western Posted October 31, 2017 Author Share Posted October 31, 2017 the old original standard pistons showing the residue below the oil rings& where I am now, nice clean timing pulleys & casing. 1 Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted October 31, 2017 Share Posted October 31, 2017 Not soda blasting and lacquering the aluminium bits then? Quote Link to comment Share on other sites More sharing options...
western Posted October 31, 2017 Author Share Posted October 31, 2017 No can't be bothered with that, haven't got the facilities & don't know anywhere this far south west that could do it, the alloy parts are as clean as I can get them, a occasional clean once all back together will do for me, Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted October 31, 2017 Share Posted October 31, 2017 Ooh, one more question, did you galvanise the engine block? Quote Link to comment Share on other sites More sharing options...
western Posted October 31, 2017 Author Share Posted October 31, 2017 37 minutes ago, Bowie69 said: Ooh, one more question, did you galvanise the engine block? Nope cos it's cast iron At last the replacement piston ring set has been delivered, it's only taken all day to get here, new rings installed, piston & conrod mated & now to fit to engine block, then I can close the bottom end with ladder frame & sump fit. Quote Link to comment Share on other sites More sharing options...
western Posted October 31, 2017 Author Share Posted October 31, 2017 New rings fitted to No4 piston, mated to conrod, installed in block, ladder frame, oil pump & sump fitted. cam followers fit tomorrow & trim excess sealant from block ladder frame/sump joints. due to collect my injectors in morning too. so I'm about where I wanted to be, hopefully get flywheel housing, flywheel & clutch on tomorrow & block back in engine bay, a few pics of today's progress. 1 Quote Link to comment Share on other sites More sharing options...
ianmayco68 Posted October 31, 2017 Share Posted October 31, 2017 Looks great and going back together quickly , will have this to do on my 90 soon when I get that far . Quote Link to comment Share on other sites More sharing options...
Scotts90 Posted October 31, 2017 Share Posted October 31, 2017 Taking shape, nice to see its not just my garage that turns into the proverbial bomb site when "on a mission" 1 Quote Link to comment Share on other sites More sharing options...
western Posted October 31, 2017 Author Share Posted October 31, 2017 I put a old clean white bedsheet on the floor, its not clean anymore , good job I've only myself to answer to, that's all the engine bits on the sheet/floor,, my workbench at far end is a mess to, must get some off the floor racks/cupboards to keep stuff in.then my bench will be more useful, hopefully have less on the floor tomorrow & more back where it should be. 1 Quote Link to comment Share on other sites More sharing options...
western Posted November 1, 2017 Author Share Posted November 1, 2017 Today's efforts have seen these fitted -- excess squeezed out sealant shaved off, cam followers, cover plates on right hand side, vacuum pump & shaft to oil pump, timing gears & new timing belt, new tensioner, injection pump, flywheel housing, flywheel & clutch, starter motor. the 2 long threaded studs in flywheel housing are to help align block & gearbox. hopefully tomorrow I can get this big lump back in it's rightful place in my 110. 2 Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted November 2, 2017 Share Posted November 2, 2017 👍 Quote Link to comment Share on other sites More sharing options...
western Posted November 2, 2017 Author Share Posted November 2, 2017 After a bit of fiddling to get the engine high enough to clear my winch, it's now back in it's rightful place, next is starting refitting oil filter head, tighten engine rubber mounts, PAS pump,alternator, wiring, cylinder head,pushrods,rocker shaft assembly, lunch next then more spanner twirling. Quote Link to comment Share on other sites More sharing options...
monkie Posted November 2, 2017 Share Posted November 2, 2017 Looks fantastic. I can't wait to see when it is running again. Can you do a video of the first start up please!😁 Quote Link to comment Share on other sites More sharing options...
