Land Rover Series 2.8 liter Performance Engine build

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Spider 1969
Posts: 160
Joined: September 22nd, 2013, 7:21 pm
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Land Rover Series 2.8 liter Performance Engine build

Post by Spider 1969 »

Not a race engine but definitely something else than overhauling the standard 2.25 that is presently powering my 1960 Land Rover Series 2.

In need for more torque to cope with modern day traffic conditions I originally intended to upgrade the 2.25 when I stumbled upon a 2.5 liter engine block for sale. The 2.5 liter is basically the 2.25 with a longer stroke as developed for the LR 90/110/Defender. I also found out that the UK based ACR has developed a CNC ported head, larger bore pistons to increase the capacity of this engine to 2.8 liter as well as a camshaft and carb kit. Aim of this kit is to increase torque and drivability which makes it perfect for my intentions.

Most parts can be interchanged between the 2.25 and the 2.5 but since I am using my Landy frequently I needed to find also a head, timing cover, sump etc. to be able to swap the complete engine after build. The head I found online as well as a donor diesel engine for the other bits and bobs. Flywheel and housing are different from other series and difficult to acquire but in the end I succeeded. In hindsight I would have been better (less expensive) off if I had started with a complete 2.5 engine as a basis.

Inspection of the 2.5 block revealed that the crank needed grinding and it turned out that the cost of a new crank is close to machining so I opted for a new crank. Send of the head to ACR for porting and skimming and it returned with the over size pistons, H-beam rods, camshaft and the SU HS6 Carburetor kit.

Block was bored and skimmed locally during which I checked the dimensions of the new crank and cleaned, sand blasted and painted all ancillary parts.

After return of the bored block it was painted too so the build could commence. Ring gaps and bearing clearances were checked and all within spec. When inserting # 1 piston the upper rail of the oil control ring snatched between the piston and cylinder wall. Possibly due to the type of ring compressor in combination with the large bore (95 mm). rail was destroyed and luckily only minor damage to the piston. Slight set back in time however due to waiting for the new rail.

While waiting I finished inserting the other pistons with another design ring compressor and inserted #1 piston without rings so I could start installing and timing the camshaft. More to follow.

Regards,
Charles
Attachments
YE OLD LANDY
YE OLD LANDY
0_LANDY_S2-001.JPG (686.08 KiB) Viewed 101620 times
Start of the project
Start of the project
1_New Block-001.jpg (960.45 KiB) Viewed 101620 times
Inspection time
Inspection time
1_New Block-002.jpg (846.3 KiB) Viewed 101620 times
Shiny Things alert!
Shiny Things alert!
2_New Parts-001.jpg (947.75 KiB) Viewed 101620 times
Another shiny thing
Another shiny thing
3_New Crank-001.jpg (842.12 KiB) Viewed 101620 times
Quality check
Quality check
3_New Crank-002.jpg (688.52 KiB) Viewed 101620 times
Back from the machine shop, decked, bored and cam bearings fitted
Back from the machine shop, decked, bored and cam bearings fitted
4_Block_Machined-001.jpg (807.09 KiB) Viewed 101620 times
Paint!
Paint!
4_Block_Painted-001.jpg (1.1 MiB) Viewed 101620 times
Bearing clearance within spec
Bearing clearance within spec
5_Rotary Assembly-001.jpg (629.85 KiB) Viewed 101620 times
Crank T-Seals fitted
Crank T-Seals fitted
5_Rotary Assembly-002.jpg (863.78 KiB) Viewed 101620 times
Crank end float within spec
Crank end float within spec
5_Rotary Assembly-003.jpg (745.91 KiB) Viewed 101620 times
Fitting the rings
Fitting the rings
8_Pistons-001.jpg (748.7 KiB) Viewed 101620 times
Oil rail escaped
Oil rail escaped
8_Pistons-002.jpg (661.08 KiB) Viewed 101620 times
Rail destroyed
Rail destroyed
8_Pistons-004.jpg (632.8 KiB) Viewed 101620 times
New ring compressor
New ring compressor
8_Pistons-005.jpg (714.63 KiB) Viewed 101620 times
Cam fitted, followers to go in
Cam fitted, followers to go in
6_Cam-002.jpg (968.67 KiB) Viewed 101620 times
Cam end float within spec
Cam end float within spec
6_Cam-003.jpg (873.9 KiB) Viewed 101620 times
Cam timed
Cam timed
7_Timing-001.jpg (866.99 KiB) Viewed 101620 times
All new parts fitted
All new parts fitted
7_Timing-002.jpg (883.01 KiB) Viewed 101620 times
Spider 1969
Posts: 160
Joined: September 22nd, 2013, 7:21 pm
Contact:

