Greetings and 2.25 diesel issue.

[Statueman17]

Hello. I have an 84 Santana Ligero (closest LR would be a Defender) with a 2.25L diesel 5 mb engine It developed a loud knock after a particularly heavy hill climb. I nursed it home and pulled the head. The #4 cylinder had the hotspot within the cyclinder and indentations on the block where the hotspot had been beaten into the block. I ordered a new hotspot and pin but the new hotspot simply drops in without any effort or retention capability. I think the old hotspot was simply rocked back and forth within the cavity thus causing it to be enlarged and creating the indentation within the block (see photo). Since the head won’t retain the new hotspot AND the block has on indentation right under where the hotspot would be, I assume both are toast at this point. My questions are: Are there any options for fixing the head to retain the new hotspot and can the block be repaired that anyone knows of? I have a 78 3 mb 2.25L diesel so can swap but would like to find a solution to keep the 5 mb engine. Down the road I may do an engine upgrade to a 200Tdi or GM 151. Appreciate any assistance.

[Les Parker]

Methinks the block is toast.
There are some new Turbo Diesel cylinder heads available from the UK, though I think you would be wiser to invest in the 200 Tdi or alternate engine.
Sorry to see this, it must be heart breaking.

[Statueman17]

Les: I’m going to see if a local welding shop that does cast welding thinks it can be repaired. Personally, I think it’s a long shot. I found a rebuilt block in the UK ($1250 with delivery) and I think I can find a head. I agree though that if I start spending too much I might as well spring for a Zombiemotors.com or or Robert Davs conversion. Thanks for the input.

[jp-]

A good machine shop could probably weld that up and re-deck the block, but not cheap and you'd have to tear down the whole motor and just give them the block. At that point, you might as well put the money toward another engine.

Other option would be to tack weld in the hotspot and/or use a hammer and punch to "stake" it in. Might last long enough for you drive it a while before getting a new motor.