Having tested the starter my next job is to fit the rear crank seal and refit the flywheel housing. It has been over 10 years since i last prepared a 200tdi to fit is the glencoyne website (
link) still the gospel for doing this as I cannot remember what I did last time. Is the below still the best method for conversion? I am awaiting a counterbore drill bit and a soon as I have that will be good to go for the final steps in getting the engine ready to fit.
From the website:
"There is a stud in the flywheel housing at about the eight o'clock position which needs to be removed and there may also be two steel dowels in the rear face of the flywheel housing (one next to my thumb in the photo below). These must be removed if present. To remove studs, simply run two nuts onto the stud, then turn them against each other to lock them together. If you turn the innermost nut anti-clockwise with a spanner, the stud should now unscrew from the flywheel housing. The dowels usually pull out quite easily with Mole grips. If they are really stuck you can drill them or grind them flat.
Now you need to counterbore the four holes in the bottom of the flywheel housing to take M10 x 80 Allen bolts, then drill and tap the housing M10 to take the four extra studs (one at around three o'clock, then three more at the bottom). The housing has blind holes in exactly the right places for the four studs. The stud above the hole at three o'clock needs to be swapped over to the new hole. The photo below shows the housing modified and fitted to the engine with all studs and bolts in place apart from the three holes at the bottom, where I normally use M10 x 30 bolts rather than studs. Note the four Allen bolts at the bottom of the flywheel housing, which go through the housing and into the block stiffener:
To do this properly you really need a pillar drill, an M10 counterbore and an M10 x1.5 thread cutting tap, as well as the Allen bolts which are hard to buy in small quantities. Also you need to fit a new oil seal, and these can be difficult to fit without distorting them unless you have the right tools."