I have just rebuilt a 300tdi. I was given a D1 that had been cooked. Pulling the motor out and putting it back in are the hardest part. The bore in mine was good, although it had a small lip at the top. I cut the lip out and honed the bores and it came up well. The motor had 400k on it. I had new pistons, but just used the old ones as they were, once cleaned and measured, in very good condition. So I have put all new seals, bearing, oil pump, thrust washers, rings, gaskets, head, rear main seal, spigot bearing etc in it for a cost of about $1,800.00. I had a hybrid turbo with only about 20k on it (I had it on my daily driver but replaced it with a VNT). I used a second hand set of injectors taken off of my daily driver that are in good condition, put new seals in the injector pump whilst it was off and fitted a new timing belt. Just waiting on new glow plugs for it and I will put it back in. If you have reco'ed a motor before, they are a simple motor to work on. Just get the 300tdi overhaul manual and it is a pretty good guide.
Good luck with it.
Tom.
1996 Disco 1 300TDI manual - Lucille a cantankerous red head! :D
1997 Disco 1 300TDI Auto - sold
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