boydy1989
Well-Known Member
- Posts
- 3,063
- Location
- Northants/Oxfordshire/Warwickshire
Right!
Im now mostly through the TDi upgrade, so i though I would tell you all whats been going on!
Started on monday, bloke (graham, wanted his name on here
) had already taken off most of the engine bay pipes etc.
By the end of monday, had the disco engine ready to be pulled, with them bastid poxy bellhousing bolts...
A wee tip for removing those, if you get the engine off its mounts, and remove the rubber blocks, then pull out the soundproofing on the disco bulkhead, you can get someone to gide the socket over the bolts. Much easier!
Tuesday saw both engines come out, and both of my wings removed to be replaced with better ones courtesy of a kindly yella!
Also, welded a piece of steel on the clutch release fork, replaced thrust bearing etc. Used a piece of the disco towing braket for the clutch release for brace, not realising until i had cut it out that it was 5mm steel! Its not wearing through again.
Fitted the old N/A flywheel housing to the TDi, with a new crank end seal. There were two tubular dowels in the block that had to be cut flat, or you could drill the holes bigger. I cut flat.
Wednesday (today) saw the removal of the old 12J mounts, and the removal and then rewelding of the TDi mounts from the disco chassis. We got the TDi in place, with much effort, got it bolted up and got the mounts welded on nicely. Realised this evening that the rope we were using has damaged an injector bleed-off banjo bolt, so im getting a new one tomorrow.
Got a quote for some extended oil cooler hoses, over £100! They can wait, using the old 12J blanking plate for now for one side, but the plug is a different thread so im getting one of those tomorrow also.
Havn't decided yet to use the 12J fuel filter or the disco one, the 12J one is however currently looking easiest, all the pipes are already there, and I can nick a plug and bit of pipe needed off the disco filter housing.
Jobs still to do:
Mount new exhaust
Put wings on
Mount radiator
Lengthen all the pipes
Reconnect the wiring
Blank off EGR valve
Put coolant in
Other odd bits
Try it out!
Then, when i get another few days ill be putting axles and t/box from the disco onto my 90, but thats another story.
Left my camera in the 90 today, so there will be more pics tomorrow hopefully, but these are a few taken so far!
Donor disco (it did come with headlights)
My 90 less bonnet, wings, engine
This shows one of the two studs on the TDi that needs flattening, This is mostly flattened. I hacksawed it off, then filed/ground it smooth.
More pics to follow soon, what you all think!
Boydy
Im now mostly through the TDi upgrade, so i though I would tell you all whats been going on!
Started on monday, bloke (graham, wanted his name on here
) had already taken off most of the engine bay pipes etc.By the end of monday, had the disco engine ready to be pulled, with them bastid poxy bellhousing bolts...
A wee tip for removing those, if you get the engine off its mounts, and remove the rubber blocks, then pull out the soundproofing on the disco bulkhead, you can get someone to gide the socket over the bolts. Much easier!
Tuesday saw both engines come out, and both of my wings removed to be replaced with better ones courtesy of a kindly yella!
Also, welded a piece of steel on the clutch release fork, replaced thrust bearing etc. Used a piece of the disco towing braket for the clutch release for brace, not realising until i had cut it out that it was 5mm steel! Its not wearing through again.
Fitted the old N/A flywheel housing to the TDi, with a new crank end seal. There were two tubular dowels in the block that had to be cut flat, or you could drill the holes bigger. I cut flat.
Wednesday (today) saw the removal of the old 12J mounts, and the removal and then rewelding of the TDi mounts from the disco chassis. We got the TDi in place, with much effort, got it bolted up and got the mounts welded on nicely. Realised this evening that the rope we were using has damaged an injector bleed-off banjo bolt, so im getting a new one tomorrow.
Got a quote for some extended oil cooler hoses, over £100! They can wait, using the old 12J blanking plate for now for one side, but the plug is a different thread so im getting one of those tomorrow also.
Havn't decided yet to use the 12J fuel filter or the disco one, the 12J one is however currently looking easiest, all the pipes are already there, and I can nick a plug and bit of pipe needed off the disco filter housing.
Jobs still to do:
Mount new exhaust
Put wings on
Mount radiator
Lengthen all the pipes
Reconnect the wiring
Blank off EGR valve
Put coolant in
Other odd bits
Try it out!
Then, when i get another few days ill be putting axles and t/box from the disco onto my 90, but thats another story.
Left my camera in the 90 today, so there will be more pics tomorrow hopefully, but these are a few taken so far!
Donor disco (it did come with headlights)
My 90 less bonnet, wings, engine
This shows one of the two studs on the TDi that needs flattening, This is mostly flattened. I hacksawed it off, then filed/ground it smooth.
More pics to follow soon, what you all think!
Boydy
