another 200 tdi convertion :-)

just looking for some help, my diahatsu 2.5 and gearbox has been removed ready for its 200tdi and s3 box, the box i got was a suffix d with broken syncro springs, got them fixed, and my 200 is sitting in a disco waiting for removal at the next chance i get, ive trawled the sneck for the past few free nights to get as much info as possible on the conversion but i still have a couple things unclear
1, i read somewhere that the clutch lever needed modified as it didnt clear the clutch properly and was causing it to drag, i cant find this again and was wondering if this is a problem that is normally overcome on this type of conversion (and how to do it)
2, i know the 2.5d 9.5"clutch plate is whats needed and you can either use the s3 diesel clutch cover or the 200tdi clutch cover is there pros or cons to either cover ? i would imagine the tdi clutch cover has more clamping pressure?

i don't know where you read that the clutch lever needed modifying but it's total bollocks, that's your first problem solved

use either the Series 9.5" cover or the disco one as they'll both do what you need them to (obviously use the Series friction plate)

that must be both of them solved

p.s.
buy a new clutch release bearing as you'll be really impressed if it gives up a couple of weeks after putting it all together

I think that clutch lever business is to do with a series 2...could be total bollocks but something in my mind says something to do with clutch is different on a series 2

I used complete series 3 clutch kit when I did mine, seems to change ok etc and not had any problems (yet)

TheKeymeister said:

I think that clutch lever business is to do with a series 2...could be total bollocks but something in my mind says something to do with clutch is different on a series 2

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the only difference on the series2 is you want the later Series2 9.5" cover plate with the boss in the middle to go with the 9.5" friction plate

but neither Series is complicated to fit the 200tdi engine into

i've fitted a 200tdi into a Series3 88" within three months of owning my first ever landy, it took me 3.5-4 days without assistance and knowing very little about landrovers, i've now been driving that one for nigh on three years

last year i built a 109 S2a again with a 200tdi and with the original S2a gearbox, it wasn't at all difficult

a little research will take you a long way and one of the best resources for these conversions is the Series2 forum as we have two sections dedicated to the 200 and 300tdi engines with plenty of us having completed threads/builds and putting the information out where it can be seen by all

i'm even in the process of building a 1959 S2 88" for a mate at present, guess what engine i'll be fitting in that lol

great thanks gents, its difficult to decide whats right online so its always good to speak to folk that have actually done the job, thanks again

Hi just wondered are you selling the diahatsu engine, cheers pete

pmd

still waiting on an engine..........................

job done, 200tdi fitted with turbo andnew gearbox, test run was a 700 mile run to the north of scotland, only thing i would change is the gearing screams a bit at cruising speed, disco diffs seem the most financially viable option overdrives seem rather pricey!

disco transfer box, not diffs.

The Mad Hat Man said:

disco transfer box, not diffs.

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diffs would be easier on series 3 box

yeah - yu right - i misread "new gearbox" as a defender box.

not what ive read, im using a suffix d

yeh it was a slitty engine and box but it decided that it didnt need teeth anymore hence 2 months of rolling about in my shed generally bleeding from the knuckles !

Fit some range rover classic diffs

ive done some off roading since the conversion and i think rr diffs may make first low too high if you catch my drift

You can fit a series 2 low transfer gear in your t/box that counteracts that,
See this Lower gearing - Series Forum - LR4x4 - The Land Rover Forum