200Tdi upgrade begins

Patman1200 said:

It looks liek the intercooler pipes might be in the way...... but until I fit it all I'm not sure. I'd like to keep it there somehow.
Yup new rad it is, but not yet. T think it is something worth buying new

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if you can find an orginal new LR rad (not a pattern part) get one as they last so much longer, and are so much more effective than the paper weight copies everyone seems to be selling

here's a pic showing some of the pipe routing when the filter is left in the orginal location - i'll take some more if it's not clear where everything goes - it's not the neatest install but it's all very easy to get to

Ye gods thats some pipework
What does the one that connects to nothing on top of the block do?

Patman1200 said:

What does the one that connects to nothing on top of the block do?

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that's from the heater rad and is for an inline coolant pre heater - when i get round to finishing it

Patman1200 said:

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I would put it up for a Turner prize

Yesterday I visited the nice men at Pirtek in Slough and they extended the oil cooler hoses for me (£68). They now fit a treat with plenty of slack.
Last night I cut down the radiator bottom mounts and then painted them up. Before I mount the rad/intercooler I am going to paint the entire area with old grease to keep any rust at bay.





The next question is if the Power Steering pipes are long enough. They reach the pump but they will not mount along the front cross member. For safety I would like them mounted behind some protection so that is something to look into further.

Patman1200 said:

Yesterday I visited the nice men at Pirtek in Slough and they extended the oil cooler hoses for me (£68). They now fit a treat with plenty of slack.

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ouch - they normally charge me about £25 but then i do pay cash, and wait till there's only one bloke in and usually go there on a Sat morning when it's very quiet

could you not have got them to extend your PS pipes as well ?

I could but I didn't think about it at the time...DOH!

reet Pat - Basingstoke crew is attending on Friday - hope you gorra job or two fur us.

Sure I can find something.
Need to shift the old TD engine into the workshop, mount a new exhaust front pipe to meet up with the new downpipe, rewire the oil pressure switch and temperature sensor and fuel solenoid and alternator..... oh did I mention shifting 3 cut down trees?
I'll ask t'Doris to get some cakes in.

Many thanks to TMHM and Grippa for popping up on Friday night to help out in the upgrade. TMHM did a very tidy job on all the wiring and Grippa did a splendid job of swapping out and mounting the old TD water expansion tank for the Disco TDi one.
Myself and Clivees found that the standard 110 exhaust on my bus was too long by about 5 or 6cm to fit to the new TDi conversion downpipe. So we started the process of cutting and welding a section out of the front exhaust pipe. It was just as well as there was a very rotten section that needed patch repairing anyway.

Did anyone else have this issue when upgrading from a 2.5TD?

Some pictures of Grippas water expansion tank mounting system (patent pending!)



PAS bottle mounted


The exhaust butchering


Got the exhaust welded up tight and mounted with the help of a club hammer and some firegum paste, so it's onto the home straight with the rad/intercooler stuff to finish so I can start it up

ere Grippa - I told ya you autta have cleaned tha washer bottle and painted that stay.

Patman1200 said:

Some pictures of Grippas water expansion tank mounting system (patent pending!)

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will the bonnet shut ?

cheeky bugger - of course it will - fully tested and checked by Grippsybabes prior to fitting. Us Basingstoke crew dont do things by halves, ya know,

must be the camera angle makes it look like you'd have to cut a hole in the bonnet to fit the lid

Getting the hoses to reach is another matter that I shall find out about tonight

ere Patman - a mere snip......

Funnily enough already got them.... will look a little too bling under the bonnet, but only until the first greenlane

A summary of last nights jobs. I re-hosed the fuel system with 9.5mm fuel hose to fit the larger fuel pipes in the tank to lift pump, filter to injection pump and return pipe. Much easier than trying to fit 8mm hose over the pipes and only getting it 1/2cm on.
The lower water to radiator and expansion tank needed a longer bit of hose to the expansion tank. An old internal heater hose and a length of heater pipe stretched the extra 15cm needed.
Also fitted the lower turbo to intercooler pipe from Darton Fabrications. Fromt he package the 90degree elbow had to do too tight a bend to get past the inner wing, so I cut 2cm off the turbo outlet side of the elbow so the turn sits very close to the turbo and reaches the lower shiney pipe without collapsing and blocking the airflow.

Not far to go now!

if the weathers ok - i will be up on thursday, Pat. Chainsaw in hand if thats OK.