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Thread: 200 TDI Disco 1

  1. #1
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    200 TDI Disco 1

    About 6 months ago I did a swap for a 93 Disco 1 that has a 200 TDI engine and R380 gearbox.
    When the bloke turned up it seemed to run ok. Next morning when I started her it was like a smoke screen. I vowed before a blue slip I would at least do the head and cooling system.
    Well have now got the head off and omg.. a miss match of old bolts and new non branded head bolts, also they had replaced the head gaskit and timing belt but got the timing out one full cycle of the No1 piston. I have the timing tool set and I don't think I could have it wrong. The No1 piston is at TDC and the pin is in the flywheel at the bottom of the case.
    Would the engine still be able to run like this????
    There is carbon caked on the top of the head and raw diesel in the manifold. Valves seem ok though and no sign of hitting.
    Also the camshaft timing belt pulley has the key mangled to one side blocking the pulley form coming off.
    Any Ideas out there please as to the best way to attack this without causing damage?
    Cheers.
    Last edited by Defender3.9; 31st March 2019 at 09:58 PM. Reason: Grammar

  2. #2
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    Well I talked to a mechanic today and he said yes it would run.
    After watching youtube I will give the woodruff key a go.

  3. #3
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    The crankshaft woodruff key cam out easily enough and the camshaft pulley slid off easy but the slots in the crankshaft for the keys is buggered.
    So it looks like I will have to make a copper key and weld the crankshaft up the machine it down. Glad I went all out and didn't just do the head gaskit!

  4. #4
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    Looks like whoever changed the timing belt last put on a new cam pulley, injector pump pulley but left the old crankshaft timing belt pulley. It is now buggered as well with wear and the key buggered.

  5. #5
    Join Date
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    I've got a 200 tdi disco that I'm about to send to the wreckers.

    It hasn't run in 5 odd years, but it was still going strong when it last ran.

    Your welcome to the engine for $100. (its still in car).

    Live outer west Sydney.

  6. #6
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    Message sent Gazza.

  7. #7
    Join Date
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    Thanks to Disco Gazza

    A very Big thanks to Disco Gazza for helping out with his old D1 200tdi. She is now on the road to me. Can't wait to see her in the morning.
    Cheers.

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