Hicap phill
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You know what size is into the rad?
I can work out the pipes as it’s the same as my adapter
Burnt out - rebuild
- Thread starter dag019
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You know what size is into the rad?
I can work out the pipes as it’s the same as my adapter
I am just measuring up the spare cone fitting I have, it is a taper fitting and looks to be 19 tpi (my thread gauge has 18 and 20 and it is between those) so I am assuming it is 3/8 bspt fitting into the rad, with then the metric o-ring fitting on the other side.
I had considered this and will have this as my fall back if all goes wrong. I also need to work out how much pressure goes through the oil cooler because I have the metal pipes and a hydraulic crimper so could potentially make my own up, but I want it to be off the shelf if possible for easy of future replacement.
Hicap phill
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£10 for 2… you want them
Absolutely! Yes please. I need to actually get my act together and come down to you if you still have the bonnet available as well!
Hicap phill
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I still have the bonnet in the safe place it’s been for years
PM your address I will pop up in the morning on the bike for a run out.
Hicap phill
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Does anyone have any suggestions for a top radiator hose for a 200tdi conversion? I cannot remember or find and invoice what I had fitted previously and don’t have the old one to compare to as it was charred and burnt. I ordered part number ntc4895 but it looks to be slightly too short and have too large an angle in it for what I need. I could make it work and extend it and am happy to do so if that is the best idea. But I had a single pipe before. you can see in the photo where it is beginning to squash where it comes out the thermostat. It will work to test the engine runs but want it fixed properly before getting back on the road.
I managed to get the oil cooler pipes fitted finally (many thanks to @Hicap phill)
This allowed me to finally add fluids to engine in preparation for a first start but this in itself showed another issue. You can just see a nice coolant leak in the picture below form the water pump. I am not too worried about it as once running I will change the timing belt so the pump will come off at that point and can be replaced.
I also passed a rather large milestone, it might not look like much but this pile of charred wiring is the last of the fire damage. Now everything has been removed and all that is left is reassembly!
This allowed me to finally add fluids to engine in preparation for a first start but this in itself showed another issue. You can just see a nice coolant leak in the picture below form the water pump. I am not too worried about it as once running I will change the timing belt so the pump will come off at that point and can be replaced.
I also passed a rather large milestone, it might not look like much but this pile of charred wiring is the last of the fire damage. Now everything has been removed and all that is left is reassembly!
Managed to hook up A battery and cobble together so temporary wiring to the oil pressure switch and starter solenoid. This allowed me to check the engine produces oil pressure before attempting to start. The good news is it does have oil Pressure.
After confirming it had oil pressure it was then very easy to check it started. I moved the "oil pressure feed" to the fuel solenoid minus the bulb and listened for a click to make sure it was working. I quick spin on the starter and it instantly fired into life as you would expect a 200tdi to do.
Unfortunately it was not all plain sailing and although it started and ran no problem there is some blowby form the glowplug that I had to drill out.
Having done a little research this appears to be a fairly common issue with diesel running ali heads and you can get re-thread kits for glowplugs. if anyone knowns what size the glowplugs on a 200tdi are that will save me measuring them but look like I will be ordering a rethread kit to properly repair.
Unfortunately it was not all plain sailing and although it started and ran no problem there is some blowby form the glowplug that I had to drill out.
Having done a little research this appears to be a fairly common issue with diesel running ali heads and you can get re-thread kits for glowplugs. if anyone knowns what size the glowplugs on a 200tdi are that will save me measuring them but look like I will be ordering a rethread kit to properly repair.
I also managed to go some of the wiring as part of temorarily hooling up the starter to get it running and have fitted the rear wiring loom. This has lead me to the inevitable wiring questions of which I am sure there will be far more to follow as I do more of it.
The engine end of the rear loom has an earth ring, where should this bolt to? I know in theory where it bolts to does not matter as long as it is a good solid and clean connection but where should it bolted to as standard?
Dedicated thread link. The engine I have fitted came with a complete discovery wiring loom which has made things easier, am I correct in assuming this is the same as the defender engine loom and will connect up no issue with the defender bulkhead loom I have ordered? the only issue with the existing engine loom is this wire as been cut next to the multi pin plug. It is a red and white wire that does not look like it has come from the multi pin plug, where should this be connected to and more importantly what connector should it have on it? I have not yet fitted my bulkhead wiring loom so have not been able to match up the connectors on the engine side of that to work it out.
The engine end of the rear loom has an earth ring, where should this bolt to? I know in theory where it bolts to does not matter as long as it is a good solid and clean connection but where should it bolted to as standard?
Dedicated thread link. The engine I have fitted came with a complete discovery wiring loom which has made things easier, am I correct in assuming this is the same as the defender engine loom and will connect up no issue with the defender bulkhead loom I have ordered? the only issue with the existing engine loom is this wire as been cut next to the multi pin plug. It is a red and white wire that does not look like it has come from the multi pin plug, where should this be connected to and more importantly what connector should it have on it? I have not yet fitted my bulkhead wiring loom so have not been able to match up the connectors on the engine side of that to work it out.
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Not sure where the earth is on yours but my 300tdi is an M6 lug in the middle of the bulkhead (just to the left actually) above the tunnel.
Electrical problems
Electrical problems
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Yes, thats probably it .... connector # C560
My bulkhead didn't have the stud so I drill/tapped an M6 thread and screwed in a brass bolt with a locknut and then cut the head off.
Hicap phill
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Yep that will do.
Or out a new one in next to the clutch pedal
Well today my new glow plug thread repair kit arrived. It did not get a glowing review from Britannica restorations but I don't have a lot of choice at this point for repair. A replacement head will be a last resort but I will try this first. I am just going to do exactly the same as he has done in the below and hope that i get better results with the tools and f not may resort to a similar "bodge" to get it doing.
What seals the glowplug in the head? I have successfully rethreaded the glowplug using a timesert. I also glues the timesert in place with high temperature epoxy just to make sure as using the glow plug re-thread kit was just as difficult and awkward as the Britannica restorations makes it out to be! Having removed the head for repair and now refitted and had running there is still a slight leak but it greatly improved. what part of the glowplug forms the seal. Is it the the threads or is there a seat somewhere that should seal? The old one was very black and sooty which the others were not so not sure if something else is worn and preventing the correct seal.
I have now done the timing belt and replaced the water pump and belts and the engine is back running. All that is needed now is to sort that pesky final glowplug and the engine work is done. I say this every time I do it but spending the money on the correct tools to do the timing belt was one of the best decisions I made. At the time I was a skint student and it cost me more to buy the tools than I had been quoted at the garage to do the job. However I have now done it half a dozen times on my engine and worked on other peoples with the,!
Once that has been completed I can put the front end back together and move back to the wiring loom and bulkhead interior.
Once that has been completed I can put the front end back together and move back to the wiring loom and bulkhead interior.
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The bit that gets hot pokes through into the chamber and the body of the plug rests on a 'face'. The body of the glow plug (which forms the seal) is held tight (to the face) by the threaded part which protrudes out of the head.
