200 tdi Engine checking / refurb??

steve2286w · Jun 27, 2019

I have removed flywheel and outer timing case cover, I have locked the injector pump with pin
Am I safe to remove the pump as is , I don’t have that LR tool round plate to bolt pump up
I can lock shaft using the pin and nut on pump, is this sufficient to keep settings when bolted back on,

I want to remove crank for polish and clean, do I now need to remove all cogs and the timing case before the crank can be lifted out ?

Thanks

jamesmartin · Jun 27, 2019

as long as you dont undo the nut on the pump shaft and just undo the 3 pulley bolts you can remove pump without worry,id would remove timing case

steve2286w · Jun 27, 2019

jamesmartin said:
as long as you dont undo the nut on the pump shaft and just undo the 3 pulley bolts you can remove pump without worry,id would remove timing case

Thanks James that’s the big nut in middle of cog you mean , not the shaft lock nut on other side,?

jamesmartin · Jun 27, 2019

steve2286w said:
Thanks James that’s the big nut in middle of cog you mean , not the shaft lock nut on other side,?

yes in middle of pump pulley, dont undo that then settings are safe just a matter of lining pin up after

steve2286w · Jun 27, 2019

Great thanks

steve2286w · Jun 27, 2019

crank out without too much fuss, the cogs came off the shafts nicely no corrosion or wear
I forgot to measure end play on the crank but noticed the thrust washers down to copper I guess these should have white metal on them as bearings , the top mains was showing signs of copper , next job polish these up, the drilled oil holes from bearing to bearing were nice and clean, not sure about cam, tempted to leave that where it is

Flossie · Jun 27, 2019

I think new thrust washers have copper showing from memory so yours may be fine.

Flossie · Jun 27, 2019

Take the oil squirters out and check they are clear too. Two copper washers on each (again, from memory)

steve2286w · Jun 27, 2019

Thanks , looking online some look copper and some tinny , I’ll measure them and see how they compare

steve2286w · Jun 27, 2019

Flossie said:
Take the oil squirters out and check they are clear too. Two copper washers on each (again, from memory)

Will do , I’m surprised how heavy the bare block is , was going to lift on bench but might leave it on floor

jamesmartin · Jun 27, 2019

steve2286w said:
Thanks , looking online some look copper and some tinny , I’ll measure them and see how they compare

just fit some new std thrust washers

steve2286w · Jun 27, 2019

jamesmartin said:
just fit some new std thrust washers

yes will do, ill start compiling the parts list soon, thanks for help, I took some meaurements using a internal mic dial gauge set to 90.47mm on a metric micrometer, however the dial gauge is imperial with a resolution of 0.0005", so got some measurements as above
some measurements are bigger than original bore size of 90.47mm
the below bottom measurement is beyond the sweep of the piston and has a small ovality but only less than 2 thou

jamesmartin · Jun 27, 2019

steve2286w said:
View attachment 182441

yes will do, ill start compiling the parts list soon, thanks for help, I took some meaurements using a internal mic dial gauge set to 90.47mm on a metric micrometer, however the dial gauge is imperial with a resolution of 0.0005", so got some measurements as above
some measurements are bigger than original bore size of 90.47mm
the below bottom measurement is beyond the sweep of the piston and has a small ovality but only less than 2 thou

the original bore size is only nominal it may vary from under to over quoted size ,a measurement fore and aft at bottom 1/4 of bore will give original size, which is why you have some - measurements i presume they are minus

steve2286w · Jun 28, 2019

YEs taking the average of bottom of bores its about 90.487mm original size rather than nominal 90.47.
Yes the - ve measurements taken from the dti set at 90.47
average wear across the 4 pots is about 0.0016 so happy with this
My new piston ring pliers came today and a new set of feeler gauges
the plier type seem hard to remove them when in the grooves and still finicky when I get them out of groove, not sure if these just intended for fitting to pistons.
I tried all the rings from Piston 1 about mid bore and each is over the allowed limit for the ring gap in bore I get between 0.7-0.8mm for each of them

