My Defender 90 200tdi rebuild

Well done, fair bit of work to get all that in ....

Thanks Mik,
Got the bumper and grille on too, mainly to prevent any damage to the radiator and intercooler.

Good job, looking smart

Hi,

I started a thread in the 90 forum but thought I would ask the same here.

I am at the stage where I will be starting my 200tdi engine after 3 years doing a restoration.

The only work done to the engine since removing it has been a replacement timing belt and new oil and filters, the engine has not run since then.

I intend to drain this oil and replace with new, fill up the coolant with anti freeze, add power steering fluid and then prime the fuel system.
The next step was to start the engine, and without revving leave in tick over to allow the oil to flow around the engine.

What is the general consensus to starting an engine that has not run, but turns over after this length of time? My concern is the turbo oil feed, should I be doing anything else?

Tirran said:

Hi,

I started a thread in the 90 forum but thought I would ask the same here.

I am at the stage where I will be starting my 200tdi engine after 3 years doing a restoration.

The only work done to the engine since removing it has been a replacement timing belt and new oil and filters, the engine has not run since then.

I intend to drain this oil and replace with new, fill up the coolant with anti freeze, add power steering fluid and then prime the fuel system.
The next step was to start the engine, and without revving leave in tick over to allow the oil to flow around the engine.

What is the general consensus to starting an engine that has not run, but turns over after this length of time? My concern is the turbo oil feed, should I be doing anything else?

Click to expand...

I’d say take plugs out and spin it to get oil in and around

Problem is most 200 tdi’s start first turn of the key what ever the weather or however long they’ve stood as long as they’ve got fresh fuel & battery charged. I’d isolate fuel pump and crank over a few times on starter to circulate oil then reconnect fuel pump.

As above stop it from starting turn over until oil light goes out, re connect should be good

Big day today, my landy started first time after 4 years!!

i added an inline filter for the diesel just in case there was debris in the fuel tank, cranked a few times it over with the fuel solenoid disconnected.

Got the exhaust to fit and investigate why the clutch is working like an on / off switch.

will try and upload the video.

Got a good few hours on the build today. Fitted the rear screen, set out everything on the bench mindful not to fit the glass the wrong way round. DumDum on the frame all good stood back to admire my work… and despite my planning the glass was in the wrong way. Feeling like a right muppet I started all over again. Also fixed the quarter light as I has put them in with the finishing fillet on the outside.

Laid the bonnet on top of the wings really just to keep it safe as moved things around.
Fitted both the drivers and passenger doors, including the security plates which prevent the theft of the doors by removing the hinges. Simple solution where the plates are behind the seam of the A pillar when the door is closed. Will fit the door seals later.

Looking very smart the noo ...

Been a little busy, and frustrate.

All the lights are in and working. The headlights are new Wipac halogen as LED too expensive at the moment, all the others front and rear are LED.
New wolf style wheels with new Davanti Terratoura tyres, I was going to leave them off until the end but needed a lift as the little things are taking so long.

I bought a gas strut kit for the bonnet as it’s a TD5 bonnet and different from the original 200tdi one.

I’ve ended up reworking the brackets etc they were not adaptable as the supplier implied and ended up with a misaligned bonnet, it’s higher on the offside than the near side, aligned left to right ok and not catching on anything underneath. I suspect something on the hinge as the rubber lock on the hinge doesn’t seem quite correct, I’ll get back to it later.

Just have the windscreen to fit and need work out how the seal orientates.Dashboard to be reassembled and then I will hand over to the local garage for a check over and MOT, let’s hope the emissions are ok

The Glynn Lewis front and rear mudflaps are all fitted and certainly looks as if that was a wise decision.

Really good .... let me know when it's running and i'll buy you a bacon roll down at the Greedy Grazer
Google Maps linky

Very nice! The wheels finish it off nicely!

Windscreen fitted, I read on here and a couple of other forums of issues with aftermarket windscreen seals, and the suggestion to use the genuine OEM seal. At £156 each that was not an option so, despite having a new screen I elected to fit the old one just to practice the install with an aftermarket seal. Initially a bit awkward until I understood the orientation of the seal it fitted easily however, the new screen is still in its packaging in the garage.

Still having fitting issues with the bonnet, are the TD5 bonnets so different? I have quickly and poorly resprayed the original bonnet (it was rusty on the under frame hence the TD5 one), so I could try and get the car in form an MoT but I still have it lifting on the nearside as was the TD5 one. I think it may be the bush on the bulkhead spreading and not moving as smoothly as the other side. I've ordered replacements to try again. Any ideas welcome.

Dashboard fitted.

Headliner in, sun visors fitted, I also added some DoDo Mat behind the headlining in an attempt to reduce the noise. I also replaced the original interior light with one from Mud Stuff, currently £10 off too. This gives the option of White or Red light in the cabin, if that's what you need.

Once I get the bonnet aligned and the handbrake switch / warning light fixed all I have left before the MoT is replace the handbrake cable, set the tracking, set the headlights, grease the prop shafts again and properly clamp the exhaust. I might get the local garage to finish that off as they have ramps making the jobs much easier.

Tirran said:

<snip>. I might get the local garage to finish that off as they have ramps making the jobs much easier.

Click to expand...

So do I and i'm just round the corner and free ...

miktdish said:

So do I and i'm just round the corner and free ...

Click to expand...

Thanks Mik, the garage is only a mile away and they will do the MoT too.

Once done I'm taking you up own the bacon roll.

Tirran said:

View attachment 289396View attachment 289397
Been a little busy, and frustrate.

All the lights are in and working. The headlights are new Wipac halogen as LED too expensive at the moment, all the others front and rear are LED.
New wolf style wheels with new Davanti Terratoura tyres, I was going to leave them off until the end but needed a lift as the little things are taking so long.

I bought a gas strut kit for the bonnet as it’s a TD5 bonnet and different from the original 200tdi one.

I’ve ended up reworking the brackets etc they were not adaptable as the supplier implied and ended up with a misaligned bonnet, it’s higher on the offside than the near side, aligned left to right ok and not catching on anything underneath. I suspect something on the hinge as the rubber lock on the hinge doesn’t seem quite correct, I’ll get back to it later.

Just have the windscreen to fit and need work out how the seal orientates.Dashboard to be reassembled and then I will hand over to the local garage for a check over and MOT, let’s hope the emissions are ok

The Glynn Lewis front and rear mudflaps are all fitted and certainly looks as if that was a wise decision.

Click to expand...

Very smart & fresh looking nice job.

Looking fantastic. I'm very envious. Only just getting back into working on mine after a two year break. You've definitely taken the lead!

I noticed that you've gone for the TD5 rear crossmember on the 200Tdi chassis, which I did too as I preferred the look of it. I wasn't expecting there to be the cradle for a rear mounted tank, which fouls the 200Tdi exhaust routing. What did you do to fix it, or wasn't there a problem on yours?

Resurgam said:

Looking fantastic. I'm very envious. Only just getting back into working on mine after a two year break. You've definitely taken the lead!

I noticed that you've gone for the TD5 rear crossmember on the 200Tdi chassis, which I did too as I preferred the look of it. I wasn't expecting there to be the cradle for a rear mounted tank, which fouls the 200Tdi exhaust routing. What did you do to fix it, or wasn't there a problem on yours?

Click to expand...

I didn’t have a problem with the exhaust routing, maybe it’s on wrong. I did have to buy new brackets but that was due to the poor quality of the original car.
Just back from a few days Nessie watching so, hopefully I can make progress in the following few weeks, then I get a free bacon roll from Miktish