Disco 200tdi engine rebuild.

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No2 piston changed and no1 con rod swapped for another that's straight. Ive been looking at the main bearings and they have an old code on Etc6422 with the last and bigger one being Etc6427, I've found that they are standard size and I hope that when I order a set it comes with the bigger one at the back as well.

Checked the big ends and they are erc8841 which I've found are standard big ends so ordered a set of those as well... Now the thrust washers that fell out when I lifted the Crank, one has no markings on and the other has 0025 which I'm assuming is.
.0025 under sized

Problem is which side does the under sized go and the two lines they have in them, do they both face each other or what?...

Also took all the rings out the pistons which have nothing stamped on them so i assume they are all std size, I'm going to use a ring to clean out all the groves of the piston then measure with a feeler gauge the ring gap, I'm going to check all my con rods are good by the test I saw on YouTube. Crank end float I'm slightly unsure about checking with these current thrust washers.

Also which side is the thrust side of the engine? If I was to look at the engine from the front the correct way up would the thrust side be on the right?
 
steel back on the thrust washers goes toward the block ,either side of main bearing housing
top 2 rings need to be fitted the right way up which is any markings to the top
 
Just found the answer to the thrust side. Major on the left minor on the right so top and middle ring gap to the front 60 degrees apart and oil ring to back.
 
Been paddocks this morning and brought everything needed for the bottom end! Got a busy few weekends and I'm away this coming week so by the time payday comes around next month I should have the bottom end ready and be ready to pull the old lump out, swap the missing bits and purchase a new clutch ect whilst fitting and hopefully have a nice running engine again
 
Cranks in and torqued up. Piston 3 and 4 are in. Just having some dinner and back out for the last 2 pistons. Gone quite well touch wood.... Ive put the top and middle ring at the front of the cylinder 60is degrees apart and the oil ring in the middle at the back! New main shells are in and new big end bearings are going in as well. Ive also lubed everything up with plenty of fresh oil! Checked all clearances on the rings to the piston and they were all in spec.

I brought a new bottom end overall set yesterday as well but Ive got to put the timing cover back on and front n rear crank and front cam shaft I'm guessing can be fitted later
 
OK so today I got the ladder frame on. The oil pump and the sump as well as the timing chest and fip with all the pulleys and popped the old belt back on just to turn the lot by hand.

I put in the new L shape seals first on the rear main bearing cap and what a nightmare they were to get back in and bolt down!

I also put on a new front crank oil seal which I brought the genuine one from paddocks however I pushed it In with my fingers and it doesn't quite sit square I pushed the bottom In too far, I'm worried if I try to remove it I'll damage it.
 
Old engines out the truck and yesterday I stripped the head off it to use on this engine as it was only skimmed and pressure tested a few months back when I did the HG....

first thing I noticed out my engine was that it has atleast one bent pushrod, now this caught my eye when I pulled it out yet I know for damn sure they were straight when they last came out, I just have no idea how its happened! Its been driving fine apart from the oil breather blowing constantly so who knows whats happened there but it looks like im back off to paddocks,

Heads on the new engine after I cleaned up the mating faces, measured piston protrusion and the 3 hole gasket was perfect. Ill get some photos uploaded at some point however I didn't bother taking too many..


Brought a new front crank oil seal as im worried the other will leak, new timing belt ect ect. If I can get some time on the engine this week im hoping to have it all together for the weekend..
 
Although it looks like I'm talking to myself here haha. I've got the rest of the bits on the truck today. Timing belt and timing sorted. Lift pump alt power steering pump oil filter housing ect ect just need a decent day now to take it off the engine stand and get the flywheel and seals fitted on the back. Get the new clutch in and drop it in the truck. Pretty nervous to say the least I just hope nothing leaks lol
 
Haha sorry guys, got the engine in last weekend. Was a pig to line up but eventually went. Battery was flat when I went to turn it over but after a charge I turned it over and she fired up lovely. **** myself at first as there was a pool of oil forming but upon inspection it was the oil filter, I fitted the oil filter housing last and when the engine was in situ, I had to remove the oil filter to squeeze it in and one of my lads stole the rubber seal off the filter and I suspect it was the 2 year old as I found it near their trampoline... Hmm so that fitted it doesn't leak oil yet! First decent drive is tonight but on a test drive it was a little slow until the turbo kicked in, probably because I used my fip lid on this new fip that came on the engine and I have wound the little t25 screw out by a few turns as my old engine was tuned by some idiot who must have liked black smoke!

I've wound it in a turn and half and hopefully she will go nicely now. Took a video but it doesn't do it justice of how quiet the engine is. I really did the intercooler pipes as I've clocked the turbo and I ended up using scaffold pipe lol. It gets pretty warm tho even on a small drive
 
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