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200tdi to 300tdi conversion

Discussion in 'Defender 90 / 110 / 130' started by 666 george, Feb 7, 2013.

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  1. 666 george

    666 george Well-Known Member

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    I've already changed the old 2.5TD to a 200tdi & there are loads of write ups on it, but how about 200tdi to 300tdi.
    I know your all going to say, why. Cos the 200 is burning more oil than diesel & the pressure is sh*t. I've already done all the botom end but still no good.
    I know I'll need a new engine mount welded on.
    Can I use the 200 rad & intercooler & oil cooler pipes?
    What do people use as a downpipe? Can I just use a standard defender one?
    Any thing else I may have missed.
     
  2. Jongould

    Jongould New Member

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    gearbox crossmember needs to change, mounts, gearbox itself, props and pipework. You can use any rad you want but may need to make your own hoses up, think the PAS pipes will need changing as well plus a few other extra bits. I asked the same when I stripped my disco as I thought about getting a TD and doing it but decided it wasn't worth it in the end... Do the 200 swap, will be less hassle and they are better engines, the 300's like to get hot (as we found out in sailsbury remember!)
     
  3. 200tdi ayre

    200tdi ayre Well-Known Member

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    Why do you need to change gearbox and props ? :confused:
     
  4. 666 george

    666 george Well-Known Member

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    I've already got a 200 fitted & wanted to know how easy it's going to be to change it over. The problems is a good 200 are becoming harder to find & mine is shagged but can't have it off the road for too long. Dan's got a good 300 for sale.
    I'm going to use the LT77 box as it will fit.
     
  5. Jongould

    Jongould New Member

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    300TDi uses a different box and as far as I was made aware its easier to change the entire lot than mess about trying to fabricate mounts to sit the 300 further back like the 200 engine, I am just going on what I was told previously, this may be incorrect but then I have never done the conversion and was passing on the info I was told...
     
  6. trax

    trax . Events Planner

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    Sounds a pita, might be better to fix the 200
     
  7. Ltwt Hybrid 300tdi

    Ltwt Hybrid 300tdi Active Member

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    I have a 300tdi mated to a 5 speed lt77. Just used the 200tdi bell housing and there are two studs and one dowel that need to be removed.
     
  8. 666 george

    666 george Well-Known Member

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    Cheers for that.
    How about the engine mounts? Do you need to do both or just one.
    Just need to find out about power steering pipe, will 200 fit 300 & what downpipe to use. The rest of the exhaust I made up with a stainless middle from a 200 & home made side exit. I'm sure I can make them fit.
    Sounds like I can use the 200 intercooler just need to sort the pipes.
     
  9. defender greg 90

    defender greg 90 New Member

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    my mate changed his 200tdi out for a 300tdi in a weekend it does look rough as there are pipes all over the place but it works
     
  10. Mark L

    Mark L Well-Known Member

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    Did he have the engine sent up on a pallet a few weeks ago, perchance...?
     
  11. 200tdi ayre

    200tdi ayre Well-Known Member

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    Well I'm currently dropping a 300 into my challenge truck as my 200 died, you can use the 300 flywheel housing onto the lt77 box just fine, all you need to do is make 1 mount for the drivers side.

    Not sure on the power steering pipes but I can make new ones so it doesn't bother me. I'm also probably rear rading too so pipes don't matter to me either :rolleyes: I think a little modding will be required to the down pipe but not sure until I drop it in
     
  12. The Ferkin BoB

    The Ferkin BoB Banned

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    be easy enough its just bolts nuts and pipes...:D

    and if yer lucky the odd flange..
     
  13. 666 george

    666 george Well-Known Member

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    Looks like I need to do a bit more searching as I need to drive it there, change it & drive it home. Oh well if it comes to it I'll just tow it home & sort it later.
     
  14. Pikey

    Pikey Dummy Ejection Facilitator..

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    Complete and utter ****e..

    yep simples intit

    Try here it's for an N/A to 300tdi but the principle is the same.

    Landrover 110 engine page
     
  15. jamesmartin

    jamesmartin Well-Known Member

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    theres 2 ways of fitting either like lr did wich just uses std parts but repositioning and different gear box as jongould is referring ,or just bung engine on the lt77 as is and make up parts pipes etc to fit ,latter is cheaper former is better imo
     
  16. landowner

    landowner Well-Known Member

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    I have a 2.5 td 90 which had a 200tdi and disco boxes fitted.

    The 90 props fitted, the engine mounts fitted and because the disco box has a longer bellhousing the oil pipes fitted and the turbo pipes, rad hoses fitted and the\ exhaust downpipe fitted together with the 2.5td exhaust.
    Only the engine mounts had to be moved forward a bit, gearbox mountings were ok but han\dbrake different on 2.5 / 200 / 300.

    I then changed to 300 tdi with R380 but it was broken so went back to another 200tdi and lt77 which is in it at the moment so I have seen the problems associated with both engines.

    If you have used the old 2.5 mounts for the 200 then only the nearside one will fit the 300 block.

    Well they will both fit but you cant get the oil filter on
    I cut a piece out of the mount and welded a strengthener in so as it clears the oil filter so I have 2.5 td engine mounts on the 300 tdi:cool:

    The power steering pipes are different at the pump end so use 300 pipes.

    the bottom hose comes out of the 300 rad at the opposite side to the 200 and the top hose is a different size

    Intercooler top pipe is a different diameter as well the 300 being bigger.

    The 300 downpipe fouls the 2.5 engine mount so will have to be fettled

    The 2.5 temp sender that you will have put in the 200 tdi will not fit the 300 tdi either.

    All can be sorted with a little ingiuity (engine uity ha )

    hope that helps:)
     
  17. 666 george

    666 george Well-Known Member

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    Thanks, thats all I needed to know. Turns out the engine has an aftermaket oil cooler so I don't have to worry about the oil pipes. Just need to sort out the intercooler pipes now.
     
  18. landowner

    landowner Well-Known Member

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    Could put the 200 inlet manifold on, wouldn't make that much difference and the pipes would be the same size then.
     
  19. Jongould

    Jongould New Member

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    When I looked into doing mine I was going to use the R380 from my disco as it is a better box so thats why I knew it that way. Are the heads the same for the manifolds? If so theres no reason not to use the 200TDi manifolds is there?

    If thats the case it should be a straight swap pretty much, pas pipes can be taken to a hydraulic place and they could simply mate the two together, hoses will be easy with a few bends and connectors, might need to get turbo feed pipes I guess but again thats easy...
     
  20. sible88

    sible88 New Member

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    I have a 300tdi and R380 in my 2.5td 90 but I used the LR conversion kit that I purchased from sawtry. You also need to think about the clutch being on the other side!!

    Mine uses standard pipes so its easier if I blow one.
     
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