I spent part of today removing more bits of the Tdi. It’s a laborious process as I’m cleaning everything as I go to make storage and reassembly easier.
The sump, turbo, manifolds, head, injection pump, lift pump, block breather, oil filter housing and brake vacuum pump have all been removed and cleaned.
The injectors have been removed from the head and will be sent for refurbishment with the pump. Luckily, the head is a recently rebuilt unit and is perfect. I moved the studs for the inlet manifold to sit the Defender type, and trial fitted the Defender manifold. The water pump and lift pump are good, as is the viscous fan. The crank shaft pulley is stuck fast at the moment, but I’ll be making up a puller from a piece of angle iron, so it should come free.
My slight concern is the number one cylinder – while all cylinders still clearly show the original honing marks and all pistons look good, the number one cylinder has some scuffing on the thrust faces of the bore (probably from some overheating, which is not unlikely considering the state of the rad and the recent head). I’m hoping it’s light enough to be removed when all the bores are re-honed ready for their new piston rings, but there is a chance a rebore will be required, along with a new piston set.
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