Scotts90 Posted November 2, 2017 Share Posted November 2, 2017 Aye that looks pretty! What about your turbo? Are you doing anything with that? (CHRA/rebuild) Quote Link to comment Share on other sites More sharing options...
western Posted November 2, 2017 Author Share Posted November 2, 2017 Turbo was replaced back in May this year, so I know it's fine, just collected my refurbished & serviced injectors. so shouldn't have a fuelling problems FIP is all good too. I'll see what I can do about a first start up video. Quote Link to comment Share on other sites More sharing options...
western Posted November 3, 2017 Author Share Posted November 3, 2017 So far today's progress --- timing checked all good, front cover & water pump & oil filter head refitted, new oil filter, pipes on lift pump connected,alternator refitted but not yet connected, starter motor wiring connected, water pump & crank pulley's refitted & torqued up where required, cylinder head refit is next, more pics later Quote Link to comment Share on other sites More sharing options...
western Posted November 3, 2017 Author Share Posted November 3, 2017 pics of today's progress as promised. head is on but still need to do the final torque tighten, on a 200tdi it's 40Nm, then 60 degrees, then another 60 degrees. refitted the water pump/alternator & PAS pump belts to, its easy when rad is not in the way. 2 Quote Link to comment Share on other sites More sharing options...
Peaklander Posted November 3, 2017 Share Posted November 3, 2017 On 31/10/2017 at 12:24 PM, western said: Yes asked for the bores to be taken out to 20thou over.......200tdi pistons only come in Standard,20 thou or 40thou oversize. but it makes no difference to the swept volume as combustion chamber is in op of the piston. Ralph, can you just explain that a little more? If the pistons and bores are wider, doesn't that increase the swept volume? I realise that the top of the chambers, above the pistons, don't change but the rest does. Not that it would make any difference with such a large compression ration in the first place. It's a great thread. Thank you for posting so many pics. 1 Quote Link to comment Share on other sites More sharing options...
landroversforever Posted November 3, 2017 Share Posted November 3, 2017 I'm guessing a little here but I'm thinking either the small difference (like 0.5mm on the diameter for 20thou) doesn't make that much difference to be measurable. Or they take less off the top of the piston to match the extra removed on the rebore Quote Link to comment Share on other sites More sharing options...
Scotts90 Posted November 3, 2017 Share Posted November 3, 2017 Also take into account any head skimming will negate the over bore to a certain extent. Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted November 4, 2017 Share Posted November 4, 2017 20 thou will make quite a difference, for example on an A series 1275 will go out to 1293 with 20 thou over bore. 60 thou I think takes you out to 1380, as the piston surface area increases by the square of the change in radius The head being skimmed is not likely to make any difference in this case, as it is flat, with no combustion chamber -this is in the piston on a 200TDI. I'm fairly convinced the swept volume will change with larger piston, however, with the combustion chamber in the piston, and a flat head, any change in compression ratio will be less than negligible. Quote Link to comment Share on other sites More sharing options...
western Posted November 4, 2017 Author Share Posted November 4, 2017 I meant 20thou change in bore size won't make much difference in the swept volume, obviously it'll be slightly more, & as noted by Bowie69, negligible to the comp ratio, which IIRC is 19.5:1 Quote Link to comment Share on other sites More sharing options...
western Posted November 4, 2017 Author Share Posted November 4, 2017 I ordered one of Excess4x4 magnetic drain plug, postie delivered just as I was getting ready to go out to 110, new drain plug now fitted, so if there are any stray bits of metal in the engine I pretty sure this plug/magnet will hold on to any stray particles, Alternator & revcounter wiring sorted, pushrods & rocker shaft assembly in place, got to adjust the valve gaps after lunch.coming together well, the pile of bits on garage floor is getting smaller. once the rocker gear & valve gaps are sorted, the manifolds & dipstick tube will be refitted, then injectors & glowplugs. Quote Link to comment Share on other sites More sharing options...
landroversforever Posted November 4, 2017 Share Posted November 4, 2017 Looking good Ralph! I really enjoy seeing an engine come together. 1 Quote Link to comment Share on other sites More sharing options...
Daan Posted November 4, 2017 Share Posted November 4, 2017 The golden engine... Nice job! Daan 1 Quote Link to comment Share on other sites More sharing options...
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