200tdi Conversion (oh and chequer plate)

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bass4carl

New Member
Posts
25
Location
Worthing, West Sussex
Hi All

I've recenty had my 90TD 19j ripped out and a rather splendid low mileage disco 200tdi plonked in - I'll shove some pics up once I've got it back from the garage as they've kept the original radiator with kenlow fans, and popped an intercooler just in front of the engine with a bit of jiggery pokery with a few hoses etc. So might be different to some of the other conversions out there, and possibly of interest to a few of you...

...anyway, I'll obviously need to advise the DVLA with the new engine number, but as I've literally swapped a 2.5 turbo diesel with a 2.5 turbo diesel will I need to worry about the insurance company? Any advice would be greatly appreciated.

One last thing - I'll be putting a bit of "bling" on the 90 with chequer plate - I'm guess bonnet ones you just drill through, and use those sunken screws with nuts on the otherside. What about the other things, like sills and wings etc. Is it just a case of self tappers or is there a better way?

Cheres one and all!

Carl
 
Well I have the 90 back now with the new 200tdi installed. It's got the new rad and intercooler in, and they kept the twin kenlow fans that were fitted when it was a TD. Air filter has been moved to just behind the radiator, modified bit of an exhaust to feed to it. Quite a tidy job all in all.

I've driven it about 200 miles since getting it back, and was told it would no doubt have a few leaks/drips due to expansion/contraction etc. I have acquired a water leak, which I've found is coming from the top of the rad (inercooler side tubing). It appears to be because a temperature sensor is dunked in the rad and it's leaving a minute gap even though the jubilee clip is done up really tight and you'd think the rubber would seal it. Any ideas if this sensor can be relocated so I can get a tight seal or is there away of sealing it? (oh will I just have to put up with it dripping?).
 
So I've now attached some pics in case any one wanted to see how my conversion was done - I like the relocation of the air filter (pic 4), pretty novel!

200tdi engine.JPG

200tdi engine view 2.JPG

intercooler and air filter pipework.JPG

new air filter location kenlowe fan behind.JPG

new downpipe.JPG

thermo probe into top of rad.JPG
The last pic is the top of the rad with thermo probe thingy in it - this little blighter leaks after is been running for a while (despite being tightly done up with the jubilee), when it's cold there doesn't appear to be any signs of any further leaking however the water level when checked has dropped - probably dripped out enough water to tak eneough pressure off the "hole". Any suggestions? Do I need that thermo probe thingy? I don't think my fans have kicked since I've had the conversion, so maybe I just need a manual switch for when it gets a bit hot on the temp gauge?
 
You know what, I actually have no idea (ashamed to say), it was a tad difficult me keeping an eye on how the mechanics were playing with it as the job was dne in Devon and I was is West Sussex! They were going to use the original rad and mount the intercooler behind (or find a gap somewhere), in the end though I think they actually went for the combined rad/intercooler off a disco (which probably meant dropping the mounts a bit). That said, I have no idea why they ran out of space for the air filter as I've seen a few other conversions with it in the same place as it was when the TD was there. They did a nice job with that bit though, the twin kenlowe fans were mounted on a frame, and they've constructed a cradle and strapped it to that. It makes getting to it to change the filter pretty accessible - I was surprised at the amount of space there was in the bay to actually move around and get to things. All round good job!
 
Looks ok that , just hope that CAF pipe to the turbo is actually on now !!! . I see youve still got the fuel filter from the 19J motor too ( just remember that when you order filters for it :D ) .
 
I know that this is an old thread.. But I have done the same thing. I just want to know how you went about the changing the V5 over, also what you did about your insurance and if it went up?
 
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