Disco 200tdi engine rebuild.

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Shopping list so far:

Big end shells
Con rod shells
1x piston
Maybe a con rod if no1 is bent
One push rod slider
8 push rods
Gasket set for bottom end
I need a 19j oil filter housing
200tdi powersteering pump and bracket/adjuster for alternator
Cyclone breather
 
IamRobbie said:
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..
Click to expand...
piston has to come out of the top
 
if its std 200 tdi which you cant see from that pic of piston top, you need err1390 if x stamped on piston or err1391 if y stamped on
you can remove oil squirts but careful retightening as they snap easy you need washers too 1 of each per squirt ,afu1879l and afu1887l
 
jamesmartin said:
if its std 200 tdi which you cant see from that pic of piston top, you need err1390 if x stamped on piston or err1391 if y stamped on
you can remove oil squirts but careful retightening as they snap easy you need washers too 1 of each per squirt ,afu1879l and afu1887l
Click to expand...
Err1387 on the three pistons I can read James
 
turners do stc1052, you just measure bottom of skirt at 90 degrees to gudgeon pin to check its the same as the rest though a 1 thou wont hurt as long as its smaller and not larger as clearance is only .5 to 1.5 thou
 
Thanks James. I'll get back to ordering a new piston and one new con rod once I manage to get piston number 1 out. Ive taken the fip off and the timing case had one rounded bolt next to the water pump bolts. I'm at a loss of how to get the Crank sprocket off, I've taken the cam sprocket off and ofcourse the fip sprocket.

The crankshaft is a little rusty where the toothed Crank cog is so I've lubed it up and left if. Maybe I need to find my pulley set or buy another to get this off?

I'm assuming that once the sprocket comes off the timing case comes off and the Crank will lift up and slide out?

jamesmartin said:
turners do stc1052, you just measure bottom of skirt at 90 degrees to gudgeon pin to check its the same as the rest though a 1 thou wont hurt as long as its smaller and not larger as clearance is only .5 to 1.5 thou
Click to expand...
 
why are you removing timing cover, theres a proper puller to remove the bottom sprocket, even so ive had ones ive had to weld m10 bolts to and use a hub puller
 
Ok thanks for the help again lol. Piston and Conrod 1 are out. Finally got the timing case off. One snapped bolt in the block ceased in next to the water way up top right... Right so and so to get the timing case off, tried screw extractors and everything. Gonna have to drill and tap that hole, something I'm proper ****e at!!

I'm so glad that I went to remove the other 3 pistons to glaze bust the bores otherwise I'd had just replaced piston 2 and put it back together. So I now need one con rod and one piston...

I've never done this before and keep thinking what the fek have I started here lol...

Cranks out and a couple of half moon Bronze things fell out. Some sort of spacers or something? I'm gonna bath the kids now as they have just got back from the monster in laws late and I'll post some pics up later. I think I'm gonna clean the block up and paint it up since its turned out to be a bigger job than first expected.... Typical landy!
 
IamRobbie said:
Ok thanks for the help again lol. Piston and Conrod 1 are out. Finally got the timing case off. One snapped bolt in the block ceased in next to the water way up top right... Right so and so to get the timing case off, tried screw extractors and everything. Gonna have to drill and tap that hole, something I'm proper ****e at!!

I'm so glad that I went to remove the other 3 pistons to glaze bust the bores otherwise I'd had just replaced piston 2 and put it back together. So I now need one con rod and one piston...

I've never done this before and keep thinking what the fek have I started here lol...

Cranks out and a couple of half moon Bronze things fell out. Some sort of spacers or something? I'm gonna bath the kids now as they have just got back from the monster in laws late and I'll post some pics up later. I think I'm gonna clean the block up and paint it up since its turned out to be a bigger job than first expected.... Typical landy!
Click to expand...
thrust washers they sit either side of the block casing for no 3 main bearing ,soft metal to crank
 
Photos from yesterday, apologies for taking so long with them.

DSC_0996.jpg


Piston 1 looks as straight as Elton John.

DSC_0990.jpg

Broken bolt in the casing, rest is sticking out the block about 5mm if that

DSC_0997.jpg


DSC_0998.jpg


DSC_0991.jpg


DSC_0993.jpg
 
Won 2 second hand piston and con rods for 22 pound off ebay as I only wanted one for the con rod so I'm going to see if they are still in tolerance and install them if good. Got a power steering pump for 25 and the bracket for 11.... Bits are coming together I'm going to get the shells from paddocks next week and hone and put things back together ready to pull my current engine and swap everything over
 
jamesmartin said:
why are you removing timing cover, theres a proper puller to remove the bottom sprocket, even so ive had ones ive had to weld m10 bolts to and use a hub puller
Click to expand...
Sorry James I didn't see this reply before. I was removing the timing cover to get the Crank out. I managed to get the bottom Crank sprocket off by prizing it slowly.
 
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