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All you can really do there is remove the window, chop out the grot and carefully let in a repair section.

Nice one, I reckon once you've got the timing correct, the smoke will go..

I think (hope) you've caught that just in time. I'd fit new woodruff keys and check the crank pulley. The good news is, that's a modified crank pulley with the shoulders so at least someone has spent some time on it. Shame they didn't do the bolt up properly.. What type tensioner and idler...

I think the cross-drilled gear was fitted from 1997 onwards.

I actually had to take my belt cover off the (new to me) 300TDi Discovery, to see if it had any modified parts. It had/ has none at all, ie it's still on the original plain crank pulley, plain idler and shouldered tensioner. It hadn't chewed the belt, but I now have the following to go on- INA...

No harm in leaving the crank seal if it's ok... I'm doing my inner one as the car is new to me and I have no idea of it's history. This is the inner seal I've bought- http://www.ebay.co.uk/itm/321918214184?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT In my opinion, there's no need...

^^ that's a good tip. Still possible to buy all the old unmodified stuff and it's what a lot of general factors supply unless you ask for the late/ modified stuff! My '95 Discovery still has all the original stuff, but not all of them shredded the belt. Nevertheless, I'll be doing mine with the...

Only thing I can think of between those two years concerns the gearbox. If original, the '95 will not have a cross-drilled input gear which transfers the power from the gearbox to the transfer box. These are a problem area as they get starved of lubrication and wear the gearbox shaft splines...

If you have the 'modded' crank pulley with the built-in shoulders, there's no need to change it. I would perhaps change one that had the old style spot welded sides as they can separate, but only really when the belt starts running on the ****. Check out Island 4x4 for details of the modified...

Lucky escape!

Yup! ;)

If it (eventually) starts with a cloud of white smoke, that says to me that plenty of fuel is getting through but there isn't the heat to ignite it. As above, the glows provide pre-heat but I've never known a 300Tdi to not start when they're faulty. That leaves compression. If the valves have...

My colleague bought a pair of Br**part wiper wheel boxes last summer. They lasted about two days, total and utter junk. I'm afraid your only surefire option is to buy some genuine ones, at the inflated price. We ended up greasing and refitting the 26 year old originals which, although show...

All our 200 and 300TDi's will fire up instantly, without using the glow plugs- it's a characteristic of a direct-injected diesel engine I think. The old 19J's.. now they really did rely on their glows! When were the valve clearances last checked?

Good, all you need now are brave pills for when you first turn the key!

That's possible. Personally, if it's turning over ok now, I'd whip the rocker cover off and very carefully check your gaps and ensure the small caps are correctly seated on the top of the valve stem. If all checks out ok, and you're confident the bottom end is correct, you should be good to go.

I would say something else isn't quite right, eg a sticking valve or the timing originally was a tooth or so out and loosening and refitting the belt 'moved' something. Personally, I wouldn't ever turn the crank with the cam shaft static though..

Correct.. but how would that change anything? When the piston/ crank is moving upwards, it doesn't know whether both valves are shut (compression stroke) or the exhaust valve is open (exhaust stroke). Turning the crank 360degrees won't change anything- if the engine is correctly timed up, ie...

Ummm.. if you turn the crankshaft 360degs, it'll be in exactly the same position as it was before...

Welcome Jamie. I would say that a 200TDi engine is simple and rugged so if you want to start learning to fix the car yourself, you've picked an excellent project. Also, you said it has a Disco' engine, but from your pictures, it seems as if the engine has the high-mounted turbo and Defender...