200di conversion

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revdj

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Ive been planning to put a disco 200 tdi I bought a while ago into my petrol 88 . I have just read an article by Glencoyne land rovers who recommend installing the engine without the turbo. As I dont particually want more power just better mpg this idea seems tempting. It also means you can use the series rad ,air filter and exhaust and dont need the modified plumbing of intercooler and turbo. Anyone got any advice or even done this conversion themselves.
 
Many reckon that the 200di conversion puts less strain on the series gearbox etc - is the way I plan to go if/when I finally persuade local farmer to part with his old series 2 :)
 
hi i have a 200tdi in a sereis 3 109 go greats mine is fitted with the turbo on. if u re going to use the series gearbox i have used a series 2 box becasue they are stronger. i had a s3 one and it kept winding the layshaft up.
 
I've done the conversion in December.
Lots of things you have to think about anyway:
Expansion tank vs just not filing up to the top and using the upper part of the rad as expansion tank.
Exhaust: I modified my petrol manifold, or if you have the spare pence buy it from somewhere.
Fuel return
Your temp sender propably screws right into the thermostat housing without the adapter used in the 2.25
Use the series thermostat housing cover!
Keep the 200tdi alternator!
DO NOT EVER EVER EVER keep the PAS pump without tank for fluid it can pump through. Or better, get rid of it if you dont need it! (Dont ask how I know. Somewhere I've put a thread up not long ago...)
Otherwise: simples. Engine crane, allen bolts (I drilled through the bell housing and fixed the bell housing through the flywheel housing to the motor block)
You can keep the battery where it is if you fit either a K&N filter or find a place for the air filter (have to cut the tray and put it higher though).

A string will do well as accelerator connection!-)
 
The tdi will probably be a smidge more economical with the turbo, the turbo at very low boost pressures uses waste heat to force air into the engine, reducing the pumping losses almost completely, only thing is when your tempted to give it a bit of welly all that goes out the window and consumption increases.
The conversion is easier as far as the exhaust is concerned, keep all the bits then the next season you can fit the 'charger.
 
If you do a search on here you'll find many a topic about it (including mine) - quite a good conversion to do, few things to think about on route but generally straight forward to do
 
is it actually cheaper? cos mine does 22 mpg with the petrol, and petrol is cheaper than diesel. do you get enough mpg out of the doozil to make it cheaper to run over the same distance? just wondering thats all :)
 
Attraction for TDI for me is that it can run on Veg oil/filtered waste oil or biodiesel without significant modification.

Therefore even if I only get 25 mpg, the real mpg for me (on biodiesel) is around 250mpg, as my bio is made from free waste oil. I only pay for chemicals/electric to convert it.

Mark
 
I think you can split up a disco radiator. 1 part is the oil cooler and the other [bigger is water] Move the water part forward for space, sling on a kenlow fan and find a standard oil cooler [nato maybe] and put in front of the primary radiator. I'm pretty sure i've seen someone somewhere doing that. Means cutting up the grill though.

May be wrong, but seems a pretty good way to do it.
 
a series 2 0r 2a gearbox isnt stronger than a series 3 apart from having no 1st and 2nd synchro ,we dont fit oil cooler blank it off on filter head ,dont use intercooler pipe direct to manifold that way still use original rad with electric fan
 
1moley said:
I think you can split up a disco radiator. 1 part is the oil cooler and the other [bigger is water] Move the water part forward for space, sling on a kenlow fan and find a standard oil cooler [nato maybe] and put in front of the primary radiator. I'm pretty sure i've seen someone somewhere doing that. Means cutting up the grill though.

May be wrong, but seems a pretty good way to do it.
Click to expand...

I've also seen conversions using a standard series 2 rad and using an external aftermarket oil cooler. Looked easy, and nowhere as awkward as a NATO oil cooler (which needs to go infront of rad).

Mark
 
Thanks guys,
If you google Glencoyne land rovers and click information there is a three page write up on the non turbo conversion, seems convincing stuff. The main attraction for me is the much simpler (and cheaper) proceedure. If the 30 to 35 mpg is realistic then its definately worth it. I am also thinking of going down the bio route.
 
300TDI exhaust manifolds fit a 200 nicely and allow use of a straight downpipe,instead of the convoluted route needed to get off a 200 manifold.

Mark
 
revdj said:
Thanks guys,
If you google Glencoyne land rovers and click information there is a three page write up on the non turbo conversion, seems convincing stuff. The main attraction for me is the much simpler (and cheaper) proceedure. If the 30 to 35 mpg is realistic then its definately worth it. I am also thinking of going down the bio route.
Click to expand...
I have just been reading the above website.............very interesting..........thanks.......
 
revdj said:
Thanks guys,
If you google Glencoyne land rovers and click information there is a three page write up on the non turbo conversion, seems convincing stuff. The main attraction for me is the much simpler (and cheaper) proceedure. If the 30 to 35 mpg is realistic then its definately worth it. I am also thinking of going down the bio route.
Click to expand...

I wouldn't be too sure. Looked at doing the de-turbo route - concluded leaving the turbo on was actually easier!

In one run out i have saved enough on fuel to pay for half of the 200tdi engine.
(I think my petrol had issues :rolleyes:)
 
1moley said:
I think you can split up a disco radiator. 1 part is the oil cooler and the other [bigger is water] Move the water part forward for space, sling on a kenlow fan and find a standard oil cooler [nato maybe] and put in front of the primary radiator. I'm pretty sure i've seen someone somewhere doing that. Means cutting up the grill though.

May be wrong, but seems a pretty good way to do it.
Click to expand...

I think you are wrong. The Disco has the intercooler and radiator mounted next to each other - these can be seperated and located in different locations, however, the oil cooler looks integral to the radiator
 
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