200tdi

hey im currently puting a 200tdi into my series 2 how do yoi get around the exauhst issue? also is it possible to swap the bellhousings on a series 2 an 3 box as my 2 box is caput but i have a 3 box and advice would be great

you can swap bell housings but you need to swap input shaft and layshaft drive gear,you can get 2.5 defender exhaust conversion pipes off ebay they fit series equally well ,why not just fit series 3 box and extend clutch pipe to other side

I ran my exhaust up and over the turbo and out of the wing
Look on the series 2 club forum workshop bit theres a dedicated 200tdi section.


Lynall

lynall said:

I ran my exhaust up and over the turbo and out of the wing
Look on the series 2 club forum workshop bit theres a dedicated 200tdi section.

Lynall

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Or refer to Glengoyne and do away with the turbo.....

ive just fitted a 200di engine into my series 3 swb, and i must say its great, a bit shakey on tickover but you cant have everything, it pulls well and does over 30mpg, its a very simple conversion and using a series 3 exhaust manifold you can use the original exhaust, i was going down the tdi route but i did not think the transmission would take it, and only having standard brakes and steering i thought forget it, i will stick to my defender for the tdi

nothing wrong with the turbo on a 200 in a series. If you are going to drive like a tw@t and floor it all the time you are going to trash the transmission, but, assuming you have an ounce of sense and drive it sensibly the turbo just acts as a bit of boost when required - and makes the conversion a tiny bit easier as you don't have to worry about taking it off!

Where I am I would like to stick with the turbo for that little extra iv rebuilt the axels with discovery diffs, and have the bonus of an overdrive so I think it will cruze quite well, so it looks like the defender exaust is going to be used. as for the gearbox the series 3 box with 2 bellhousing thanks for your help, I just hope its worth the effort and better than my old perkins lump.

ive done quite a few for people and is not something anybody would regret ,only down side is a bit noisy without sound protection

I have a cunning plan for that im hoping to ebay a kidney to get one of those nice exmoor trim moulded sound proofing set, Its only my toy not a daily driver so a little noise is ok, how did you get around removing the power steering pump? is there a bracket I can buy or is it time to get the mig fired up?

you can fab bracket etc but i normally remove can off pump strip out rotor etc and fill with cv grease refit can and block holes,with plastic caps

that sounds like the best plan, a simple idler thanks

jamesmartin said:

you can fab bracket etc but i normally remove can off pump strip out rotor etc and fill with cv grease refit can and block holes,with plastic caps

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Where are you getting these plastic caps from mate?

doesnt have to be plastic caps but anything to block hole and hold cv grease in

Yeah I've got this to do, just trying to think of where I can find something suitable lol, thought if you found somewhere that sold some sort of correct fitting plastic caps then I'd just get those cos I'm lazy

i get them with new injectors

I installed a 200TDI in my Series 3. I ran the exhaust out over the frame rail and down the outside of the frame. It's somewhat of a tight bend out of the turbo, but seems to work. No problems with heat on the floorpanels. One note, after researching how to route the exhaust, I read someone else installed their exhaust in the same way, but kept cracking exhaust pipes due to the vibration. I used a flexible exhuast coupler and have had no problems for 15,000 miles and 3 years.

i'd advise getting rid of power pump all together.
move altenator down and run one belt.

83series said:

i'd advise getting rid of power pump all together.
move altenator down and run one belt.

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move alt down where? It needs moving forward to come into line to run with one belt

i used some angle with a hole drilled for the adjuster to tighten on and spaced the altenator with some washers, hard to explain but easy when you see it. makes more room for the intercooler and piping aswell.
i'v done the pump full of grease and of the two this is the way to go in my opinion.

83series said:

i used some angle with a hole drilled for the adjuster to tighten on and spaced the altenator with some washers, hard to explain but easy when you see it. makes more room for the intercooler and piping aswell.
i'v done the pump full of grease and of the two this is the way to go in my opinion.

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:nopics: mines filled but would rather take it off.....I'll make something up but haven't decided on the best way yet