200Tdi upgrade begins

what date are you aiming to get it up and running Pat ?

As soon as I can....... don't do dates as they keep slipping. Same as work really

I am just going to do bits as and when I can. Once the engine is in then the rest is working out how do all the pipework.

Patman1200 said:

Once the engine is in then the rest is working out how do all the pipework.

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the first one i did took nearly a day to work out (and then find the correct length/dia)

there is a thread on here somewhere where i've posted quite a few pictures showing engine bays after conversion which might help with your pipe route planning

Sean said:

the first one i did took nearly a day to work out (and then find the correct length/dia)

there is a thread on here somewhere where i've posted quite a few pictures showing engine bays after conversion which might help with your pipe route planning

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that was the biggest problem i had .... it took ages to figure out , i never seamed to have the correct combination of pipework and hoses.....

I might shell out some more dosh for the Disco 200Tdi into defender intercooler pipe sets that have sprung up on fleabay. Will save me a load of time that I don't have.

Last night we changed the gearbox oil for the Difflock stuff. Very easy to do with no engine in the bay. Used a 1/2litre bottle with a tube stuck in it onto some hose that dropped into the gearbox filler. Clivees pored the oil in and out it pured into the gearbox. Simple!
Will give an update when I get the bus back on the road.

Also changed the rear crankshaft oil seal. Dead easy when the engine is on a pallet on the floor.

One question. How easy should it be to turn the engine over with a spanner on the crank when the engine is out? Mine seems to be very easy, almost like there is very little compression. I say this 'cos we had to put a 32mm socket and breaker bar on the front of the crank to tighten up the clutch and crank bolts.

Patman1200 said:

I might shell out some more dosh for the Disco 200Tdi into defender intercooler pipe sets that have sprung up on fleabay. Will save me a load of time that I don't have.

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as far as i know there's only 1 seller on ebay that does them

Items for Sale by debrad65

he keeps uping his price - that lower intercooler pipe set is a new item, shame his picture isnt more clear

it's the air filter/air intake plumbing thats the cumbersome task - would like to see what one of those expensive steve parker kits looks like installed

Steve Parker Land Rover Servicing, Land Rover Spares and Repairs

it's shame he doesnt put more details on his site as to whats included - he's actually put that price down and it looks better value fer money now the air filter housing isnt included

sounds like its coming on well, Pat.

despite me not being there to oversee and give you my valuable advice

Darton Fabricatiosn were doing them, but they seem to have dropped everything on fleabay but it's listed on their website here Darton fabricated parts and accessories
Don't get me started on the airfilter to turbo gubbins yet, looks like a nest of trouble a comin'.

Wotcha Daft... we miss your witty banter and critical repost whilst stuck under neath an engine dripping hot oil on us

Hope fully the engine is going in tomorrow night (Friday) if you would care to come along and trap your fingers betwixt the engine and bellhousing

That AFT stuff is nasty.
it took me 2 showers and good deal of scrubbing to get rid of the smell last night.

The kitchen did whiff a bit last night!

Last night I compared the old 2.5TD and 200Tdi with respect to the bellhousing studs and found the 2 to remove and also a dowel to check for a recess in the gearbox bellhousing. The stud on the left hand side has to be removed. The one on the right has to be removed, but there is a hole already below this that can be drilled larger and tapped the stud to be moved to.

'sall lookin really good patman, keep up the pics! I am thinking of doing this conversion myself, but I have been told so many stories by so many people that it is nice to actually see someone doing it step by step. lookin forward to seeing it in and complete!

Well we got the engine in finally last night after rocking angling, removing an extra long bolt in the chassis that was stopping the exhaust downpipe and removing the front section of the exhaust under the 110. With some persuasion, removing the front bumper, remoding a dowel in the bellhousing and a third set of hands the bellhousings met but they would not slide together. So a 32mm socket on the crankshaft nut and turning the engine and the splines in the clutch lined up and the engine slide into the bellhousing on 1 side. I got this nut done up and slowly by doing each stud up the whole thing met and looked good. Then up with the entire engine and gearbox to slide the 2 engine mounting rubbers in and then down on the mountings. Job done for the night.

Questions to those who have done it though. The lower 3 bolt holes only line up with dead end drilled holes in the 200Tdi, not the long bolt holes that were in the Disco. How did anyone get 3 new bolts into these holes?

Oil cooler pipes. I just tried to mount the cooler pipes from the TD engine but the threads do not seem to be the same in the oil filter housing. Is this right or is the thread just very tight?

I'll be back with more questions soon

Until then some more photos of the engine finally in.

and dont it just look right sat in there ???? nice work patman.....

i cant remember havin a problem with the oilcooler pipes other than they wer'nt long enough so i had some made .... i'll have a think and see if i can remember tho....

as for the bottom bolts i did'nt bother , but i was prepared to do them should the need arise but it was fine ....


p.s i just remembered i think i changed the oil filter housing over and that solved the pipe fitting problem .... they still needed extendin tho ....


looks good keep it up nearly there ...

I'm glad you getting this all sorted. just right to do mine when that goes bang....when are you free???

Patman1200 said:

Questions to those who have done it though. The lower 3 bolt holes only line up with dead end drilled holes in the 200Tdi, not the long bolt holes that were in the Disco. How did anyone get 3 new bolts into these holes?

Oil cooler pipes. I just tried to mount the cooler pipes from the TD engine but the threads do not seem to be the same in the oil filter housing. Is this right or is the thread just very tight?

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you should be able to tap those dead end hole with a M10 fine thread tap

and use the Tdi filter and some new or extended cooler pipes - the TD filter would work but it's got lots of unused ports that would need blanking off

Sirus said:

I'm glad you getting this all sorted. just right to do mine when that goes bang....when are you free???

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At this rate in about 3 months time
To add to the delay this is what flew over my house this afternoon
Beauty in flight! My hat goes off to the team who got it back into the air!

you wanna hope yer household insurance is up to date cos the locktite hasnt set on that thing yet

Patman1200 said:

At this rate in about 3 months time
To add to the delay this is what flew over my house this afternoon
Beauty in flight! My hat goes off to the team who got it back into the air!

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bastid,was gunna go ta cosford to see that,caa dint clear it ,decided on fairford an the bastids cancelled tha ,still waitin for me bloody money back

an bugger si,my enjuns out allready un waitin
still need them oil cooler pipes thou