Determining condition/wear in a 2.5D NA engine

My 110 (ex-MOD likely ex-ambulance) has a venerable 2.5D in it with well over 300000Kms. Still runs well, but it occurs to me that it is likely due for a refreshing and/or replacement with an overhauled unit.

Question I put to the assemblage (yes, you lot) is how do I determine this other than just by the mileage?

It's not quite as easy to start as it was, and is blowing clouds of blue smoke until all 4 cylinders start firing. it's also smoking a bit on overrun (valve seals I expect).

SO, how to tell how worn is worn?

Lastly, I can hear the shouts of '200tDi!" from here. I have one of those in my shop - however I kind of like the 2.5D - it's a simple, no-nonsense engine that is easy to maintain. Anyway, with all of them being converted it amkes this one more valuable as a collector car.

Alan

TDI it if you don't the next person will,just as easy to maintain than the 2.5D with twice the power

Re: Conversion:

If I could get a real Defender manifold set for less than crazy money I'd agree - but this truck is LHD (served in Germany) and the TDi I have is a Disscovery one.

In short, not at all easy or simple. Not all that interested in doing a lot of hacking about to make it work when I have a simple, reliable truck now that just needs fettling. Here in the States this truck is a collectible vehicle and not just another beat-up ex-MOD tratter - so that is a consideration.

And yes, I do have the skill set and shop to do it - just don't like the idea.


Alan

NOTE: I was in Manchester last weekend - Manchester, new Hampshire, that is...

I'm a fan of this engine too , as are the guys over on the 2.5 forum page. The first thing I'd do is a compression test. If the pressures are good, it may just need to have the injectors serviced/timing checked. If the injector pump has covered a lot of miles, it may be time to refurbish or replace that.
If the compression has dropped, it's head off and look for wear/a step in the bores. The valve seals are easy enough to do while you have the head off. Without a turbo to think about, the whole engine is very straightforward to work on and under stressed.

rebuild the original engine for originality imo given your location as the US.

I like my NA aswell super simple and reliable and just as good off road as the tdi boys

zeaphod said:

I'm a fan of this engine too , as are the guys over on the 2.5 forum page.

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2.5 forum page? You mean the one here, or is this a place I am unaware of?

If there is a special forum for the 2.5 clue me in!

Re: Condition/compression. Works for me. I should have planned to do that in any case. Dumb question - what's the compression PSI/bar supposed to be on this engine. I will be VERY surprised if this one is up to sprcification after 300,000 kilometers.

Alan

2.5 forum at the top of home page in engine section. From what I remember anything over 70 psi on first stroke building to 120 plus is not to bad.

tottot said:

2.5 forum at the top of home page in engine section. From what I remember anything over 70 psi on first stroke building to 120 plus is not to bad.

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Those numbers seem a little low for a Diesel...

mrchurchill109 said:

Those numbers seem a little low for a Diesel...

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Yes you are right,thinking petrol.

More like 140 first stroke, building to 280 min.

Re: 140-280: Great - brilliant. Now I have something to work with.

Figuring I can yank the engine, strip it, send the head out for guides and valve refacing (might replace the valves as well depending on condition) and do the block up with new rings and bearings all round.

Considering the way it's been behaving of late I have a serious suspicion that the compression is nowhere near where it needs to be. I doubt it's fuel related - it had new injectors last year and the performance is consistent (no misfiring) so I tend not to suspect issues with the CAV DPS pump.

On the subject of the CAV pump - anyone got a link to a service manual for it?

Any other gotchas other than the timing belt (BTDT 20K miles ago).

ajr

You might have a look at this: http://www.solidebolide.nl/downloads/CAV Workshop Manual fuel-injection-pump.pdf

It's for the 2.25, but I believe the pump is similar. Apart from that, it's "ask Google"