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200 tdi Engine checking / refurb??

Discussion in '200 TDi' started by steve2286w, Jun 11, 2019.

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  1. steve2286w

    steve2286w Well-Known Member

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    759454DA-5C9C-43FE-BFC6-2677348EDF0E.jpeg D843BC75-F783-48BE-AD01-81B7E32DA4BE.jpeg C9BDF376-2ACD-46A4-B575-2BF3EBA413ED.jpeg I have removed flywheel and outer timing case cover, I have locked the injector pump with pin
    Am I safe to remove the pump as is , I don’t have that LR tool round plate to bolt pump up
    I can lock shaft using the pin and nut on pump, is this sufficient to keep settings when bolted back on,

    I want to remove crank for polish and clean, do I now need to remove all cogs and the timing case before the crank can be lifted out ?

    Thanks
     
  2. jamesmartin

    jamesmartin Well-Known Member

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    as long as you dont undo the nut on the pump shaft and just undo the 3 pulley bolts you can remove pump without worry,id would remove timing case
     
  3. steve2286w

    steve2286w Well-Known Member

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    Thanks James that’s the big nut in middle of cog you mean , not the shaft lock nut on other side,?
     
  4. jamesmartin

    jamesmartin Well-Known Member

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    yes in middle of pump pulley, dont undo that then settings are safe just a matter of lining pin up after
     
  5. steve2286w

    steve2286w Well-Known Member

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    Great thanks
     
  6. steve2286w

    steve2286w Well-Known Member

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    14D7616C-E34D-4E1C-A9D5-798E371099E4.jpeg crank out without too much fuss, the cogs came off the shafts nicely no corrosion or wear
    I forgot to measure end play on the crank but noticed the thrust washers down to copper I guess these should have white metal on them as bearings , the top mains was showing signs of copper , next job polish these up, the drilled oil holes from bearing to bearing were nice and clean, not sure about cam, tempted to leave that where it is



    7E4A0DE5-B931-4417-B606-875039D04CE2.jpeg
     
  7. Flossie

    Flossie Well-Known Member

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    I think new thrust washers have copper showing from memory so yours may be fine.
     
    steve2286w likes this.
  8. Flossie

    Flossie Well-Known Member

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    Take the oil squirters out and check they are clear too. Two copper washers on each (again, from memory)
     
  9. steve2286w

    steve2286w Well-Known Member

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    Thanks , looking online some look copper and some tinny , I’ll measure them and see how they compare
     
  10. steve2286w

    steve2286w Well-Known Member

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    Will do , I’m surprised how heavy the bare block is , was going to lift on bench but might leave it on floor
     
  11. jamesmartin

    jamesmartin Well-Known Member

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    just fit some new std thrust washers
     
  12. steve2286w

    steve2286w Well-Known Member

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    upload_2019-6-27_16-8-17.png
    yes will do, ill start compiling the parts list soon, thanks for help, I took some meaurements using a internal mic dial gauge set to 90.47mm on a metric micrometer, however the dial gauge is imperial with a resolution of 0.0005", so got some measurements as above
    some measurements are bigger than original bore size of 90.47mm
    the below bottom measurement is beyond the sweep of the piston and has a small ovality but only less than 2 thou
     
  13. jamesmartin

    jamesmartin Well-Known Member

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    the original bore size is only nominal it may vary from under to over quoted size ,a measurement fore and aft at bottom 1/4 of bore will give original size, which is why you have some - measurements i presume they are minus
     
  14. steve2286w

    steve2286w Well-Known Member

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    YEs taking the average of bottom of bores its about 90.487mm original size rather than nominal 90.47.
    Yes the - ve measurements taken from the dti set at 90.47
    average wear across the 4 pots is about 0.0016 so happy with this
    My new piston ring pliers came today and a new set of feeler gauges
    the plier type seem hard to remove them when in the grooves and still finicky when I get them out of groove, not sure if these just intended for fitting to pistons.
    I tried all the rings from Piston 1 about mid bore and each is over the allowed limit for the ring gap in bore I get between 0.7-0.8mm for each of them

    top max gap 0.5mm
    2nd max gap 0.45mm
    Oil control max gap 0.6mm

    the defender manual says fit oversize piston rings, just wonderring if worth doing
    would this additional gap be noticeable in smoke or crankcase pressure
    what do these gaps get to when engine realy gone
    if new rings fitted is the existing honing still ok

    thanks

    IMG_6360.JPG









    IMG_6359.JPG


    IMG_6353.JPG
     
  15. jamesmartin

    jamesmartin Well-Known Member

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    a slightly larger gap wont hurt too small would, its ring to cylinder surface that matters ie fresh ring and bore surface
     
  16. steve2286w

    steve2286w Well-Known Member

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    Thanks James, I will check others as I go but plan to remove rings clean pistons and refit if all no worse than No 1
     
  17. steve2286w

    steve2286w Well-Known Member

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    Measured the main journal diameters which should be 63.475-63.487mm I measured 63.485-63.49mm for inline with crank key way and 90
    The big ends should be 58.725-58.744mm
    No 1 was 58.71 in line and 58.73 90 deg with all others 58.72 -58.73mm
    so I can live with them I have polished them with 600 grit and will order standard replacement bearings from Turners
     
  18. steve2286w

    steve2286w Well-Known Member

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    IMG_6397.JPG

    IMG_6400.JPG
    Painted block today with some Frosts Old Gold, 1st coat on
    I noticed the cam can be pulled out by hand about 20mm or so, I have not removed it or the followers although I have rotated block while doing jobs can this move the followers tappets around leading to this end play
    is the play taken up when the cam pulley is on or is it located by the skew gears vacuum pump to keep it in position

    Been cleaning pistons and refitting the rings
    it looks like the oil control can go on any way round
    the middle ring I could see top marked on them all so that was ok the top ring in section is not rectangular but more wedge shaped but I cant work out if


    one side is 90 deg (B) or both less than 90 deg (A) anyone had a very close look before
    the upper side of the top ring is more stained than the shiny underside so this is my double check just incase I got mixed up while handling them

    RING SHAPE.JPG
     
  19. jamesmartin

    jamesmartin Well-Known Member

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    cam pulls forward because its been allowed to be pushed back , id remove the followers and refit once cam pulley is back on so cam cant move back again,top ring will have markings showing top face
     
  20. steve2286w

    steve2286w Well-Known Member

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    Thanks will do
     
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