200tdi Locked up after rebuild

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ivancrx

ivancrx

Well-Known Member
Posts
601
Location
Burton on Trent
Well I am back again asking more questions.

200tdi from a disco. As a few will know I have had issues with oil coming through the turbo and all the hoses, with help on here I have put it down to build up of pressure in the sump and needing new piston rings.

With this in mind I purchased a cheap replacement engine and have stripped the bottom end completely and rebuilt it with new bearings, piston rings and seals, I had the bores all re-honed and the deck skimmed. I am reusing the head from my original engine as this has already been rebuilt and only done about 500miles.

Yesterday I bolted the two together as per the manual, came to turn it over by hand on the front pulley and it locked up, you get about 3/4 of a turn but no more.

I was a little puzzled as to what has gone wrong so this morning I have pulled the head off it again to see if there was anything that had dropped into one of the bores (Was thinking one of the dowels may have dropped in) and there is nothing wrong there, turns over with no problems.

I have put the head back on it but not bolted it down and it turns over fine now, but I haven't put the rockers back in this time yet. Could it be one of the valves locking up or a pushrod not seated correctly?

I don't want to bolt it all up again and have the same problem, so any ideas greatly received.
 
Sounds as if timing is out and one or two of the valves are coming into contact with pistons.Good job you just turned it by hand if this is the case.
 
Bottom pulley has the woodruff key at 12 o'clock and the crankshaft pulley has the timing mark at around 8 o'clock in line with the webbing, for some reason there are no arrows to line them up against.
 
Did you measure piston protusion? as youve head the deck skimmed you will need thicker head gasket.
 
ivancrx said:
I have a 3 hole gasket on there which is the thickest I believe.
Click to expand...

I may be wrong, but I thought the no hole gasket was the thickest.

I found this the other day when i was looking for something else. Cannot validate if it is correct or not .

1 hole 1.30mm ----- ERR5261 for piston protrusion between 0.50 to 0.60mm
2 hole 1.40mm ----- ERR5262 --------------------------------- 0.61 to 0.70mm
3 hole 1.50mm ----- ERR5263 --------------------------------- 0.71 to 0.80mm
NO holes 1.60mm -- ERR7154 ------------ if higher than 0.80mm use the NO HOLE gasket.

Cheers
 
I will drop the the front cover off and check it. Would having the head not fitted make that much difference when setting the timing?
 
Not sure how you can get it 180 deg out, if you think about it, the crank is aligned to the cast arrow or even better the slot in the flywheel, the cam sprocket is aligned to its mark and the fip is pinned, its proper simple at its best.
From memory advice is not to turn motor over with no load on the tappets.
 
Well this morning I have dropped the front cover off and checked the timing marks; all spot on where they should be. As Lynall says I can't see how I could get this wrong as all the marks are in the right places.
 
Images to show marks I am using, Fuel pump is locked with a locking pin
 

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