 | Home > Maintenance & Modifications > 200tdi Head Removal, Inspection, Refitting |
 
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347   
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Hi guys,
Welp, today is the day that the head come off. Overall quite a nice job, just a bit nerve racking at times. I used a combination of manual, Haynes book of suggestions and this pictorial http://forums.lr4x4.com/index.php?showtopic=30111 I was surprised at how easily bits came apart and the quality of everything. Most of the threads were clean and even had there original golden/zinc plating on them. Anyway, Photos!  Click image to enlarge Turbo off and and intake off. All looks good though the intake for cylinder 4 was very oily and greasy Click image to enlarge Bits coming off! Click image to enlarge View overhead, all looks good bar cylinder 3 which I very heavily oily. Click image to enlarge The Head. Now it seams cylinder 4 is very oily and I found the exhaust port was not sealing properly with some oil dribbling out. More details to follow, I need to have some food because I am starving. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter  |
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19th Sep 2015 8:11pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Some more pics showing the head.
Firstly, the gasket. I found the leak- as expected it was Cylinder 4 to Push rod so yay it was definitely worth taking apart. Click image to enlarge This however doesn't account for the coolant loss so investigation needed. Click image to enlarge No.1 Cylinder Click image to enlarge No.2 Cylinder Click image to enlarge No.3 Cylinder Click image to enlarge No 4 Cylinder. We have got a bit of an issue. I cant get 2 of the injectors out. I don't have a slide hammer and giving them a wiggle with a spanner has yielded no results. Anyone got any ideas? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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19th Sep 2015 8:53pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Quick pics of the Bores.
They all look good though but it worries me that no 4 is so oiley. Can still see the honing marks at 167k miles is fairly good. Click image to enlarge 1 Click image to enlarge 2 Click image to enlarge 3 Click image to enlarge 4 Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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19th Sep 2015 9:09pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Ahh interesting.
Where do I need to look on No. 3 then as I don't seem to be able to spot it? When I removed the head off the tiny hole between 3 and 4 was gummed up with what looked and felt like silicone sealant which probably hasn't helped. Also, looking at the block, looks like there may be some slight scoring as there are maybe one or 2 shiny vertical lines per bore against the honing marks (which are still present which is good) but it doesn't feel any different to the rest of the bore feels nice and smooth. Also, how can I check the block for cracks or issues? I think the head itself is going to go away to turners to be done as there are some lumps protruding where the dead end waterways (seriously?) between the bores go, which combined with the leaking valve and stuck injectors is making me think its time to send it off. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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20th Sep 2015 11:45am |
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| Fatboy Slim Member Since: 04 Feb 2008 Location: Bridgend Posts: 1006 
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If you look at the picture of number 3, you can see where a patch of carbon has been washed just above the inlet valve. Same corresponding patch on the piston crown suggesting you're getting coolant in there. If you look at the 4th picture down from the top the section between 1oclock and 2oclock ay you're looking at that photo looks black where the firing ring of the gasket sits. Also the gasket looks as if it was on the verge of failing from the two coolant galleries between 2 and 3 on the turbo side of the engine but difficult to tell from pictures.
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20th Sep 2015 11:55am |
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| Fatboy Slim Member Since: 04 Feb 2008 Location: Bridgend Posts: 1006
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With regards to the block, clean it up with a sharp scraper and some wet and dry on a sanding block. Clean it thoroughly with brake cleaner, make certain all the bolt holes for the head bolts are clean and tap them if possible. Have a good visual inspection of the block surface, if you've got a good quality straight edge check the face for any deformation diagonally from corner to corner and straight across. I don't think you'll find anything wrong with it
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20th Sep 2015 12:02pm |
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| Fatboy Slim Member Since: 04 Feb 2008 Location: Bridgend Posts: 1006
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I'd imagine the valves just want a decoke and a lap in.
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20th Sep 2015 12:04pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Thanks slim very helpful. I still cant get the injectors out though 
I don't really want to tap them through from the bore side as they are very delicate but no amount of swearing, soaking in petrol and wd40 and tugging on them and spannering them will get them to release
Out of interest, why are the coolant galleries full size on one side but restricted on the other? And why is there a dead end in between the bores? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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20th Sep 2015 9:32pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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After what I can only describe as an epic battle between willpower and stubbornness (I'll let you decide who is who) with the help one of my friends, 4 hours of sweat and lots of wd40 the final 2 injectors released.
It did cost some scraped knuckles, a few beers and I broke a adjustable spanner which is somewhat of an achievement. The head has now gone off to Turner Engineering for pressure testing, inspection and if required re-manufacturing. The injectors now out have been sent to a local diesel injector specialist for testing. The results were that the initial pressure was down to 180bar - given the set pressure is 200bar with a 5 bar tolerance ether way- they needed some work, but even so quite impressive for 23 years and 167k miles! The decision has been made to recondition them and much to my shock and pleasant surprise you can buy them brand new - for £150 each mind 
This is turning into a horrendously expensive month  Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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24th Sep 2015 8:27pm |
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| Retroanaconda Member Since: 04 Jan 2012 Location: Scotland Posts: 2717 
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Let us know how the injector recon works out. Thinking of treating mine to a set when it hits 250k.
Don't worry about the cost, a 200Tdi is always a good investment. They're not making any more after all. |
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24th Sep 2015 8:33pm |
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| Triggerfinger Member Since: 18 Aug 2015 Location: landyrotty Posts: 129
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Recon injectors are not cheep either west of Scotland engineering charges 80 quid a pop
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24th Sep 2015 8:55pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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I must admit, having very quickly been very pleased with Miss Shaggydogs Td5, its not the same as my 200Tdi. I really miss it.
I still can't get on with the light throttle and the clutch is really light. But we shall see. Typically, after searching for ages for a good condition 200Tdi 130 in blue with a pto winch and finding ether wrecks or nothing......This turns up
Click image to enlarge http://www.ebay.co.uk/itm/1992-LANDROVER-D...2a5877cbc3 Miss Shaggydog has already said no though
But yeah, it will be fine as long as I get paid at the end of the month Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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24th Sep 2015 8:59pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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I know the feeling
But, better than £115 from Turners or risking a "job lot" from fleabay. The real highlight for me though was that parts are still available Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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24th Sep 2015 9:06pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Welp, got a phone call from Turner engineering today.
The head is cracked on no 3 Inlet between the inlet and the water jacket. Cannot be welded as there is no access so basically the head is a write off.
What a pain! What a faff! How Bothersome! or words to that effect were muttered today. So, my options are... 1. Buy outright Gas flowed head from Turners at £720 ( )
2. Buy Second Hand Head from Foley Special Vehicles (£300) and then get it shipped to turners for possible news its no good (again )
3. Cut my losses and sell her without an engine NOT GOING TO HAPPEN 4. Look at Engine conversions -300Tdi? 2.8TGV? Cummins 6BT? When will it get done? costs? Will it work? 5. Any Suggestions? So that's where I'm at at the moment. Worst news is I'm still not getting on with the Td5. I keep stalling it and I have a feeling its clutch related as there is next to no biting point on it and it keeps stalling on me which is really annoying. I'm not a td5 expert so it could just be operator error, but it very much seems like the only way to pull away smoothly and consistently is to boot it. Which is hard to do in stop start A21 Traffic. On the plus side my injectors should be back tomorrow Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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30th Sep 2015 7:45pm |
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