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JOSNOS



Member Since: 06 Apr 2012
Location: Bucks
Posts: 154
United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue
Took the flywheel cover off the 200 tdi and a spare 2.5 diesel today whilst taking the cover off the 200tdi found out the gasket has broken so need to buy one Big Cry and scrapping it off was a Censored . but gradually getting there Mr. Green

200tdi engine complete


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Got clutch off and unbolted the flywheel but it was stuck on there tight


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got the flywheel cover off


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the gasket was hard to scrap off


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the remains of the gasket


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trying to take the clutch off the 2.5


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couldnt get the impact driver on it. had to hammer a socket on the nuts


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nearly there Laughing


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took all the parts back home from my dads work in my fiesta
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such a good piece of kit Mr. Green


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bolts in labeled bags for each step

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Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green  2003 TD5 90
Post #196320 24th Dec 2012 8:46pm
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JOSNOS



Member Since: 06 Apr 2012
Location: Bucks
Posts: 154
United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue
Found some photos of removing the engine out of the discovery with help with my dads friend nicknamed the mad professor

Disco stored in the back garden for a year or two


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200tdi looking a dirty but nothing that the steam cleaner


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the mad prof getting to work


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It out didnt take that long


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Got a good engine crane Laughing


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done a bit more on the engine today took the water pump, crankshaft pulley bolt and more just to get the tiiming cover off. snapped a few bolts in the process Evil or Very Mad


time to start


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water pump off probably buy a new one only 20 years old Laughing


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first snapped bolt on whilst taking off the water pump off due to the gasket failed and the bolt rusted Evil or Very Mad


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the crankshaft pulley bolt wouldnt come off so applied a bit of heat to it


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finally got the timing cover off after stud extraction of the snapped bolts Very Happy


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took the timing gears out


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its always good to have the right tools for the job for the stud extraction Mr. Green


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one of the studs i took out and the crankshaft phosphor bronze spigot bush


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Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green
Post #196584 26th Dec 2012 9:54pm
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JOSNOS



Member Since: 06 Apr 2012
Location: Bucks
Posts: 154
United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue
Finally stripped down the engine ready for painting today, starting to look good Mr. Green


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Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green  2003 TD5 90
Post #196755 27th Dec 2012 7:01pm
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johnszs



Member Since: 16 Aug 2010
Location: Hereford
Posts: 459
United Kingdom 2004 Defender 90 Td5 XS CSW Alveston Red
Cool its nice to see someone doing the rebuild for themselves for a change Thumbs Up 2004 TD5 Defender 90 xs station wagon
Post #196798 27th Dec 2012 8:16pm
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JOSNOS



Member Since: 06 Apr 2012
Location: Bucks
Posts: 154
United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue
johnszs wrote:
Cool its nice to see someone doing the rebuild for themselves for a change Thumbs Up


Cheers mate Thumbs Up 2003 TD5 90
Post #196801 27th Dec 2012 8:17pm
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GUM97



Member Since: 05 Feb 2012
Location: Cheshire
Posts: 3555
United Kingdom 1997 Defender 90 300 Tdi HT Stornoway Grey
johnszs wrote:
Cool its nice to see someone doing the rebuild for themselves for a change Thumbs Up


Ahem, so did I Very Happy Would have been a lot easier if I'd had someone to do it for me, but I wouldn't have had as much fun Mr. Green An engine to TDi for!
"Land Rover- Proudly turning drivers into mechanics since 1948"
Post #196803 27th Dec 2012 8:25pm
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JOSNOS



Member Since: 06 Apr 2012
Location: Bucks
Posts: 154
United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue
GUM97 wrote:
johnszs wrote:
Cool its nice to see someone doing the rebuild for themselves for a change Thumbs Up


Ahem, so did I Very Happy Would have been a lot easier if I'd had someone to do it for me, but I wouldn't have had as much fun Mr. Green


lucky I'm only doing the engine so it pretty straight forward but the next project is my V8 90 which is going to be fun Rolling Eyes 2003 TD5 90
Post #196807 27th Dec 2012 8:29pm
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johnszs



Member Since: 16 Aug 2010
Location: Hereford
Posts: 459
United Kingdom 2004 Defender 90 Td5 XS CSW Alveston Red
GUM97 wrote:
johnszs wrote:
Cool its nice to see someone doing the rebuild for themselves for a change Thumbs Up


Ahem, so did I Very Happy Would have been a lot easier if I'd had someone to do it for me, but I wouldn't have had as much fun Mr. Green



Just so you dont feel left out Thumbs Up 2004 TD5 Defender 90 xs station wagon
Post #196814 27th Dec 2012 8:49pm
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JOSNOS



Member Since: 06 Apr 2012
Location: Bucks
Posts: 154
United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue
Painted the block today in fordson blue Very Happy


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Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green  2003 TD5 90
Post #197024 28th Dec 2012 7:17pm
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JOSNOS



Member Since: 06 Apr 2012
Location: Bucks
Posts: 154
United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue
I've been busy with my engine. polished up the vacuum pump and oil filter housing also got a new fuel pump and fitted them to the engine. Very Happy

bit blurry

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Bought a another 200 tdi engine because it had the zeus timing gears on it so i took them apart. but need to change a plug on my engine for the zeus gears to let the oil in the timing case.


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Polish up the front timing case still need to the rear one though.


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Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green  2003 TD5 90
Post #213927 24th Feb 2013 7:57pm
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JeremyJ



Member Since: 16 Nov 2011
Location: Aylesbury
Posts: 1758
United Kingdom 
Looks good, (love blue block), but are you sure about the Zeus gears? I find the noise really annoying (ironic slightly being a Land Rover!) and really don't see the benefit over a correctly changed belt.

Just my thoughts though! Whistle
Post #213932 24th Feb 2013 8:08pm
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JOSNOS



Member Since: 06 Apr 2012
Location: Bucks
Posts: 154
United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue
Well my dad swears by them as they are more economically as the keep the timing more accurate and i dont mind the noise as i going to take the roof off in the summer 2003 TD5 90
Post #213963 24th Feb 2013 8:54pm
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Rob



Member Since: 04 Sep 2012
Location: Brownhills
Posts: 40
England 1993 Defender 90 200 Tdi HT Epsom Green
I'm sorry but I DON'T agree with you sticking a TDI in, you have ruined a very original 90 Mad I go round the classic car shows and land rover shows and I've yet to seen an ORIGINAL 90 or 110 with its ORIGINAL engine in!!!!! Sad
Post #214524 26th Feb 2013 6:34pm
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JeremyJ



Member Since: 16 Nov 2011
Location: Aylesbury
Posts: 1758
United Kingdom 
And I completely disagree with that!!

Yes its a nice early 90, yes its getting unusual with its original engine. Its not unique, its not special, its not particually rare.

Its his 90, nothing is reversable if he wants to change it back (I hope he doesnt, he's doing a very nice job on it!) Thumbs Up
Post #214529 26th Feb 2013 6:57pm
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foxkilla



Member Since: 01 May 2009
Location: J23 M1
Posts: 156
United Kingdom 2008 Defender 110 Puma 2.4 USW Auto Tonga Green
+1 Thumbs Up
Post #214534 26th Feb 2013 7:19pm
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