves, machining lip on top of cylinders for top-hat/flange of liner, installing new sleeves, honing each cylinder to each piston, and decking/re-surfacing the block.
 

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Wow that seems really cheap for the machine work ! I thought you installed the sleeves?


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I was going to, but the machine shop that did the sleeve work was 1 hr away, the machine work wasn't too expensive, and I didn't want to waste gas going back just to push in the sleeves. It wouldn't have been hard though. I had them use my grill propane bottle and flamethrower/large torch.
 

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Update:

Engine is in the car, have to install radiator, coolant temperature sensor gauge, hook up oil pressure gauge, rebuild driveshafts, change transfer case oil, and then I can start it up.

Some pictures to look at until I upload all my engine assembly videos in glorious 720p High Definition.

Block back from machinist - $510 total for boring lip and large cylinder diameter to accept sleeves, install sleeves, hone each cylinder to each individual piston, resurface block. Took a week because they had 2 aluminum cutting bits break on my block.





Pistons Installed:





Oil Pump Gears Installed & Packed With Vaseline/Permatex Red Assembly Lube Mix:



Installing Rocker Shims/Calculating which size shim to use:







Accessories Installed:





 

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Great work man! You doing a cam or anything while its apart?? Maybe cut the heads,port the heads,anything??
 

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Great work man! You doing a cam or anything while its apart?? Maybe cut the heads,port the heads,anything??
It is back together and already in the car. Completely stock rebuild. Should be starting it up today and then after doing a transmission fluid + filter job and doing some test runs, I'll finally have time to post all my assembly videos and pics.
 

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This one of those posts that makes you regret ever paying someone to do your work for you or throwing out a bad block.

Great job
 

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This is a great post. Well done on pulling the sleeves yourself - this is probably why your machining was so cheap. I was quoted between $150 and $200 per cylinder.

Really good seeing a success story.
 

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Hey Jake, do you have the name and number of the machine shop in south Florida. I have a Land rover block I would love to have them put the liners in. I know this was a couple years ago, but thought I would try it anyway. Did you ever get to take the truck to South America? Thanks Martin.
 
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