top max gap 0.5mm
2nd max gap 0.45mm
Oil control max gap 0.6mm

the defender manual says fit oversize piston rings, just wonderring if worth doing
would this additional gap be noticeable in smoke or crankcase pressure
what do these gaps get to when engine realy gone
if new rings fitted is the existing honing still ok

thanks

jamesmartin · Jun 28, 2019

steve2286w said:
YEs taking the average of bottom of bores its about 90.487mm original size rather than nominal 90.47.
Yes the - ve measurements taken from the dti set at 90.47
average wear across the 4 pots is about 0.0016 so happy with this
My new piston ring pliers came today and a new set of feeler gauges
the plier type seem hard to remove them when in the grooves and still finicky when I get them out of groove, not sure if these just intended for fitting to pistons.
I tried all the rings from Piston 1 about mid bore and each is over the allowed limit for the ring gap in bore I get between 0.7-0.8mm for each of them

top max gap 0.5mm
2nd max gap 0.45mm
Oil control max gap 0.6mm

the defender manual says fit oversize piston rings, just wonderring if worth doing
would this additional gap be noticeable in smoke or crankcase pressure
what do these gaps get to when engine realy gone
if new rings fitted is the existing honing still ok

thanks

View attachment 182531

View attachment 182533

View attachment 182532

a slightly larger gap wont hurt too small would, its ring to cylinder surface that matters ie fresh ring and bore surface

steve2286w · Jun 28, 2019

Thanks James, I will check others as I go but plan to remove rings clean pistons and refit if all no worse than No 1

steve2286w · Jul 6, 2019

Measured the main journal diameters which should be 63.475-63.487mm I measured 63.485-63.49mm for inline with crank key way and 90
The big ends should be 58.725-58.744mm
No 1 was 58.71 in line and 58.73 90 deg with all others 58.72 -58.73mm
so I can live with them I have polished them with 600 grit and will order standard replacement bearings from Turners

steve2286w · Jul 13, 2019

Painted block today with some Frosts Old Gold, 1st coat on
I noticed the cam can be pulled out by hand about 20mm or so, I have not removed it or the followers although I have rotated block while doing jobs can this move the followers tappets around leading to this end play
is the play taken up when the cam pulley is on or is it located by the skew gears vacuum pump to keep it in position

Been cleaning pistons and refitting the rings
it looks like the oil control can go on any way round
the middle ring I could see top marked on them all so that was ok the top ring in section is not rectangular but more wedge shaped but I cant work out if

one side is 90 deg (B) or both less than 90 deg (A) anyone had a very close look before
the upper side of the top ring is more stained than the shiny underside so this is my double check just incase I got mixed up while handling them

jamesmartin · Jul 13, 2019

steve2286w said:
View attachment 184285

View attachment 184286
Painted block today with some Frosts Old Gold, 1st coat on
I noticed the cam can be pulled out by hand about 20mm or so, I have not removed it or the followers although I have rotated block while doing jobs can this move the followers tappets around leading to this end play
is the play taken up when the cam pulley is on or is it located by the skew gears vacuum pump to keep it in position

Been cleaning pistons and refitting the rings
it looks like the oil control can go on any way round
the middle ring I could see top marked on them all so that was ok the top ring in section is not rectangular but more wedge shaped but I cant work out if

one side is 90 deg (B) or both less than 90 deg (A) anyone had a very close look before
the upper side of the top ring is more stained than the shiny underside so this is my double check just incase I got mixed up while handling them

View attachment 184283

cam pulls forward because its been allowed to be pushed back , id remove the followers and refit once cam pulley is back on so cam cant move back again,top ring will have markings showing top face

steve2286w · Jul 13, 2019

Thanks will do

200 tdi Engine checking / refurb??

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Similar threads