200tdi cut out on motorway.

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top drive

top drive

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Got a call last night off a mate

his 200 tdi - disco conversion in an 89 110 cut out on the motorway last night.

He managed to limp it to an asda where he found he was low on oil- as in barely on the dipstick so he topped it up - 5L took it to max. - which i reckon leaked out the flywheel housing to block as i noted that leaking between block and housing when he bought it - so we intend to do the seal and drill the housing to bolt it to the block propper.

now it cuts out at high revs.

My money would be on his lift pump packed in and the low oil thing being purely coincidental ?

any further theorys we need to investigate ? i have a few spare lift pumps about so we going to change that sharpish. but my thoughts are although not ideal is unlikely that going down to bottom of dipstick has done much harm due to the size of the sump on the 200tdi , its one of the biggest ive seen short of a commercial truck
 
Which housing do you need to drill to bolt it to the block?
Is his low oil pressure light working , if it works ok might have got away with it but if driven far with low oil pressure it will have done some damage.
 
testing it says it does work and the bulbs good so i reckon it should have been ok .

the disco fly wheel housing mated to a defender lt77 needs bolting to stop the housing flexing from the block.

this means counterboring the flywheel housing to fit cap head m10s as per glencoynes tutorial. thats how the defender 11l engine is done.
 
top drive said:
Got a call last night off a mate

his 200 tdi - disco conversion in an 89 110 cut out on the motorway last night.

He managed to limp it to an asda where he found he was low on oil- as in barely on the dipstick so he topped it up - 5L took it to max. - which i reckon leaked out the flywheel housing to block as i noted that leaking between block and housing when he bought it - so we intend to do the seal and drill the housing to bolt it to the block propper.

now it cuts out at high revs.

My money would be on his lift pump packed in and the low oil thing being purely coincidental ?

any further theorys we need to investigate ? i have a few spare lift pumps about so we going to change that sharpish. but my thoughts are although not ideal is unlikely that going down to bottom of dipstick has done much harm due to the size of the sump on the 200tdi , its one of the biggest ive seen short of a commercial truck
Click to expand...

fly wheel housing is already bolted to the block you arent going to alter that , age and wear are what causes the leaks from rear main seal and main bearing cap , bearing in mind they hold just shy of 7 litres adding 5 may well mean damage has been done whether it appears to run alright in the present
 
we are going to change the seals and gaskets as a matter of course while doing the above but i looked into it on my engine - without the 4 bolts in the bottom as per defender engines the blocks only restrained at the top and its only a paper gasket between the 2. any flex will let oil out.

you know as well as i do that in the disco the 4 bolts come through the gear box - sandwich the flywheel housing and go to the block to hold it all solid.
 
top drive said:
we are going to change the seals and gaskets as a matter of course while doing the above but i looked into it on my engine - without the 4 bolts in the bottom as per defender engines the blocks only restrained at the top and its only a paper gasket between the 2. any flex will let oil out.

you know as well as i do that in the disco the 4 bolts come through the gear box - sandwich the flywheel housing and go to the block to hold it all solid.
Click to expand...

the extra bolts go into to the sandwich plate not the block , the block has enough bolts, if gasket and seal and rear main cap are in good condition
 
The 4 across the bottom there.

While we are in about it we could go and tkae head off for a look but its more likely to have melted the journals which would entail pretty muh a rebuild if we go that far.......

Probably just change lift pump/bolt the block up / change seals and do a compression test for piece of mind an take it from there. Much more and we will look for a scrap disco.
 

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the gasket between block and flywheel housing was used to try and cure rear main cap oil leaks , it due to heat and age fails eventually not because of bolts or lack of them the other area for leaks is were sump covers rear main cap joins
 
fair enough , but if i whip it off and drill it as per design - AND change the seals - we should be good in that respect - i did it on my 200 recently its not a silly big job.

just have to keep fingers crossed for the rest atm , a full rebuild is off the cards atm.
 
Low and behold Safe to say he was never low on oil

He checked it when hot and just turned off ... Course it will show low most of its on its way round the engine .

He had stuck 5 litres in

I drained out 10litres , spilt another litre over my drive and by the looks of his prop/sump , injection pump and filter another litre came out the breather at the top - where when the engine was running it eas actively bubbling out ......

Put back about 6.5 litres and it showed almost max on dip stick after settling.

Also changed out the lift pump for a britpart item i had lying about , significant differnce and doesnt cut out under high revs now , continues through out the rev range.

Think he has dodged a bullet there.
 
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