My friends Discovery 200tdi cylinder cracked in the usual place between the valves. He couldn't find another cylinder head and as I have parts here we decided to give it a whirl to show others our findings when we put on a 300tdi cylinder head without changing out pistons. We couldn't find anyone else on the internet who had chronicled it to date.
If it all goes horribly wrong we don't care......it's only a 30 yr old engine on a 30 yr old Land Rover.
I'll list what parts are required at the end along with some mentioned as we go along...
200tdi cylinder head
I had a 300tdi head kicking about so as you can see the distance between the valves is further apart than on the 200tdi.
We set about cleaning the dusty head that's been in the workshop with copious amounts of brake cleaner.....
We will need the rocker assembly too.....
We cleaned off the block as best we could in readiness for the head to be fitted, scraping off any left over gasket material........
We put on a new cylinder head gasket and mounted the head.......we torque down first to 40Nm then continue two tightening sequences at sequence at 60 degrees.....each flat on a bolt is about 60 degrees hence the marker pen marks.
300tdi pistons have a different combustion chamber to the 200tdi pisttons......so there should not be a perfect burn pattern going on. We'll see what it drives like later.
300tdi pistons......
200tdi pistons......
You'll need the 300tdi injectors.....glow plugs are the same as are the pushrods.....the 200tdi valve stem caps will work if you haven't lost any down into the pushrod holes.
The first goofy thing you'll find is the hard fuel lines from the injection pump need to be 300tdi....17mm same size to tighten as with the 200tdi, but the thread is different to 200tdi injectors....
You'll also need to take off the connectors that keep the fuel pipes together and parallel. You'll be pulling and bending same to make them fit
Once we set the valve clearances and put on the rocker cover the next goofy thing we found was that the water heater tube was fouling the connection of the water temperature sender which meant the tube would not pass......after tightening the sender gingerly the tube was able to pass.....so no need for a 300tdi inlet manifold.
You'll also need the 300tdi rocker cover breather canister and the thermostat housing.....after that it's ready to go apart from rummaging about for some water hoses to connect the water pump and heater.
First brief start up just to see that it works......we'll find a water hose routing solution next.....we're thinking it should not be up to full power when we test drive due to the different pistons, injectors but we'll see and report back. We should give it a whirl this weekend.
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