Tdi is Stripped – Oh Dear

I have finished stripping down the Tdi engine.
The crankshaft pulley had to be removed with a lashed-up puller as it was so tight on the shaft. It was due to a trace of corrosion on the mating faces that left nothing more that brown staining – it polished off instantly with emery paper and left no pitting.

Once the puller was gone, the timing case could be opened, the timing sprockets removed, and the timing case separated from the block. The belt was in good condition, but clearly due for replacement.

Next came the aluminium ladded which is sandwiched between the bottom of the block and the sump. This is a stiffener that was introduced on the 200Tdi engine. Removal of the ladder allows access to the big end caps and main bearing caps. Once undone, the pistons and conrods can be with drawn and the crankshaft lifted out.

The pistons in bores 2,3 and 4 are all good and will just be re-ringed. Number 1, though, was worse than expected. It is clear that the damage to the no.1 bore was caused by this piston seizing, and the piston is now scrap. The conrod and gudgeon pin are fine, though, and will be re-used.

The big end and main bearings showed some signs of wear, but are very good for 160,000 miles. The outer layer has worn, but not all the way through to the middle layer. There is no significant deposition or marking, and not a sign of scoring. Incredibly, the crankshaft looks like a brand new, unused item. It won’t require any attention at all, and will go back in quite happily with new bearings. I left the camshaft and followers in place as they’re in perfect condition.

I opened up the oil pump for inspection. The gears are mint, with no play on the laygear’s shaft and only minimal surface scratching on the inside of the casing lid. It’s clear that despite having suffered an overheat at some point which cause the damage to the number one bore and piston, and presumably required the new head, that this engine has been well cared for in the past.

The whole engine, ancilliaries, rad, intercooler, expansion tank and piping cost me £300. The rebuild of the injectors and injection pump currently