How to - Land Rover 90 TD to Discovery 200TDi Engine Conversion

[mark-d]

Man, I love great information...

Thanks to all who have contributed to this thread - i have a 1986 110 3-door that is going to benefit greatly from it.

however, said 110 has a kink that I have not seen mentioned here - it is left-hand drive (ex-MOD but served in Germany with BAOR)! Realizing that this is not the norm in the UK (I'm over in the States and this truck is here via Canada) I am wondering if anyone has had the opportunity to work with a Disco TDi conversion into an LHD vehicle?

I am sincerely hoping I won't have to source a Defender manifold set, as these seem to have astronomical prices from being made of hen's teeth and rocking-horse dung sprinkled with fairy dust...

Thanks - and any advice is sincerely appreciated - Al

cant say i have seen it done with the disco turbo. have seen it done with 19j manifolds or defender ones.

Maybe you could use a 300tdi turbo, i believe they fit or maybe you should put a 300tdi engine instead

 

[mrchurchill109]

cant say i have seen it done with the disco turbo. have seen it done with 19j manifolds or defender ones.

Maybe you could use a 300tdi turbo, i believe they fit or maybe you should put a 300tdi engine instead

Great thought, but I already have the 200 TDi... a bird in the hand and all that.

If I need to source manifolds I will - 19J being the old 2.5TD? THose might be doable, but from watching FleaBay and the like Defender manifolds are not to be had.

Alan

 

[Ohlins]

I have a 1986 ex army 110 LHD Defender 3 door with a Disco 200tdi installed....

If you want pics I can take them and post.

Just say'in like...





.

 

[RealSillyTilly]

Finally, tomorrow looks like the day that I will turn Tilly's new engine over. Been a lot of hard work and a steep learning curve, but fingers crossed. Couldn't have done it without this guide. Gave me the confidence to give it a go. Thanks

 

[landowner]

Just thought this might help someone.

I have just put Discovery 200tdi with both boxes into my 90.

I modified the Disco engine mounts to fit on the original Defender chassis mounts to save chopping, moving and welding the chassis mounts.

pics of new mounts attached

 

[RealSillyTilly]

At 50 (and still a girl at heart)with very limited mechanical knowledge, this thread gave me the confidence to attempt a conversion. This is the happy result https://www.dropbox.com/s/5q1tjytp1el5mwz/2013-11-27 21.53.26.mp4 Very happy thank you one and all.

 

[blue beasty]

At 50 (and still a girl at heart)with very limited mechanical knowledge, this thread gave me the confidence to attempt a conversion. This is the happy result https://www.dropbox.com/s/5q1tjytp1el5mwz/2013-11-27 21.53.26.mp4 Very happy thank you one and all.

Very tidy looking job there RST

 

[Turboman]

At 50 (and still a girl at heart)with very limited mechanical knowledge, this thread gave me the confidence to attempt a conversion. This is the happy result https://www.dropbox.com/s/5q1tjytp1el5mwz/2013-11-27 21.53.26.mp4 Very happy thank you one and all.

Looks like a very clean and tidy installation, RST
Did you do that on yer own?

 

[RealSillyTilly]

Very tidy looking job there RST

Thanks really quite proud of myself. Couldn't have done it without all the great info on here.

 

[IamRobbie]

Just thought this might help someone.

I have just put Discovery 200tdi with both boxes into my 90.

I modified the Disco engine mounts to fit on the original Defender chassis mounts to save chopping, moving and welding the chassis mounts.

pics of new mounts attached

how do you know where to weld the mounts onto tho? without it sitting cock eyed or wrong?

 

[jamesmartin]

how do you know where to weld the mounts onto tho? without it sitting cock eyed or wrong?

dry fit engine to box in the vehicle

 

[Javelinadave]

I used Richards instructions for my swap last weekend and it worked out perfectly! Thank you to him and everybody that has contributed to this thread.
Cheers,
Dave

 

[IamRobbie]

Which I knew that before fitting a disco 200 :doh:

i second that!!!

 

[sp00k]

i second that!!!

There is a reasonable write up here: Landrover 110 engine page . I wanted a 200 though, they seem to be held in slightly higher regard than the 300's, but are a bit long in the tooth now.

Might do a 300 next time - get one lined up as a spare engine ready to go in when the 200 needs a rebuild.

 

[IamRobbie]

hope my 200 lasts for years to come now

 

[alexr]

I've just finished this conversion on mine yesterday.
Definitely very worthwhile and beats the sluggish 19j hands down.
I pretty much followed this guide but found I had to do a few things differently.

- I retained the td oil cooler pipes, swapped the td oil filter housing onto the 200tdi and put the td rad oil pipe fittings into the 200tdi radiator.

- I ended up having to use both of the td pas pipes and managed to find a banjo bolt for the high pressure pipe to the pump and with a bit of persuasion she fit. The reason I couldn't use the disco high pressure pipe was because it didn't fit into my steering box, I'm guessing this is because mine has the 3 bolt box.

I'm now into the tinkering stages, all I need to do now is get the air box to fit where it did before (the only problem being the PAS pipe and bottom intercooler pipe are in the way) or relocate somewhere else. And fit downpipe once it arrives.

My only question is which temp sensor do I fit (mine currently reads top of the white when up to temp)?
Also I've been looking at a temp gauge on eBay to go in my raptor dash and it's supplied with sensor but it's a 1/8npt thread, can anyone tell me if that's the same size as the 200tdi temp sensor?


Cheers again for the excellent guide.
Alex

 

[chunkymunky]

Ooo this old chestnut. I think its 16tpi from recollection. I bought an aftermarket kit. Think it was a "TIM" kit ( maker) straight off ebay. If you look for 52mm temp gauge they usually come up. That actually fits into the defender/90 dash. You may want to look at fuel and temp gauges as a separate thing at dome point as they will all match up (only the gauge for in dash for them) and be lit up really well!

Will have a browse now and see if i can't get a link for you.

 

[chunkymunky]

Temp gauge kit
http://bit.ly/1drjWCb

Can't remember if you need and adapter but they are not hard to get.

 

[alexr]

Temp gauge kit
http://bit.ly/1drjWCb

Can't remember if you need and adapter but they are not hard to get.

Ahh I see, that also says 1/8npt thread for the sensor so that would need an adapter to fit the engine am I right?
Cheers
Alex

 

[chunkymunky]

I think so. Pretty sure you need a 16tpi adapter. Mine came with one. There are kits on ebay with them in.