PARTS

LEVEL TWO KIT ‘ENGINE MASSAGE’ Average cost $9,500. –I typically only sell fully rebuilt engine kits anymore, but if you insist on a ‘cheaper option’ , I have these : I like to call it an ‘Engine Massage , but you may consider it a ‘Major Engine Service’ with New Parts Kit. It’s the same as a level one kit, but includes the following work and parts:

• Engine is torn down enough to send the flywheel to a machine shop, and cylinder head is removed to install a new head gasket and inspect cylinders. If necessary, engine block may be spruced up a bit at this time.
• New timing belt kit installed at this time with new belt, tensioner, idler and in case of 300Tdi, an updated crank gear is installed to prevent timing belt problems this engine had. Everything properly timed using correct equipment.
• New front crankshaft main seal fitted. New camshaft front seal fitted.
• New water pump installed. In case of 300Tdi , water pump housing ‘P’ gasket replaced.
• New diesel lift pump fitted.
• Flywheel resurfaced and modified for easier ‘locating pin’ removal in future.
• New 4-piece clutch kit fitted (clutch disc, pressure plate, throw out bearing, and input shaft bushing fitted to crank).
• New serpentine belt tensioner fitted, with new serpentine belt.
• Valve adjustment / inspection/ new valve cover gasket fitted.
• New head gasket.
• NEW EGR Delete plate fitted.
• New silicone intercooler hoses included.

• 300Tdi will be fitted with custom-made RHS bolt-in-motor-mount-kit, meaning you can fit engine without having to cut and weld chassis mounts!
• Custom-made intercooler pipe kit made for your particular application. Custom made hoses and pipes mean you do not have to make your own, look for adapters or fittings or have to buy anything else to hook up your engine.
• Custom made coolant hose kit – same as the IC pipe kit – bolt on solution with no modification necessary from you.
• NEW radiator/ oil cooler.
• New oil cooler hoses.
• Tdi-style under-hood simple diesel filter housing assembly.
• Clutch housing/bell housing modifications performed here so you can install directly to LT77 transmission, or Series transmission ~ A Zombie Motors Exclusive! Makes this an ‘unwrap and install’ reality with no extra work for you or your mechanic.

LEVEL THREE, COMPLETE REBUILT ENGINE OPTION. PRICE STARTS AT $12,500 

My # 1 Seller! For those of you restoring your truck, building that high-dollar vehicle for resale, or wanting to extend your warranty/peace of mind, or needing that ‘perfect cosmetic’ engine, this is for you!

• Will include all install kits/new parts as in Level Two, but every engine totally torn down, and block/crankshaft/flywheel sent to machine shop.
• All freeze plugs removed and replaced with new. Oil galley plugs removed, cleaned out and replaced.
• Engine block can be painted your choice of color, most people go with black, but many choose silver or gold.
• After inspecting, machinist either hones cylinders, or opens up to next oversize. Crankshaft polished. If out of spec, it is replaced with a new one. Camshaft bearings inspected/replaced (machine shop can only do this as they have to be ‘cut in’ and machined to fit cam. This is one of several things the bargain rebuilders never do).
• 200Tdi engines will have their cylinder heads rebuilt with new valves, springs, keepers, and guides if necessary. Valves cut/seated. Pressure tested and skimmed. 300Tdi engines will receive BRAND NEW (not rebuilt) cylinder heads.
• Engine is now rebuilt using new bearings, seals and gaskets throughout.
• NEW pistons/ rings always used. We NEVER re-use old pistons like the bargain rebuilders.
• Camshaft inspected. If at all worn, new fitted and matched to bearings.
• Aluminum parts wire-wheeled and steam cleaned for handsome look once assembled. We NEVER rattle-can aluminum parts with silver paint like the bargain ‘rebuilders’.
• Oil pan painted black.
• Completed engine is fitted with new alternator, and new started motor.
• Engine fitted with brand-new front timing cover (to get benefit of new fan hub bearing, which is non-serviceable).
• Turbocharger stripped, inspected, cleaned, painted and rebuilt with new cartridge/bearings/seals.
• NOW AVAILABLE – 200Tdi/300Tdi Hybrid engine , another Zombie Motors Exclusive !! – We build an engine starting with perfect 200Tdi block for advantage of better water pump and cooling/stronger bottom end, but use 300Tdi connecting rods and pistons so that 300Tdi cylinder head can be fitted. Big benefit is that brand new 300Tdi cylinder heads are still available for very reasonable prices, while those for the 200Tdi are not. This also allows the use of brand-new, much more affordable 300Tdi diesel injectors. Consider this the best of both engines in one!
• OPTION OF REBUILT INJECTION PUMP/ INJECTORS AVAILABLE AT EXTRA COST, otherwise pump will be good/used/guaranteed – This one step adds significant money to the job.
• TOTAL REBUILT ENGINE KITS SOLD. PRICE STARTS AT $12,500 – This includes all install / conversion kits required for particular application.