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EGR filter, do you mean DPF filter?

I had the 2 litre, nursed it on for a years or two then binned it. They like to crack the cyl head, liners like to leak from the tell tales. If it is puffing out of the dipstick it might mean it needs another rebuild, does not take much to pressurise the crankcase. Are you still running a stat?

Old Trump would put a stop to that!

Interested to hear how this expedition will help the charities?

Wont be air left in the system, once stat has opened it should have self bled. Get head pressure tested would be my advice.

Maybe 77 and 380 boxes have different set up as cables differ?

Simply because the engineers only have room on the round stamp for so many years, in this case last year was 2008, and before they got to 2008 they would have made a new stamp ready for next run.

Good find.

The read/blue/yellow heatshrink crimp connector are pretty good at resisting water so long as you melt them fully. Always earth back to the battery negative.

Is the belt flinging the oil up there? ie it is leaking from the front of the engine and not the top.

My 200 has a cheap facet copy pump off ebay, starts and runs just fine without it, but I can notice a power loss up long hills if not switched on. I think the lr mech lift pump is fine when working, but when it pack s up it actually causes a restriction to the fuel supply. Quite a few cars used...

well in that case I think your first diagnosis might be correct. I am not sure where the vane pump is the VE pump and whether it is a DIY job or not? if I remember correctly the internal pressure in the VE pump is something like 70 psi, so it might be worth trying the earlier suggestion of using...

Have you had theinj pump feed and return banjo bolts out for any reason?

Light hone/new shells/rings and stick it together, in the old days this was called a top and tail. I would defo fit new rings, bet you a coffee the old one have lost their twang! I took some out of a truck the other day and was amazed how much depth they had lost. Do not go mad with the hone...

My series 2 tdi breaths like thomas the tank engine, still runs okay apart from the breathing, starts well, pulls well.

well if a hone and a new piston rings only gets you a year or two that might be good enough. The 200 can run okay even when well worn.

Turner engineering have new liner sleeves for 21 quid.

I reckon that might be the case. That bore damage looks like water damage? Was it breathing much before you stripped it? I would still try the hone first, you never know you might strike it lucky.

I would give it a light hone and see, but I think you may be on a hiding to nothing there.

Give it a decent service, then keep an eye on the levels for a week or two, then start diagnosing stuff as you will then know what the car does.