200TDi & R380 into my 90 - what exhaust?

I am ready to start fitting my rebuilt 200TDi and R380 gearbox / LT230 TBox from a Discovery 1 to my 1987 90 2.5NA.

I am using the standard (long) R380 bell housing but I've fitted a Defender selector rail so I can use the LT77 selector quadrant and gear stick to keep everything inside the cab the same.

I've got new engine chassis mounts to weld in to accommodate the relocated engine as I calculate the engine will be a few inches forward due to the longer bell housing. I am fitting an electric fan so I can delete the viscous fan which should eliminate any fitment issues, and I will figure out the hoses once it is in.

The last "big" thing I need to buy is a new exhaust system for the larger bore to get the most out of the turbo (and the head / manifold porting I've done) and I am debating what to get. I have the Parkers downpipe conversion so I want to use something that involves the least modification, taking into account the revised engine location, ie an exhaust that gets me roughly to where the downpipe exits so I can cut and reattach.

My choice seems to be between a 19J and a 300TDI system, and logically the 300 seems the better bet since it should in theory be longer anyway as that engine also sit further forward, but the I figure a 19J system will probably fit better into my year of LR whereas a 300 will probably have different hanger locations.

Has anyone done this and got any advice please?

Use a 200tdi exhaust and make up an extension piece.

custom exhaust centre will knock one up for you. not that expensive for a straight thru

I haven't moved my 200tdi forward but I used the TD exhaust and also got the TD downpipe. I welded the flange end from the TD downpipe to the SP pipe do the TD system remains stock for easy replacement. The TD downpipe should, I think, have enough on it to give you the extra length needed from shifting the engine forward.

If your engine is in the same position as a 200tdi Discovery, will a 200tdi Discovery front pipe fit? Assuming it is a Discovery engine.
It could be that the R380 puts it a couple of inches further back though.

Thanks for the replies.

In the end I bought a 300TDI (straight thru) system and mated it to the Steve Parkers downpipe. I went with the 300 system as it looks a lot simpler than the 200 and I figured I might need the extra length to play with. I bought some hanger brackets from YRM, the rear hanger works fine, the middle hanger works if I bend the exhaust bracket to face the rear of the vehicle and use the original mounting point (I don't think it was designed like that but it works so...) and I cant see how I use the front hanger so I will fabricate a bracket to hang off the T-Box rear plate.

I am about to weld the cut 300 downpipe to the Parkers downpipe so wish me luck LOL I've never welded exhaust before!

Rougharse Racing said:

If your engine is in the same position as a 200tdi Discovery, will a 200tdi Discovery front pipe fit? Assuming it is a Discovery engine.
It could be that the R380 puts it a couple of inches further back though.

Click to expand...

the problem is the chassis rail is right in the way, you either need to fabricate some extra turns to take the downpipe past the chassis, or buy the Parkers downpipe.

Pretty happy with that, I will upload some pics of the mounts when I am done but overall that was a much easier job than I was anticipating.

All done bar some tidying up.

Here’s a picture of the bracket I fabricated to hang the centre pipe off the t-box and one of the exit.