110 200 tdi disco & turbo

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Seaswood

Seaswood

Active Member
Posts
232
Location
Falmouth New England
Pick Up came with a defender 200 tdi that was mostly shot.
Now has a Disco 200 tdi where the intercooler connection is quite close to wheel well marked blue line.
If anyone has any suggestions, in process setting up turbo.
I had mounted the air box fwd, but what pictures I can see the airbox is somewhere above the turbo.
Assuming to make routing of hose easier.
If anyone has photos where theirs is.
Fitting turbo & connections then the wings & cab bulkhead come off for rebuild.
Seems some British farmer welded the sills to the bulkhead, So!

F9CAC81F-A421-4871-9C41-84B4AD1F4A38 by seaswood, on Flickr
 
If you still have the defender engine, swap the defender exhaust manifold onto the Disco engine.
Otherwise, you can move the turbo outlet to point upwards by drilling and tapping a couple of new holes.
There is a link somewhere to a website that shows it. I cba linking tonight, I may do so tomorrow- if I remember.
 
Seaswood said:
Pick Up came with a defender 200 tdi that was mostly shot.
Now has a Disco 200 tdi where the intercooler connection is quite close to wheel well marked blue line.
If anyone has any suggestions, in process setting up turbo.
I had mounted the air box fwd, but what pictures I can see the airbox is somewhere above the turbo.
Assuming to make routing of hose easier.
If anyone has photos where theirs is.
Fitting turbo & connections then the wings & cab bulkhead come off for rebuild.
Seems some British farmer welded the sills to the bulkhead, So!

F9CAC81F-A421-4871-9C41-84B4AD1F4A38 by seaswood, on Flickr
Click to expand...

I will get you some pictures of mine next time I am at the farm. There may be some on the rebuild thread that may help (link). I have a disco 200tdi with the original TD airbox. From the turbo intake you pictured I have a silicone angle hose that is slightly over 90, then a straight metal pipe towards the front, a silicone pipe straight joiner to a stainless 90 taking the the pipe upwards along the side of the airbox, and then a series petrol oil bath intake pipe as a 180 joining the top of the airbox to the stainless pipe. Might not sound an elegant solution when written down but it has worked for the 12 years I have had the vehicle with no issue.
 
I am assuming from S.Parker’s notes the intake on turbo that is marked, comes from the intercooler goes to intercooler.
And the intake facing fwd (no hose attached) below alternator goes to air box.
I will look see what I have in the silicone bag.
 
Seaswood said:
I am assuming from S.Parker’s notes the intake on turbo that is marked, comes from the intercooler goes to intercooler.
And the intake facing fwd (no hose attached) below alternator goes to air box.
I will look see what I have in the silicone bag.
Click to expand...
In which case I apologies If it is the turbo to intercooler pipe I have a silicon elbow that is slightly over 90 degrees and a straight metal pipe to the intercooler which is then joined with another silicone elbow. Again should be able to get some pictures this afternoon of my setup.
 
Thanks once I get wood pile moved I will look.
The intercooler pipe to turbo seems the biggest challenge a silicone hose may be best there.
Then the air box location?
 
These might not be the clearest photos but hopefully will give you a better idea of what I was doing a fairly poor job of trying to explaining. I do have a full width 300tdi intercooler, but previously had a standard 200tdi and used a 90 elbow rather than the straight pipe seen. Again it might not be the most elegant solution but it has been working no with no issues for many years.

C0D4F32E-5BCC-45C0-8524-D84C18D79CA4.jpeg 9D5A5D82-BDF9-4EC6-97B5-62FA3B85AD0C.jpeg 3DEF7B0A-A37C-43C4-9E87-FF99F19AE82B.jpeg
 
Assuming the upward pipe not attached goes to the air filter box.
I am looking how to do that one.
Also looks as tho you installed this with wheel well off.
I am fitting turbo then wings & bulkhead get a do over.

thank you for photos.
 
Seaswood said:
Assuming the upward pipe not attached goes to the air filter box.
I am looking how to do that one.
Also looks as tho you installed this with wheel well off.
I am fitting turbo then wings & bulkhead get a do over.

thank you for photos.
Click to expand...

Everything is currently off because I had an engine fire and have replaced the bulkhead, wings, engine (was a disco 200tdi previously as well) etc. as part of the rebuild which is only half finished. You can do all of that with the wings in place as they were fitted when I first installed it all.

The upward pipe not attached does go into the top of the air box and for that I used the rubber elbow from a series petrol oil bath air filter. I am back at the farm again tomorrow so will take a picture of that installed.
 
