Disco 200tdi engine rebuild.

So my 3 friends who I off road with all have a broken truck for one reason or another and I'm ready for a new engine in mine as it's blowing like a mofo, I have a spare block and head and turbo which all need some tlc so I plan to get it done now bit by bit. I wanted to do this when I had my garage built at the end of the year but with the current circumstances I'm gonna do it nice and steady now. Ive never done it before so it's all a learning curve

Sump finally off after 6 bolts were fitted by the hulk last time the sump was off

Ladder frame removed




Oil pump out and the long drive bar thing looks well!


Now this is what I'm left with.. Not sure of my next steps. Do I remove all 4 pistons or swap the one that's damaged, do I replace all 4 sets of rings and hone the bores. What do I need to measure before removing anything.

Found these in the sump between sump and ladder frame.....

the round object looks like a cam roller

jamesmartin said:

the round object looks like a cam roller

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Yup that's what I thought. I'll do a bit more tomorrow and hopefully everything else is looking well. Is there anything I need to measure before removing the pistons

put more pics up when you strip it further ,measuring comes once its stripped

If you are totally striping it down make sure you keep everything in order so you put it back as it was, ie which piston went in which bore try not to mix parts up

If you don't remove the pistons from the con rods all well be well because they are numbered.
Good advice though giveitago .

I havnt done anything with it over the weekend as the Mrs has been on a hen doo and I've had to look after the kids.. (how dare she lol)...

I managed to change my winch bumper to hold my recent acquired 8274 tho so I'll start the engine again tomorrow but I've decided I'm going to change just the single piston as I know the engine was a strong puller before as it came out my mates truck who keep going on about how good that engine was compared to what he has now. Then I'll also change the bottom end shells I think they are called or shall I not bother?

Once I've got this engine running and in I'm gonna rebuild the existing engine fully with new pistons new cam bearings ect ect

IamRobbie said:

I havnt done anything with it over the weekend as the Mrs has been on a hen doo and I've had to look after the kids.. (how dare she lol)...

I managed to change my winch bumper to hold my recent acquired 8274 tho so I'll start the engine again tomorrow but I've decided I'm going to change just the single piston as I know the engine was a strong puller before as it came out my mates truck who keep going on about how good that engine was compared to what he has now. Then I'll also change the bottom end shells I think they are called or shall I not bother?

Once I've got this engine running and in I'm gonna rebuild the existing engine fully with new pistons new cam bearings ect ect

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While you have got it apart pull the big end and main bearings and have a look, if they are ok then fair enough leave them as is, however if you plan to keep the engine and they are showing wear I would replace them as they are not that expensive in the big scheme of things and at least you know the bottom end will last ok for the next few years.

Kwakerman said:

While you have got it apart pull the big end and main bearings and have a look, if they are ok then fair enough leave them as is, however if you plan to keep the engine and they are showing wear I would replace them as they are not that expensive in the big scheme of things and at least you know the bottom end will last ok for the next few years.

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How do I check the big end and main bearings and what shows wear or not? It's my first time taking an engine apart so I don't wanna cock up but I'd like to learn so that when I rebuild the engine that'd currently in it I know alot more than I currently do. This engine I need running to get it into the truck

IamRobbie said:

How do I check the big end and main bearings and what shows wear or not? It's my first time taking an engine apart so I don't wanna cock up but I'd like to learn so that when I rebuild the engine that'd currently in it I know alot more than I currently do. This engine I need running to get it into the truck

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Chris has done some excellent videos on his YouTube channel see here for a start. Have a look around the rest of his videos as they are very informative.

Kwakerman said:

Chris has done some excellent videos on his YouTube channel see here for a start. Have a look around the rest of his videos as they are very informative.

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Appreciate it, thanks!

Ok so I've pulled out the culprit piston and the bore (to me) looks well, the shell things that were on it look well and no worn although I honestly wouldn't know if they were fooked or not. The con rod I can still see criss cross marks where the shell sits on it. Anyway let's get down to the pictures so the experts can tell me what's what lol.

Sorry for such a long wait I've been sat in 40 degree sunshine all inclusive for a week lol.














I have more photos and can take more if needed. I'm uploading them via my phone which is a pain in the ass.


What do I need to get next? I used my new bore gauges and dial gauges and measure 90.35 for the bore that I have taken the piston out of. About half way down the bore.

bore looks very shiny ,its the other side of shell you need to see

IamRobbie said:

Ok so I've pulled out the culprit piston and the bore (to me) looks well, the shell things that were on it look well and no worn although I honestly wouldn't know if they were fooked or not. The con rod I can still see criss cross marks where the shell sits on it. Anyway let's get down to the pictures so the experts can tell me what's what lol.

Sorry for such a long wait I've been sat in 40 degree sunshine all inclusive for a week lol.

I have more photos and can take more if needed. I'm uploading them via my phone which is a pain in the ass.


What do I need to get next? I used my new bore gauges and dial gauges and measure 90.35 for the bore that I have taken the piston out of. About half way down the bore.

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Pic of the inside face of shell please ...

cos it'll show any wear up ... like these

These are what I took earlier. Do shiny bores mean I need to hone them?


Also the engine has alot of chap on it. Sticky oily stuff with mud ect stuck to it. Alot of this is sat inside things like down the holes where the cam is, how can I clean this out?

What do I need to order piston wise James?

jamesmartin said:

bore looks very shiny ,its the other side of shell you need to see

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yes hone but read u on first so as to get the right angle,and watch the oil squirt a rag pushed down the bore firmly helps just dont catch it with the hone ,petrol or paraffin is good for cleaning ,shells look good but id buy a fresh set,pistons should be marked ie + or std have you a pic of a piston top thats readable

I've just been to take the rest of the pistons out to deglaze all the bores, I can see the oil jets I was going to remove them do they just unbolt or is there extra things behind them?

Anyway I came against another problem, piston 3 and 4 came out nicely and both of those piston tops show sign of slightly hitting the valves. I couldn't get piston 1 out, no matter how many times I popped it back down the bore and tries again... It goes past the first ring and that's it so I removed the big end? Bolts and **** me they are mega tight, took the caps off and put them in order.


My question is do I need to remove the timing case off the front to remove the Crank? My plan was to drop the piston out the bottom as I'm suspecting a slightly bent con rod won't allow the piston out the top.

Anyway pictures to follow, I'm already alot deeper in than I wanted to go with this engine and I appreciate all the help and guidance with it.

I'll upload some pictures now and get them on..

Worn control bearing shell from piston 1 the rest were fine