200tdi into hybrid series / disco, with pics!

jamesmartin said:

old boxes, i used to drive them when new,you could pull anything you wanted in low but couldnt tow a caravan above 30 in wind,half shafts the weakest point if you can drive

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Aye but they're not new now guess we have to put up with that though unless you've got a time machine ?

luckily the lt77 i bought had less than 100k on it

It's not how many miles it's how the miles were done

yeah fair enough, but can have been that bad, bought the defender from a farm that had owned it since new. unit it rotted out and sold the parts.

200tdi ayre said:

Aye but they're not new now guess we have to put up with that though unless you've got a time machine ?

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no you could rebuild one properly ,not cheap now but you still can

cut out engine mounts



disco interior




rear prop all lined up. front prop fits too. need to move the box up 1.5 inches , Moved it forward 2 inches. got the engine in to line it all up, but have to do it again tomorrow.

i'll try to remember to take some more photos tomorrow, got a job list with about 25 jobs on!


Move gear box
grind down old engine mounts
sort raditor and intercooler mounts
fit engine mounts
move fuel filter
remake gear lever to clear bulk head
fit air box
fit exhaust
fit axel breathers
speedo cable
fit new clutch, flywheel and flywheel housing
Move brake pipe junction
bleed power steering
bleed clutch
sort glow plug relay / wiring
change 200tdi oil + filter
fit seatbox
fit battery
fit handbrake

going to bolt on engine mounts




offering up the engine.




throttle cable on. assuming the tension from the injector pump return spring will keep it in place.





rad and inter cooler on okay. using frame from disco





gearstick bent the other way, went really easily with heat from blow torch. Now clears the bulk head.




offside engine mount on

Not a SIII front end then

noo, wouldnt have the space other wise.

yeah you would its been done before

okay , but dont want a foot long prop shaft haha!!

didn't get up to much today, just painted the bottom of the seat box and tidied everything up, ready to start getting the other engine mount into position.

Need to fabricate some new corners for the seat box as the have corroded. can someone advise on that?

propshafts measure up okay. I can use the front prop shaft from the disco in the front of this landy, and use the front prop shaft taken off the original gearbox will be used on the back as the original rear prop is a tad short.

got some bits for sale, the old engine, a ford transit 2.5di that fits onto a series box, and the old transfer case. just drop us a message.

Clutch fitted, used a 19mm sock wrapped in some electric tape to align, worked perfectly.

Gearbox and engine bolted together, and nicely mounted.

not bled the clutch but it seems okay, will have to see.

Radiator pipes hooked up, need to mount expansion tank and air filter.

going to bodge air pipes with some 2.25 inch stainless exhaust pipe.

power steering res mounted , still to get fuel filter on.

will hook up battery tomorrow and give it a wiz after getting some fluids in.

Oil cooler pipes also need to be extended, I am going to use some hydraulic hose and some jubilee clips

Please could a moderator or someone move this into series land rovers? thanks

got all pipes extended and fitted, radiator moved, fuel pipes hooked up, re done wiring for front lights got it posh loom tubing,

all lights working, only problem is alternator / charge is on when ignition off, looks light a new alternator, got a lucas one from a transit that I can stick on, just need to cut the oil pump shaft on it off haha.

been lazy with pictures but will put a few up soon.

Need to get seat box painted and fitted on, Might fill it up with some water tomorrow and test the engine!! may even go for a little drive round the farm!

You sure your wires are the right way round. Charge light comes on if you've mixed up wires on the barrel

yeah all worked no problem before,had problem the disco too, battery light on when ignition off.

I have a battery isolator too.

Wiring on starter and back of alternator correct ?