Engine rebuild thread

[payydg]

Going to strip and rebuild my 200tdi. I’m in two minds about having the block professionally rebuilt or do it myself. Either way this is more for me to ask questions and of course post photos.

Lesson no. 1 - a 300kg trolley from B&Q will crumple like a tin can when trying to shift an engine down a garden path.

More to follow.

 

[goonarmy]

That should have taken that weight.

 

[payydg]

I think it was the set of steps that signalled the end for that particular trolley. Still I recon I can hammer it out for when I put it back in.

 

[goonarmy]

I think it was the set of steps that signalled the end for that particular trolley. Still I recon I can hammer it out for when I put it back in.

Well may be don't eviel kinievel it on the way back

 

[payydg]

Does anyone know the tread size and width for the injectors on a 200tdi? Need to have an adapter for my slide hammer made.

 

[jamesmartin]

Does anyone know the tread size and width for the injectors on a 200tdi? Need to have an adapter for my slide hammer made.

put a adjustable spanner on the flats of the injector and twist clockwise

 

[payydg]

put a adjustable spanner on the flats of the injector and twist clockwise

Don’t you need a slide hammer to get them out?

 

[jamesmartin]

Don’t you need a slide hammer to get them out?

some just wont come out without destroying them or the head ,usually the method i suggested works you can rock back and forth but undo in a clockwise direction otherwise the injector will unscrew itself

 

[payydg]

some just wont come out without destroying them or the head ,usually the method i suggested works you can rock back and forth but undo in a clockwise direction otherwise the injector will unscrew itself

Ok thanks. Will give it a go. Tho do you know the thread size? Would be nice to have an adapter

 

[jamesmartin]

Ok thanks. Will give it a go. Tho do you know the thread size? Would be nice to have an adapter

not off hand , ive never needed to use a slide hammer on a tdi injector

 

[payydg]

not off hand , ive never needed to use a slide hammer on a tdi injector

Thanks James, I’ll see how I get on with the JM method.

 

[Retroanaconda]

Just avoid using the spanner where the banjo bolt for the leak-off pipes goes in. This area needs to be flat for the washers to seal properly and levering the injector about with a spanner could damage the sealing faces if not carefully done.

 

[payydg]

So how the devil do you attach an engine stand to the back of this. Flywheel housing removed.

 

[jamesmartin]

via 4 of the 6 flywheel housing bolt holes and suitable length 10mm bolts,youd need to raise it with the engine crane

 

[payydg]

via 4 of the 6 flywheel housing bolt holes and suitable length 10mm bolts,youd need to raise it with the engine crane

Also do I need to lock the fuel pump before removing if stripping the whole thing down?

 

[jamesmartin]

you dont need to mark the pulleys or lock the pump unless you slacken the large nut,which you dont need to just the 3 bolts

 

[payydg]

you dont need to mark the pulleys or lock the pump unless you slacken the large nut,which you dont need to just the 3 bolts

Great thanks!

 

[payydg]

How do you get the timing gears and pulley off?

Got the injector pump and gear out.

The pulley looks like it’ll just come out after taking the bolt out.

How do you get the crank and cam shaft gears off?

Also, I can’t seem to budge the engine ‘breather’ housing - bolts are out but seems totally stuck?

 

[Flossie]

Bolts are still in in your pic.
When the bolts are out tap it with a mallet or block of wood.
Lots of components stick to each other where there is a gasket or sealent.

 

[payydg]

Bolts are still in in your pic.
When the bolts are out tap it with a mallet or block of wood.
Lots of components stick to each other where there is a gasket or sealent.

Yeh that’s just a pick. Bolts out and I’ve given it a fair wack with a soft mallet.