200Tdi upgrade begins

So begins my the upgrade of my 110 from the 2.5TD to a Disco 200Tdi.
So far I have removed the 200Tdi from Dento the donor Disco


For all those of us who like photos.


New clutch fitted


New exhaust downpipe fitted


Now the Radiator and front panels have been removed from Big Blue Bus there's no going back!



The exhaust downpipe lower joint was easy to do


The engine mounts were easy but the bellhousing stud nuts... bastids!


Can't see any on the starter side of the bellhousing..removed 1 though.


Power steering pump is disconnected. Just got to remove the electric loom and fuel system and assuming I've undone all the bellhousing studs it will come out!
Then it's lower the radiator mounts for the new rad/intercooler and test fit, then haul the 200Tdi in.

post a picture of yer shiny new engine stand with an engine attached to it

oh and while you've got the engine out take the opportunity to clean and protect/paint all the areas of the chassis you'd not normally be able to get to

Yeah good idea sean. We got 4 new engine stands at college this year, they don't look it now lol. Keep us posted! Looks like yer not hangin around with this

Sean said:

post a picture of yer shiny new engine stand with an engine attached to it

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LMAO! No way the engine stand will cope with a fully fitted 200Tdi. The only way the engine will sit in it is if I remove the entire clutch side of the engine. The pallet will do.

Also checked out the engine bay and chassis rails and all is covered in a thick layer of old oil with not a hint of rust anywhere. I will be squirting waxoyl into all the rails and anywhere else I can find.

Anything other suggestions of what I can do with the engine out to make life easier?

TheVengefulElephant said:

Keep us posted! Looks like yer not hangin around with this

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Sadly with 2 kids and a preggers wife I don't get all the time I need, but it's getting there.
Maybe another week to get the 200 in and a week after that to connect it all up properly. Just in time for the Farnborough Airshow to drown out the noise of all my swearing when it goes wrong

Patman1200 said:

Anything other suggestions of what I can do with the engine out to make life easier?

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just blat the bay with gunk/parrafin and clean it - and then protect - there's plenty of rust in those pics around the rad mounts

oops

Eggs-ackerly what I was going to do. All the rust is surface thankfully. Unlike the rear cross member!

done the clutch release bearing ?

Old 2.5TD isn't out yet.... but the part is waiting, as is a new clutch slave cylinder. Also the 200Tdi cambelt has been changed along with the idlers.

no probs gettin the old egsawst orf then, Pat?

Nope, 3 bolts came off easily, but I am not doing the bolts at the eggsauce'T manifold. I am leaving the downpipe attached to make life easier.
The 200Tdi is going in with the new modified downpipe attached, as it's a b'stard to do once in the engine bay.

I also think it might be easier to do the bellhousing bolts by taking the gearbox off it's mounts, resting it on a jack and pushing the whole lot a few inches into the engine bay. Then crane the engine in and do the bellhousing bolts, and then push the whole lot back into the gearbox mounts and engine mounts.
Does this sound too much like forward thinking?

Ere Pat does the floor come up in BBB?

Ps
Cool pics.

Patman1200 said:

I also think it might be easier to do the bellhousing bolts by taking the gearbox off it's mounts, resting it on a jack and pushing the whole lot a few inches into the engine bay. Then crane the engine in and do the bellhousing bolts, and then push the whole lot back into the gearbox mounts and engine mounts.

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might find it's an arse to get it lined up properly when both the engine and GB are "free"

Patman1200 said:

Sadly with 2 kids and a preggers wife I don't get all the time I need, but it's getting there.

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Oi cheeky moo! Only thing stopping you is that you were ill at the weekend big girls blouse, your old and worn out and tonight the rain!

MBG (T'other Half)

MadBikerGoth said:

Oi cheeky moo! Only thing stopping you is that you were ill at the weekend big girls blouse, your old and worn out and tonight the rain!

MBG (T'other Half)

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Ear watch out pat I wunt let the doris on ear, I knows what everyone is like!

wer dya get that downpipe from ?? its nowt like the one i got .... this is the one i got .....

Mine was from this seller on fleabay, goolygalas.

TheVengefulElephant said:

Ear watch out pat I wunt let the doris on ear, I knows what everyone is like!

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Dunt worry, she can beat you all up, or scratch yer to bits wiv her nails

clivees said:

Ere Pat does the floor come up in BBB?

Ps
Cool pics.

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Still won't help as the bulkhead is in the way of some of the bolts I can't see at the moment anyway.