200DI engine rebuild complete

Well after a long few
Months I have completed the total strip down and rebuild of my 200DI engine.
Blocked off turbo and oil cooler pipes (Spring etc removed from oil filter housing)
Victor reinz gaskets used throughout, no expense spared.
New shells/bearing/rings/skimmed etc it really has been a great project.

I fitted it with the discovery exhaust manifold but have a NA manifold ready to go with it too now.

Doesn't seem to be the market I thought there would be to sell it though
New fuel/water pumps, new starter motor.
I either need to find a project 90 now or sell it privately.

Complete rebuild with measurements taken and final runnin vid here:

Total rebuild of a 200TDI Engine.

Overhaul pics and vids here:
http://s548.photobucket.com/user/joe27979/library/200DI overhaul

what engine is in your series, you could always swap that out and refurb it.

how much were you expecting for the di?

Surely you should have checked the market before you started spending money rebuilding an engine.
Don't know what you've spent of rebuilding it, but their is probably a buyer out their, it's just finding the right one at the right time who wants exactly what you've built.
One thing I would do is refit the turbo so it appeals to defender/disco owners too.

I think it would be more desirable if you took it back to being a tdi?

Purchased without a turbo Sam,
To buy a used turbo without knowing its history will increase sale cost and leave me with the unnerving feeling it was a bad turbo :/
If someone has a bad engine they can use own turbo, my main aim was to put it into my series 3 so didn't need the turbo in the first instance

Ps sold my series before I managed to complete engine.
Receipts for rebuild over £1300,
I was looking for £1000 with a brand new N/A exhaust manifold chucked in too

Came out of a discovery
Totally stripped to component level and all parts decreased and wire brushed.
Crank and head sent to engineers for measuring and testing. Crank was fine no polishing required, head skimmed and pressure tested ok (slight crack between ports and heater plugs, told this is normal on 200s-passed pressure test no probably)
Block professionally re-honed/de-glazed.
Block painted, 4 coats of calliper paint (gold). Pistons and cranks measured, all within tollerance and reused.

New crank bearings (all good quality from turner engineering, no Britpart stuff at all) new big end shells, rear crank t-seals, piston oil jet washers etc, end float measured and new thrust washers.

4 sets of Genuine piston rings, earring head gasket. Camshaft and bearings checked, all good. Renewed couple of sliders and pushrods. Valves lapped in, rocker rebuilt with new spacing washers etc.
Block and head both totally stripped and rebuilt down to every last component!
All components coated in rebuild oil to ensure a healthy first fire.

New heater plugs, injectors left in ultrasonic bath for a day, brand new dayco timing belt kit (including tensioner and idler!)

Genuine rear crank seal, flywheel dressed. Exhaust manifold **** blasted and sprayed with high temp paint.
Oil pump stripped and tolerances measured, vac pump stripped and new o-rings installed.
Brand new bearmach fuel pump and started motor, new belts.
Genuine oil filter, oil galleys to cooler are plugged and filter housing Spring removed. Turbo oil feed and drain lines plugged.
Sump rubbed down and painted, ladder block sealed properly-all threads re-tapped and cleaned out.

Think that's most things, all the pics tell the whole story,
Genuine victor reinz gaskets used throughout.
Doughty rear crank seal (not cheap single rubber piece type)

It fired first time and doesn't miss a beat on pallet.

pity, it would be ideal for me in a year or two. I plan to build a new galv'ed rolling chassis with engine, box new loom and galv'ed bh then just transfer the body panels of my s3 and scrap what is left behind I do have this underlying hankering for a v8 or v6 though

couldn't justify buying an engine in readiness now though

joe27979 said:

Well after a long few
Months I have completed the total strip down and rebuild of my 200DI engine.
Blocked off turbo and oil cooler pipes (Spring etc removed from oil filter housing)
Victor reinz gaskets used throughout, no expense spared.
New shells/bearing/rings/skimmed etc it really has been a great project.

I fitted it with the discovery exhaust manifold but have a NA manifold ready to go with it too now.

Doesn't seem to be the market I thought there would be to sell it though
New fuel/water pumps, new starter motor.
I either need to find a project 90 now or sell it privately.

Complete rebuild with measurements taken and final runnin vid here:

Total rebuild of a 200TDI Engine.

Overhaul pics and vids here:
http://s548.photobucket.com/user/joe27979/library/200DI overhaul

Click to expand...

Amazing job on the engine you must be pleased with your work but desperately disappointed about the lack of interest.
I have a series 3 and am thinking of the same engine swap long term but had no idea of the cost. You would be better off getting a series 3 for yourself and making a real drivable classic.
The trouble is at £1000 anybody spending that sort of money on an engine is not going to fit a non standard one into a series 3.

Only just seen this thread good job man

hydraulic locked my 200DI at the weekend in a river so may be needing an engine but price is too high can probably fix mine for less.[Water splash ingested by engine brought me to a dead stop]
Mate just commented 20 min before I killed it how well it was running.

Strip it down hopefully it's just a few bent bits lol

Lost the last two days with swollen foot hope to get it lifted out and looked at over the weekend.

I am sure your engine is built to a good standard, be patient and you will find a buyer.
For most people in this hobby the price is close to what they paid for the Landy and there is your problem. Very few can afford to pay that sort of money for something without a warranty.
I bought a motorcycle engine rebuilt by a professional and it was a disaster that I had to rebuild and spend lots on. I would be wary of anything now.

Can I get a warranty to cover engine, and sell with warranty do you think? Even advertised it £850 without warranty with no interested, that's at a £500 loss!
Would £900 with a warranty attract more people do you think?

Fire her up every week on the pallet, brings shear joy to my heart as she starts in the button and idles like a dream

If you're happy and confident in your work then just offer warranty. I would if I was 100% sure things where correct.
You can see why people would be wary though, hardly inspires confidence in your product.

your project 90 might be the best idea, auction off whatever is in it and put your rebuild in, better than taking such a hit on all that good work imho.

if you still have it this time next year I would be interested

actually sounds more like a petrol in your vids

joe27979 said:

Can I get a warranty to cover engine, and sell with warranty do you think? Even advertised it £850 without warranty with no interested, that's at a £500 loss!
Would £900 with a warranty attract more people do you think?

Fire her up every week on the pallet, brings shear joy to my heart as she starts in the button and idles like a dream

Click to expand...

I think the last two posts are good advice and would also be interested in it this time next year.
Do you have a link to the engine running video?

http://s548.photobucket.com/user/joe27979/library/200DI overhaul

click on the above link from first post takes you to a page of pics and vids