200tdi Head Replacement

- Completed final round of 60 degree turns, was not as bad as I feared. A few creaks and groans but then the bolts were doing that also. Final 20 degree turns on the 10 long bolts and my arms were done.

- Push Rods back in and valve stem caps back on.

- Rocker assembly inspected for wear on the contact points, all good so lowered into place and bolts hand tight. All rocker arm line up well with the valves.

- Rocker rail torqued down to 28nM WHICH WAS WRONG!! I followed an online video 'tutorial' that showed this value and *SNAP* the center bolt broke and the stud remained in the cylinder head. Looked at the workshop manual and torque should be something like 5NM with 50 degree turn (check!). Always double check, and go by the book.

Session ends here :mad:

Snap bolt solutions:
http://www.aulro.com/afvb/showthread.php?p=1687784

Session Finale

Ok after a holiday break I finally finished the job.

It all went back together reasonably easy after extracting the broken rocker bolt from the CH as well as a broken stud for one of the injector clamps.


Lesson learnt: On old engines like this - use new nuts, bolts, studs wherever torque is important... the CH heats and cools many times in its life which must weaken the fasteners over the years. The two breaks I had were stressfull for me to fix and added alot of time to the job.


As a result of the snaps I've only feel good torqued some fastners which I will have to keep an eye on or may get a smaller range torque wrench and some new fastners to be sure. I have the timing belt to do next as I found faint valve marks on the pistons - it may be engine history. Soon as I am sure of the belt and timing I will start her up and give her a whirl. When I get there I'll let you know if it was all worth it!


Heres the timelapse that covers it all.
[ame="http://www.youtube.com/watch?v=WH01InkcRK4"]Land Rover 200tdi Cylinder Head Replaced - YouTube[/ame]

Quote:

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Originally Posted by manic

Also if you have any tips/tricks or things to look out for when the head is off then please post - I would rather not have to learn from my mistakes :)

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Hello every body, I have done this kind of job, may be you can find some information here:
Land Rover FAQ • Consulter le sujet - Remise en etat d'un bloc 200Tdi 12L
It's a 200tdi disco in a defender.
Laurent

Quote:

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Originally Posted by LØLØ

Hello every body, I have done this kind of job, may be you can find some information here:
Land Rover FAQ • Consulter le sujet - Remise en etat d'un bloc 200Tdi 12L
It's a 200tdi disco in a defender.
Laurent

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Merci beaucoup pour le reportage...c'est très bone avec beaucoup d'information.

For anyone else carrying out this job I would have a glance through the above thread as there are some great images and info.

All the best


Ohlins


.:D

So has anyone fitted a 300tdi head to a 200tdi??? Looks like it should bolt straight on.

Seen a few posts where people say they are going to do it, but then silence.

It's not as straight forward as it would seem. You would need a complete/built 300tdi cylinder head with rockers, injectors etc. AND you would also need to consider putting in 300tdi pistons because the combustion chambers are aligned differently for the injectors.

See
who actually has a 300tdi head on a 200tdi block!? - Land Rover Zone

The 300 TDI head is different if you fit it you'll also red to change the pistons and injectors due to the angle of the injectors



Will helphttp://www.landyzone.co.uk/lz/f48/wh...ck-171270.html

Cheers mark

Sent from my Xoom 3G using AULRO mobile app

Thanks for the echo Mark. :p

OK, so 300tdi has combustion chambers centred in the head:
http://www.lrdirect.com/images/T/STC298210.jpg
http://www.lrdirect.com/images/T/STC298210.jpg

200tdi are offset:
https://www.aulro.com/afvb/images/im...14/07/1185.jpg
http://www.rimmerbros.co.uk/ItemImag...e/ERR1390P.jpg

Would be a bit of work, but better than throwing away a good 200tdi block.