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https://shielderchassis.com/products/land-rover-series-3-88-109-inch-galvanised-bulkhead Looks like the bulkheads are the same just whether the vents are supplied it not?

Well they need replacing! Just seen a nice 200tdi crank on eBay decent price

If the bores are ok and within tolerance of the +20 oversize and pistons not worn or damaged they can be used again but then youlll need to check the end gaps of piston rings in the bores to see if they are in spec if they are use again without honing , if gaps too big they new rings needed and...

Yes it’s had a rebore. Hopefully won’t need another

Found this might be useful, and you can re grind the tdi crank according to doc

Some higher res photos would be better a few MB rather that KB ,but the area where the crank seal runs looks better, I cleaned bearing surfaces with some 1000grit wet and dry and some wd40 Need a mic to measure diameters to check, not sure you can regrind the diesel cranks, not advised on the...

Think I’ve had exhaust noises coming out of air filter when one exhaust valve not set properly as that was only way gas could get out! , glad you sorted it

I would leave pump on for now , if you rotate crank until all the timing marks line up ,then you can insert the locking tool in pump then release the tensioner wheel to remove belt , then you can unbolt pistons and push them out top of block with wood end of hammer. Then the main caps can be...

Did you remove the battery connectors and clean then tighten up , similar issue on daughters Corsa other week with the click , and batt terminal need nipped up

I use UNF/UNC and metric pitch gauges as well as micrometer to ascertain thread types along with a ZEUS book most useful could also none a bsf

Does the clutch pipe fit it and have you correct clutch cylinder What year S3 perhaps earlier ones have a imperial thread Can you measure any thread sizes These have lots bits https://www.carbuilder.com/collections/braking-clutch-parts/unions

http://smithies.co.nz/land_rover/ Also the 200tdi article on turner engineering The discovery 1 manual very helpful and Britannia does good videos , he has loads so have a search Sump:bolts should not be tight, sometimes a 1/4 “ drive rattle gun helps with small tight bolts The crank is a...

Yes big socket on crank nut

Hole in cylinder or piston , sounds like a strip down check and rebuild if block ok Seen an eBay advert and there was a barn full of tdi engines at reasonable price

Have you checked the tappets

I used 100mm long bolts, yes use the circled holes, don’t need to go full depth, I used additional nuts on the bolt to nip them up and saved cutting bolts https://www.toolstation.com/high-tensile-set-screw/p51414

you should use the top 2 and the bottom 2 holes , my stand is a clarke and you can see the adjusting brackets and the long 10mm bolts with additional locknuts, it can revolve 360 degrees and lock in position just under the rubber gloves with a pin this is on my 2286 engine but very similar block...

CharlesY knew his engines and how to loosen bolts, That plug is similar position to the 2286 but without the inspection cover , do you have one at btm as the 200tdi should, wonder if it’s a hybrid or off another engine, see if it lines up when engine at TDC a or EP with slot in flywheel There...

I got a kit like this, the 9.5mm? dia goes in injection pump, while the other bit screws in btm flywheel cover screws in slot in flywheel stop it turning

If you have original honing that’s good, similar to mine the rusty coloured pot might clean up ok ensure no pitting , it’s probably standard bore , if you clean top of pistons some stamping might confirm it Bore should be nominally 90.47mm , if you borrow internal mic you can check between bores...