Series 3 200 tdi conversion, completed.

[WoodyO]

Evening all,

Just a quick post to say I'm just back from a road test in the 109 since installing my 200 tdi conversion, and wow, what a difference it makes.

I know that seems a bit obvious, but it's just so much more usable in every way.

I plan to make another thread detailing my problems and fixes I had along the way, but if that doesn't appear please just message me if you're in a similar position.

In summary;
Full strip and rebuild on a Disco 200 tdi.
300 tdi manifolds and turbo.
Relocated battery.
Custom exhaust.
Standard Series radiator.
No intercooler.
Oil cooler ports blanked off.
Standard gearbox.

Oh and not a single drop of oil or coolant! ...from the engine at least.

 

[border]

Evening all,

Just a quick post to say I'm just back from a road test in the 109 since installing my 200 tdi conversion, and wow, what a difference it makes.

I know that seems a bit obvious, but it's just so much more usable in every way.

I plan to make another thread detailing my problems and fixes I had along the way, but if that doesn't appear please just message me if you're in a similar position.

In summary;
Full strip and rebuild on a Disco 200 tdi.
300 tdi manifolds and turbo.
Relocated battery.
Custom exhaust.
Standard Series radiator.
No intercooler.
Oil cooler ports blanked off.
Standard gearbox.

Oh and not a single drop of oil or coolant! ...from then engine at least.

Well Done , Mate, I am trying to do something similar 200tdi in to series 2, so will be watching your thread for hints and tips.

 

[Wildefalcon]

Did you remove the bypass thermostat thingy in the oil filter block when you blanked off the cooler?

 

[Wildefalcon]

Mine is a disco timing chest, defender manifolds, Skoda fabia RS intercooler, mocol oil cooler, battery over the relay, shuffled forward. Turner head and diesel Bob high power IP. I really like it. Got some upgrades coming, though.

 

[WoodyO]

Yes, whipped out the thermostat before blanking. Where have you got the intercooler mounted? I've got a small one here but was just slightly too big to fit with the electric fan in place.

 

[doriz]

Evening all,

Just a quick post to say I'm just back from a road test in the 109 since installing my 200 tdi conversion, and wow, what a difference it makes.

I know that seems a bit obvious, but it's just so much more usable in every way.

I plan to make another thread detailing my problems and fixes I had along the way, but if that doesn't appear please just message me if you're in a similar position.

In summary;
Full strip and rebuild on a Disco 200 tdi.
300 tdi manifolds and turbo.
Relocated battery.
Custom exhaust.
Standard Series radiator.
No intercooler.
Oil cooler ports blanked off.
Standard gearbox.

Oh and not a single drop of oil or coolant! ...from then

Not sure Thomas and Sons are still there

 

[WoodyO]

Not sure Thomas and Sons are still there

They never were, technically. My family name is Thomas, it's been in the family since new being used by my grandfather and his father as a recovery truck for their workshop in the village.

So getting the sign-writing was just a throwback to them.

 

[Wildefalcon]

Yes, whipped out the thermostat before blanking. Where have you got the intercooler mounted? I've got a small one here but was just slightly too big to fit with the electric fan in place.

Series rad in the standard place. Spal fan and flat shroud between rad and engine.

Similar to this, with some minor trimming.

Intercooler in front of the rad with some not great brackets holding it. Both cooler hoses under the expansion bottle. Oil cooler in front of the intercooler. It all just fits. Just.

 

[WoodyO]

Gotcha, thanks. Ive got my electric fan on the outside of the radiator which limits my options somewhat.

 

[WoodyO]

Spoke too soon... leak from the rear main seal, I assume. Engine oil from the flywheel housing, only a slow drip so too concerned at the moment.

Obviously a new seal went on during the rebuilt, but it wasn't one of those fancy Teflon ones.

Spare gearbox is getting rebuilt over the next few months so the seal will get replaced when the box comes off.