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Next thing to do was fit the new second hand leak back pipe connector which I bought from flea bay. I fitted it with new washers and connected the new hose. Following that I fitted the right hand engine mounting. I’ve used the later defender type rubber mounting with a series 3 bracket. I’ve...

Second on the list was clocking the turbo outlet round 90 degrees to move the outlet away from the inner wing and make it almost vertical. This will give some more space for the pipe to the intercooler and that clearance really is needed. Clocking entails removing the housing, drilling and...

A couple of jobs that I have been putting off for a while and thought needed doing now, finally I have got them done. First on the list was to modify the bellhousing, installing the four countersunk bolts which secure the sump, then drill and tap three holes and fit studs which match the series...

Happy with that progress, I thought I would put my blast cabinet to good use and blasted the timing belt cover. Once it was cleaned up I gave it a blast of silver paint to protect it a bit. Must admit though that it looks a bit blingy in comparison to the rest of the silver bits. Anyway, not to...

Made a bit more progress again tonight. I sorted out the studs holding the turbo on and swapped over studs from the old turbo that holds the down pipe down. I fitted new copper washers to the turbo oil feed pipe and fitted the return to the block. Also cleaned up and fitted the injector pipes...

Moved onto the exhaust manifold, and I had to cut one of the studs holding the turbo off! What a nightmare….Anyway I managed to save the manifold. I heated up the remaining part and unscrewed it which was a relief. I replaced the stud with another one, wire brushed the manifold and hit it with...

One issue I did find was that one of the banjo connectors was damaged some time ago. I would be surprised if it allowed any flow back at all! Need to source another soon As I want to get this buttoned up soon. I cleaned up the rocker cover box and fitted a new seal. Unfortunately the set was...

Feeling as if I’m making some progress now with the engine build. 😊 The valve stem caps, heater plugs, leak off pipe and injector seals turned up, so I got cracking fitting them…..Noticed that the original injector seals looked to be the wrong way round, so that may have caused some problems. I...

I bought an Elring make head gasket (3 hole) which matches the original and fitted new steel dowels. I sat the head on carefully and cleaned up the head bolts and fitted them. Dug out an angle torque gauge to do the angle torque, so fingers crossed that’s a done deal. I checked the valve stem...

Once the valves were clean, I removed the old valve stem oil seals which were pretty hard and cracked, so probably were allowing oil through…. I lapped in all the valves then fitted new valve stem oil seals, which I lubricated with fresh engine oil so they are not dry on first start up. I...

On to the cylinder head now…. I gave the head a good scrub up to get rid of the oily grime off as far as possible. After the clean up I stripped out the valves, springs etc, cleaned them up on my pillar drill with emery cloth to get rid of the carbon and oily mess. See before and after 🙂

Once the sump was on, I installed the injection pump and bracket. Fairly easy to fit, but thought it was worthwhile fitting the sprocket and timing belt while the going was good 😊. Next time I’ll focus on the head and try and get the valves removed, valve stem seals done and valves lapped back...

Hi, all, it’s been good to get moving on the engine again. I finished off the bottom end by installing the alloy sump frame using the same gasket sealer as there doesn’t appear to be a gasket for it. Unfortunately , one of the long bolts snapped going back in so the whole lot had to come back...

Managed to make a bit more progress today. I cleaned all four pistons , removed the old rings, fitted new along with big end bearings. Torqued everything up and spun it all over. Seems to be nice and smooth….thankfully 😀. Fitted new oil seals and gaskets to the timing belt cover and fitted that...

Yes, you are right, the 200tdi is a direct descendant of the original 2.25. The later 2.5 n/a apparently uses the same crank as the 200tdi.. I think there are parts that fit across both.

It is a 5 bearing but it’s a 200 tdi, so I don’t think the original colour was red. Fairly sure it would be gold?

I gave the bores a good clean up with a bore hone and this gave a good surface (deglazed) for the new rings to bed in. I flipped over the block and cleaned the inside of any debris or dirty oil. I vacuumed and blew it all out to make sure it was as clean as possible. After that, I lubricated the...

So, moving on with the block, I cleaned, prepped and painted it with VHT although the block will never get that hot, it’s good protection for it. I also replaced all the core plugs, using the age old method of a hammer and old screwdriver. I put some Wurth sealant around the new core plug to...

Next, I’ll clean the lot up, possibly replace the core plugs and paint the block. Not sure on the colour for the block. The original seems to be a gold colour? Maybe a satin black would work well? I have ordered new main bearing shells along with big ends, thrust washers and a set of piston...

Laid out the lot on the table, cleaned the deck of the block and cleaned of the outside of the block too.