200tdi dead cylinder #4

burlsube

Well-known member
I've been working with my mechanic to figure out what's wrong with my 110 200tdi. The latest info is that the #4 cylinder is dead. I rebuilt the top end maybe 4-5k miles ago, so I'm a little disappointed something like this popped up.

The garage is saying isnt worth even trying to investigate, but I'd like to try to at least see if there isn't anything obvious. They seem to be pushing for a new engine or a GM conversion, neither of which I am interested in.

Is there anything I can suggest they look at, etc. as they don't seem very initiated on their own.
 

abraded

Active member
Probably a blown head gasket between cylinder #4 and the rear cam follower/pushrod passage. Are you seeing evidence of excess crankcase or valve cover pressure?
 

expanse

Well-known member
I'd best hope they'd give you a reason to it's "dead" status. these engines are not that complex.
 

MountainD

Technical Excellence Contributor
Probably busted ring. You’d think a stuck valve would be visible to inspection.
 

expanse

Well-known member
The only other info was that it had zero compression.
I can see some logic in not diagnosing any more and going swap route (invest in a swap vs. labor on a possible bad motor).

Me personally, I'd pull the head to confirm if head gasket is blown out on cyl 4 (in location abraded mentioned above). worst case, you eat 1-2 hours labor and can sell the motor with an accurate description of 'blown'.
 

burlsube

Well-known member
If these guys aren't willing to do what you want you should really just take it to another shop. Pay the bill and move on
Yeah I agree. Most shops in the area seem to be like that. They are really focused on restorations and the high tickets builds, not so much the rolling restoration.
 

expanse

Well-known member
I second the pay the bill and move on. Plenty of good shops in New England that will work with you and not just give you generic answers/options.
 

burlsube

Well-known member
So the latest is that the leak down test was done and as I understand it, the cylinder lost pressure so quickly that the thought is there is a hole in the piston.
They still recommend scrapping the engine or going with a Chevy conversion. I have put so much time an money into the engine I feel bad just scrapping it, but I also have no idea what it takes to replace a piston and rebuilt it.
 

Napalm00

Technical Excellence Contributor
To replace a piston on a 200 TDI the engine has to come out of the truck. Head comes off. On a slap-dash job you would just measure the bore make sure it's within spec and put a brand new re-ringed piston in and put it back together. Would require a removal of the bottom ladder frame and the crank. It's essentially a complete engine disassembly. The one big downside of a 200 TDI compared to a 300 TDI.

Even blown it's worth probably $800 to $1,000

For $50 on Amazon you can get a bore scope and remove the injector from that bore, bring the Piston all the way to TDC and then physically look and see if it has a hole in it. It is possible it's either holed or cracked. You have really had to push the engine really really hard to do this. Could easily be done if it has non-stock fueling and you don't have an EGT gauge

Or just remove the 18 bolts and yank the head off
 
Last edited:
Top