1986 90 rebuild / restore

Jonny miller said:

Good news !! Picked this up on Sunday View attachment 144601 View attachment 144602

Quick 6 hr round trip on mother’s day ! Had lunch booked for 12 so hit the road at 6am and made it to the pub at 12:05
So 200tdi project is under way just hoarding bits into my eBay basket

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thats excellent, its literally (almost) a drop in - only bit i had to do with removing a dowel on the bellhousing and tapping it for a stud.
the difference is like night and day, it will blow your mind

good choice going genuine def 200tdi, keeps it factory and makes parts sourcing in future easier as standard components can be used

flat said:

they aint that hard to get yet!

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Used to being in Europe then, much harder to find there, haven't seen that many since I've been home either.

I keep meaning to ask, what is your ex-mil 90, certainly not petrol lol

dieseldog69 said:

Used to being in Europe then, much harder to find there, haven't seen that many since I've been home either.

I keep meaning to ask, what is your ex-mil 90, certainly not petrol lol

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200tdi was NA but i junked that after a few years, rebuilt the 200tdi from the bare block up (well a mate did the complicated bits but he made me bolt it all back together)
had the head done, the pump done etc, good injectors, good turbo and lightweight car. it pulls very well.

flat said:

200tdi was NA but i junked that after a few years, rebuilt the 200tdi from the bare block up (well a mate did the complicated bits but he made me bolt it all back together)
had the head done, the pump done etc, good injectors, good turbo and lightweight car. it pulls very well.

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It's quick!!! We'll have to get you a boost gauge to drive by lol

i did wonder about fitting one temporarily jsut to see what i am making, but it does pull very well

Head done , belt done and turbo rebuild done and a good clean
I put new alternator and pas pump on mine in the summer so swapped them onto the 200 , alternator is the same but the 2.5 na uses a tensioner on pas belt but 200 uses a bracket on the pump that you rotate so just had to swap the front plates .

Orderd new rear oil seal from turner engineering and flywheel housing gasket . So will get the old engine out this week and then hopefully get the 200 in week after and start pluming her up

Old 2.5 lump out


Got the flywheel housing , clutch etc bolted onto the 200 and radiator and intercooler into the frame just need to drop the mounts then I will drop the new lump in hopefully this Friday

Looks excellent.

Difference is night and day. Your gonna love it

Looks crackin!

Chopped the radiator mounts and rewelded and drop the 200 in which was a complete **** only because I was using a forklift so kept on running out of side shift and didn’t have enough slack in chains to push it back onto the gearbox !!! After a lot of swearing and banging she slotted in


Need to get oil pipes extended next week and waiting for intercooler hard pipes, hopefully be running by next Friday .

Got the exhaust on had to shorten it a bit but works
Also got her running today after waiting for ages for new leak off pipes
But may need to rethink the air filter !!! as that k&n is loud ,only used it as I had it lying around and the standard air boxes are very expensive.
Also as you can see it’s a straight through exhaust as well which may need to be re thinked
I haven’t actually driven on the road yet but think is just going to be irratating!

hi nice build fairplay ive got a disco 200 in mine but ive had to move around the pipework kept the standard airbox tho

Had a bit more time on it today to actually get it up to temp etc and it runs like sh*t lumpy and missing smoking and stinking of fuel ,will re check timing first but the pump has definitely been played with at some point as anti tampering thing on back screw is missing and the four screws on top of the pump are slightly damaged ..... so it continues

Ok ...It’s finally alive again long story short engine no good rebuilt now good

Broken valve guide why it ran like **** ‍

Head rebuilt

Going back together

Then turbo let go on first test drive so new turbo!

It’s now sweet! straight through exhaust may be to asbo tho but it’s fun for now will upload a video!
Sorry for the slow updates

So the mistakes have been buying turbo cartridge of eBay! and I must of had the push rod on valve 7 out of line! lesson learned

It's looking good, and you're nearly there!

Just read this from beginning. I love reading project threads as it helps me see end of tunnel with mine and love seeing a resto. I will do a 90 one day...... don't tell Mrs. Think I'll have to buy a ring first haha. Lovely job and lovely motor. Well done!

Dropped of ready for MOT tomorrow, exhaust is too loud tho it’s going to be changed, sounds cool but is just to asbo for me.

I recognise where you are lol looks great

Almost exact same vehicle I am currently restoring (bar the colour). What size wheels and tyres are they? And is that on standard height suspension?