Re: Land Rover Series 2.8 liter Performance Engine build

Post by Spider 1969 »

It has been a while since this post and a lot has happened. New piston rings cam in and I uneventfully finished the engine build. Took out the old engine, fitted the new one.
Then I had to modify the carburettor linkage as the new SU carburettor repacked a worn Solex PA40 on which the linkage opens the other way round.
Next to that I made a stainless steel exhaust based upon a silencer I had lying around and a 4-2-1 header that I purchased in Australia.
For ignition I installed a 123 tune distributor for which I uploaded a dyno developed curve as supplied by ACR.
Since I will be running petrol as well as LPG I installed a Lambda Gauge to be able to tune for different fuels.
Commisioned the engine for first start up and drove away with a smile on my face: this conversion really makes a difference! Able to keep up with modern traffic and acceleration to 100 km/h does not take a week anymore ;-) Nor do hills slow down anymore.

Next jobs:
Re-install LPG mixer and tune evaporator
Install new doors as the old ones are bad. I found doors with galvanised frames that should keep rust out for decades
Install a new wiring loom to replace the home made three color one as fabricated by the previous owner. (had no issues sofar but it it looks horrendous)
Attachments
New oil pump
New oil pump
9_SUMP-001.jpg (114.49 KiB) Viewed 100692 times
9_SUMP-002.jpg
9_SUMP-002.jpg (97.41 KiB) Viewed 100692 times
10_Head-002.jpg
10_Head-002.jpg (116.89 KiB) Viewed 100692 times
10_Head-003.jpg
10_Head-003.jpg (114.67 KiB) Viewed 100692 times
11_Ancillaries-001.jpg
11_Ancillaries-001.jpg (120.44 KiB) Viewed 100692 times
12_MAnifold_Header_Mock Up-001.jpg
12_MAnifold_Header_Mock Up-001.jpg (119.18 KiB) Viewed 100692 times
13_FW_Assy-002.jpg
13_FW_Assy-002.jpg (124.66 KiB) Viewed 100692 times
13_FW_Assy-09.jpg
13_FW_Assy-09.jpg (110.55 KiB) Viewed 100692 times
Old Engine out
Old Engine out
14_Engine_in-001.jpg (109.62 KiB) Viewed 100692 times
New One in
New One in
14_Engine_in-002.jpg (137.72 KiB) Viewed 100692 times
14_Engine_in-003.jpg
14_Engine_in-003.jpg (137.09 KiB) Viewed 100692 times
14_Engine_in-004.jpg
14_Engine_in-004.jpg (129.95 KiB) Viewed 100692 times
15_Exhaust-001.jpg
15_Exhaust-001.jpg (113.73 KiB) Viewed 100692 times
15_Exhaust-002.jpg
15_Exhaust-002.jpg (163.11 KiB) Viewed 100692 times
15_Exhaust-004.jpg
15_Exhaust-004.jpg (98.55 KiB) Viewed 100692 times
15_Exhaust-005.jpg
15_Exhaust-005.jpg (101.29 KiB) Viewed 100692 times
19_AFR-001.jpg
19_AFR-001.jpg (95.63 KiB) Viewed 100692 times
GC_26
Spider 1969
Posts: 160
Joined: September 22nd, 2013, 7:21 pm
Contact:

Re: Land Rover Series 2.8 liter Performance Engine build

Post by Spider 1969 »

I have been driving this conversion for almost 2 years now. Combined with two differentials with taller ratio it is a real pleasure to drive and keeping up with present traffic is easy. Due to the higher compression and taller differential fuel economy has improved from 3,5 km/liter to 7 km / liter (on lpg). The crusty doors have been replaced with new ones with galvanised frames which should last for the next twenty years.
I had a truck cab, tailgate and tonneau cover laying around since 2015 but last year I finally made the time to install them.
Attachments
IMG_5240.jpg
IMG_5240.jpg (1.28 MiB) Viewed 5787 times
GC_26
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