Just thought I might get an Inclination of whats wrong , if anything is. But lets face it the bloody thing has been stood for god knows how many years , at the least its gonna get a timing belt and water pump, but think the best bet is like steve2286w says , think I will take the head off and inspect things in there .
I am no expert, but have just finished rebuilding a 2.4 none turbo toyota hilux , changed crank, new big end and main bearings , new piston rings , honed the bores , lapped the valves etc, head pressure tested and skimmed. first time Ive ever tried anything like that, always been frightened to have a go but it runs great, . I am assuming / hoping the 2ootdi will be quite similar to do ?

Stick some oil in it and turn it over by hand, you'll feel anything too amiss at that stage ...

Small steps mate ...
 
Just had a look on mine
1 comes from top fuel filter connection and is the supply to the IP
2 pumps to fuel filter , the other union on lift pump is from tank
3 is the fuel spill line from injectors and back to tank via a banjo union
 
3 is feed from filter
1 is return
Different to how mines plumbed in 😗
IMG_3844.jpeg
IMG_3845.jpeg
 
The PO started it 4 years ago when he bought it, it had stood like that for about 10 years before without starting so only started the once in the last 14 years or so. Not sure but think the best thing is to when I get time and funds is just strip the thing down and look for wear and tear and replace whats needed. as said before going to get timing belt and all seals ect , plus a clutch so might as well get it out on engine stand and see whats what.
Dont suppose the 2 second start up on vid gives any clues away ?
 
Started to strip it down, Got the manifold, Turbo and Starter off one side. on with the other side, bit nervous about taking glow plugs and Injectors out, heard storys about them been hard to loosen but soaked them with penetrating oil overnight so hopefully they should come out ok. Another thing I am worried about is the Injection Pump, dont want to damage anything on there whilst taking it out, Any tips would be great. Cant find any online manuals on the 200tdi, either.
 

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Some manuals here, the injectors strip down easily if you’re going that father, i bought one of them ultrasonic cleaners to the clean the disassembled injectors worked really well getting rid of hard carbon
Just leave injection pump in for now until time to change timing belt
 

Some manuals here, the injectors strip down easily if you’re going that father, i bought one of them ultrasonic cleaners to the clean the disassembled injectors worked really well getting rid of hard carbon
Just leave injection pump in for now until time to change timing belt
Thanks Mate found the 200tdi manual, some others too.
Depending what state Injectors are in I might get them rebuilt, there is a guy local that does them. Will get a few more bits off over the weekend, Once the heads off will probably get it out on engine stand to take sump off and check crank and baring's too, then replace whats needed. Might even paint it while its out. watched a few youtube vids so hopefully I shouldn't go wrong if I take my time.
 
Cleasby’s good for rebore cost me £240+ vat 2 year ago on the 2286cc, but the 200tdi practicallly had no bore wear could still see the original honing marks after 125k
 
One other thing to do while it is out is to change the rear crank shaft seal. I recommend you use a Dowty type seal ERR2532 OEM along with a new gasket between block and flywheel housing. Follow book instructions with fitting the seal.
 
Cleasby’s good for rebore cost me £240+ vat 2 year ago on the 2286cc, but the 200tdi practicallly had no bore wear could still see the original honing marks after 125k
Took my Toyota Hilux head to them for pressure test and skim last year, 100 quid, the bores were ok so I got one of them honing things that fits on drill and honed the bores, kept the origional pistons but put new rings on and everything was ok, hoping this 200tdi is going to be similar or even easier.
One other thing to do while it is out is to change the rear crank shaft seal. I recommend you use a Dowty type seal ERR2532 OEM along with a new gasket between block and flywheel housing. Follow book instructions with fitting the seal.
Yes planning to get a full seal kit and change every one.
 

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