200tdi rebuild

greyhair said:

i have the new chassis loom here mate if you needs pics of it

I also have the original loom that I marked up when i removed if you need that for a ref pm me and we can sort something mate

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That would be great thanks, I'll pm you in the morning when I'm on my computer

ok mate no worries

Well hit another issue today. The bulkhead I bought was known to be off an accident damaged vehicle and upon first inspection it looked ok. However now ive stripped it down it looks worse because of a ripple across the flat panel behind the dash where the drivers footwell has been pushed in plus the other damage on it looks a little worse aswell. After giving it some panel beating (lump hammer and a piece of wood) it now looks a little less twisted but there is still nearly 2 inches difference across the footwells

There is also some damage to the left hand pillar and footplate which should be easy enough to hide

Now I know the full extent of the damage I could do with some advice, a mate says fit it to see how bad it is on the chassis, which I'll do when I have some help.

In the meantime I want to know if you lot think it's worth having it galvanised or just sandblast and paint it? Also if I get it galved, should I cut off the fly screens to stop them getting blocked up?

Not done much over the last few days though my day out to Peterborough on Sunday proved to be quite productive.
Firstly I managed to get a td5 fuel tank complete with cradle, pipe work and sender which I test fitted tonight.

I'm not sure whether or not I need the sender unit or how to wire it in at the moment so any advice would be great.

Secondly, I spoke to Ashcroft about my bulkhead. They said that galving it will probably make it worse and that they would be able to refurb it for between £400 and £700 and that they would take my other bulkhead aswell. So before i make a decision I'll test fit the bulkhead to see how bad it is.

Finally I spoke to duckworth about a rear tub. They said that they will be collecting again within the next few weeks and that depending on which spec I want will be between £400 and £600. Which seems quite reasonable for what would essentially be a brand new tub 😊.

So although it's going to cost some money I afoul be able to get somewhere between now and Christmas. Next job on the list is to sort out bits for dismantling and blasting and to create an understandable wiring diagram for both a standard 200tdi and a modified one for myself. I'll try to keep you all updated as I go along.

use a disco sender 2 pipe unit and sender for gauge ie feed and return for fuel and no pump fitted like the one in a td 5 so dead easy to pipe and wire ,regards gatso

GATSO said:

use a disco sender 2 pipe unit and sender for gauge ie feed and return for fuel and no pump fitted like the one in a td 5 so dead easy to pipe and wire ,regards gatso

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Thanks, would an early defender unit work at all?

a sender from early side mount or a late side mounted tank ,,will not fit into a rear mount td5 plastic tank ,u need the disco type ,makes the job really easy ,regards gatso

GATSO said:

a sender from early side mount or a late side mounted tank ,,will not fit into a rear mount td5 plastic tank ,u need the disco type ,makes the job really easy ,regards gatso

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What he said ^^

You need the one with 2 outputs not 4. The 4 one would have to have all of the pipework altered as it has a pump in.

The disco one is ESR1223.

Ace, thanks

Had a recent fleabay spending spree although I've not spent a lot, buying waterproof connectors for my wiring loom. I think I'll have enough now 😜

After you have got all the wiring working and sorted, its well worth putting some sort of grease in them connectors as they are not 100 percent waterproof, see quite a few corroded ones at work.
Was a recall on the trucks a few years ago to open all of this style of connector and put a thin smear of white grease in them.

lynall said:

After you have got all the wiring working and sorted, its well worth putting some sort of grease in them connectors as they are not 100 percent waterproof, see quite a few corroded ones at work.
Was a recall on the trucks a few years ago to open all of this style of connector and put a thin smear of white grease in them.

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Yeah, where I used to work they put contact grease in them there so it's a precaution which I'll be taking

Not got much done this weekend other than prepping the a frame and the rear axle for sand blasting. I was hoping to get a load more done today but the bevvies i had last night said otherwise

Quick update, rear axle is fully prepped for blasting tomorrow and ive got a full set of parts for rebuilding it . Ive also sorted out a load of other parts for blasting so that i can get everything painted in one hit rather than in dribs and drabs. All going well i should have something that resembles a rear axle by the end of next week and ill be one step closer to a rolling chassis

nice one

So I picked up my rear axle from the blasters yesterday and it's come up quite well.

So today I dug out a decent diff which I cleaned and inspected before oiling and fitting to the casing. I also fitted new stub axles today as well.


So once the sealant has set fully tomorrow I'll clean up the diff casing and treat the axle with fertan ready for painting.

looks like a good job done by the blaster.....would you mind telling me how they charged to do one axle?

Had a local quote for £100 for front and rear axle which feels,a bit steep but then I'm probably out of touch in getting work done by other people

Pricilla said:

looks like a good job done by the blaster.....would you mind telling me how they charged to do one axle?

Had a local quote for £100 for front and rear axle which feels,a bit steep but then I'm probably out of touch in getting work done by other people

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Hi, where I went they charge by the hour which is £42 inc Vat. It took 1 1/4 hours to do the rear axle casing, hubs and two gearbox brackets so £100 is perhaps a bit dearer. Bear in mind that my axle was also well hammered in waxoyl, paint and rust so wasn't the easiest thing to clean.

AlbertDefender90 said:

Hi, where I went they charge by the hour which is £42 inc Vat. It took 1 1/4 hours to do the rear axle casing, hubs and two gearbox brackets so £100 is perhaps a bit dearer. Bear in mind that my axle was also well hammered in waxoyl, paint and rust so wasn't the easiest thing to clean.

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Thanks AlbertDef90 that gives me a good idea of what I've been quoted and whether it's near the mark or not....might look elsewhere

Good rebuild thread by the way

Quick update, ended up not doing much in the end because of work and me wanting to have a bit of a break for a few afternoons.

Anyway I've got back into it again this weekend and I've finished cleaning up the diff and I've started removing the Fertan i applied because I don't trust the finish I got.



I was half tempted to laquer it instead of painting because I think it looks cool but common sense intervened so I'm going to give it the gloss black treatment like the front axle 😊

Not sure how much im going to get done this week as my brother rolled his micra so I've got to put that right this week but I'll keep you all updated.