200tdi rebuild for 2.5NA Tithonus

I am halfway through my cheap eBay 200tdi rebuild and wondering if there is any interest for a thread?

Thankfully the engine internals were all fairly good. Crank has been polished and checked (fine at standard sizes), cylinders being bored to +20 with KS pistons and the head is being fully rebuilt as well. Since it it going into an ex military defender everything is being painted duck egg.

Whilst the block and head is being worked on I am stripping, blasting and rebuilding every other casing and ancillary so when it all goes together it should be a very well sorted engine! Payen gaskets are being used all round so hopefully it will have half a chance of holding oil

I have also pulled the 1.6 transfer box to fit a 1.2 that I have recently given a light refurb too (new seals and input gear), but have found that the gearbox output splines are badly worn so it will need a refurbished gearbox as well which is another unwanted expense. Plan is to fit a new clutch, gearbox and transfer box to the existing healthy 2.5na to get the car on the road so i can take my time with the 200tdi.

Anyways, enough waffling. I can post some progress pics if anyone is interested?

One thing I do need is a set of injectors if anyone has any spare, and some air filter / exhaust advice as I am fitting a 300tdi turbo and manifold for added complication

Ok well you are getting some pictures anyways

Here is what it looked like after delivery and during strip down:







Starter motor stripped, cleaned and new bearings



PAS Bracket



Thermostat housing



Vac pump and cam cover



Block wire brushed prior to rebore



Busy painting

Really smart work! I shall be more interested in the 200tdi now I know it has a cake stand fitted.

What was the casting date on the back right side of the cylinder head I bet 1991/2 onwards?

The 1.6 tfer boxes are worth a bit of money not a fortune but more then the 1.2

200 injectors not that hard to come by on ebay, I would get them tested before replacing

Engine building and cake is always a good mix

Once the head is back I will check the casting date. The 1.6 transfer box might be going to Ashcroft with the gearbox to offset the rebuild cost a little, will see what they end up offering me for it.

I have seen a few secondhand injectors on eBay, but people seem to be asking a fortune for them! (Almost as much as I paid for the whole engine which seems crazy). I have a pop tester and ultrasonic cleaner so rebuilding is not a problem if I find a serviceable set.

If you have the pop tester you might find they are serviceable.
The early 200tdi engines had an extra breather pipe from the front right side of the rocker cover down to the cam cover plate and normally a green oil filler cap instead of the usual yellow one.
If you are in no rush pm me in a couple of weeks time as a mate has got me a 200 tdi in bits with two heads but not sure if they have injectors still in them.

Pile of finished parts getting bigger ☺

Looks great, What car was the engine originally out of

Thanks

nice. looks super good

Looks good, your doing a fantastic job getting those parts so good! We love pictures, don't hesitate to put a few pics of the Tithonus up either....

Its an old Disco lump but will be getting a 300tdi manifold and turbo

Here's a teaser since I don't have many pictures of it at the moment

You should take loads of pics of even the most mundane parts as they will come in handy at some time, either for your own reference or to help someone else.

Goos choice in tyres just be careful on wet roundabouts!

Well the gearbox is back already from Ashcroft Transmissions.

I am going to bolt it and the new transfer box to the standard 2.5NA for the time being whilst I finish off the 200tdi rebuild

Looks well smart.

I have a paint chip in my wheel arch almost identical to that....

A1.2 transfer box on an NA engine, may find it a bit gutless.

Huddy84 said:

A1.2 transfer box on an NA engine, may find it a bit gutless.

Click to expand...

I imagine it will be, but it is only for a couple of months max. The 1.6 in it at the moment is very low geared so it will be odd at the other end of the spectrum!

Yeah, I went from 1.6 to 1.4. It is much nicer to drive round town and much less revvy but I have to be much more careful with hills and long gradients as it has far less guts at speed.

Engine is back from the machine shop!

Time to start reassembly (after the chassis dinitrol / gearbox / trasferbox)

More cleaning today and bolted the transfer box and gearbox together.

Well things are carrying on despite the lack of updates. Reassembly will begin as soon as my plastigauge turns up.



I have been tarting up the rear end as well (getting ready for War and Peace in July)