What caused the fire? what are you doing different this time I wonder.

the connector from the turbo to intercooler lower hose runs into the aft support on the frame of the shock tower.
Wondering if you had cut that down as it sorta is where the hose likes to fit.
Thnx
 
Seaswood said:
What caused the fire? what are you doing different this time I wonder.

the connector from the turbo to intercooler lower hose runs into the aft support on the frame of the shock tower.
Wondering if you had cut that down as it sorta is where the hose likes to fit.
Thnx
Click to expand...
I think it was an electrical start. I am looking to battery fit isolators moving forward.

I have not made any modifications to anything. The hose is a tight fit to the shock tower but there is a tiny gap and just clears with the setup I have. It is not a straight pipe it has a short angle on the end after the silicone elbow from the turbo so with this it clears around the inside of the turret mount on the chassis.

Here is the intake connected up to show the 180 degree flexi I was describing. Please note the air box is not quite at the correct angle and would be slightly more anti clockwise with the open intake pictured facing more the rear of the vehicle rather than off to the side as pictured.

EDE68D6C-CB14-448A-869B-06E198C685AB.jpeg
 
Last edited:
As mentioned before, you need to "clock" your turbo - this means rotating the cold part of the turbo until it's facing upwards. Have a look at the Glencoyne Engineering website, or a few of my older posts re tips for a conversion. Bits of a 2.5NA exhaust will fit quite neatly to the clocked part of the turbo and bring the boosted air to the intercooler. I was able to use the disco air filter and lots of the pipework.
 
The elbow I have from Steve Parker seems just a bit short maybe the silicone would work better.
The air box connector will be sorta like what you have, I have the original oi bath & got a 200 tdi one for this.
See what works. Looks like I need to go to the truck store get some bits.

in my other truck I have a shut off so when you leave you can pull the pull key out cut off battery power.
Not sure if that is what you mean.
 
Seaswood said:
in my other truck I have a shut off so when you leave you can pull the pull key out cut off battery power.
Not sure if that is what you mean.
Click to expand...
yes that is similar to what I am thinking about but rather than use one of the keyed switches I am looking to use one of these (link) I currently have one for my winch, so am just looking to fit a second for the main electrics. Just need to do a bit more research and check it is powerful enough for starting amps and then wire it to small toggle switch to activate.

Seaswood said:
The elbow I have from Steve Parker seems just a bit short maybe the silicone would work better.
Click to expand...

Which bit is too short? Looking at the steve parker website the joiner elbows are 90 degrees whereas my silicone elbow out of the turbo is more than 90degree, on a quick look on ebay it may be a 135 degree. But I will try and measure next time I am with the vehicle. Although clocking the turbo as mentioned above is one solution mine is not clocked, I am using a Steve parker stainless downpipe and standard TD exhaust for the rest of my exhaust system.
 
The switch I use is wired into the harness it has a key that is red f which when switched off it comes out kills power to vehicle.
When in use I tie it so will not move, a somewhat basic option versus a solenoid.

if you have the links to the ebay for that hose I would appreciate that, as yes the steve Parker hose is 90 degrees.
As it exits around the inner wheel well & goes over the shock support it is compressed a tad bit hard to even get the SP pipe into hose.
They suggest cutting it back yes makes it too short.
The turbo is a Alisport as is the intercooler andrew advised against clocking the turbo.
I also have the Steve Parker exhaust, once you start changing things there is some other effects.
 
I think the SP hose is too short, they could of spare another 10 mm hardly enough length to squeeze on a strap. Tho I believe the inner wheel well has two dimples each side of the shock tower, the fwd edge of the aft one could be flattened a bit to relieve some pressure on the hose?
The intercooler pipe is right on the arm for the alternator!
The steering pump hose needs to be held down as it is right there also.
This is just fitament the wings come off soon.
673DD1FE-4FE3-40E8-BCC0-51D7CD007D3B by seaswood, on Flickr
 
Seaswood said:
I think the SP hose is too short, they could of spare another 10 mm hardly enough length to squeeze on a strap. Tho I believe the inner wheel well has two dimples each side of the shock tower, the fwd edge of the aft one could be flattened a bit to relieve some pressure on the hose?
The intercooler pipe is right on the arm for the alternator!
The steering pump hose needs to be held down as it is right there also.
This is just fitament the wings come off soon.
673DD1FE-4FE3-40E8-BCC0-51D7CD007D3B by seaswood, on Flickr
Click to expand...
Mine is against the alternator arm as well. It is a tight fit to get everything into that space between the chassis and the alternator with everything that need to go there.
 
I was wondering if you used the Steve Parker kit for exhaust piping?
Had to make a manifold flange the the SP pipe sighting from rear goes outboard then inboard.
As goes outboard hits frame as it goes inboard hits engine?
 
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