configuration

putting 200tdi into series 3 88


i have a 19j in mine, what if i swapped the inlet and exhaust manifold to 19j, withj the 19j turbo, then it would have less stress but still have a turbo !, and then i could fit my already modified 19j exhaust ??

any ideas would be really great, parts i have to play with are 19j complete, 300 tdi rad, and a whole 200tdi disco engine,

so how should i play it ? which parts shal i use ?

mine has sh*t hot breaks btw

:confused2::wtf::whoosh::whoosh::whoosh:

what ? im on about 200 conversion, what i am asking cannot be read in the guides as it has not been asked/ answered

lordluke1995 said:

what ? im on about 200 conversion, what i am asking cannot be read in the guides as it has not been asked/ answered

Click to expand...

The 200tdi is a much tried and tested, reliable and long lived unit, why **** about.

so use all the bits out of my 200 disco then ?

19J turbo is quite a bit smaller than the 200 unit, plus the manifold locates to the head differently, may work.
i did ask similair question on another from and answer was it had been done before but the guy had problems with head to manifold gaskets.
Fit the disco lump complete and buy a steve parker adaptor exhaust pipe.


Lynall

ok cheers mate,

any ideas oin alternator and set ups ?? could i leave powersteering pump in as a pulley ?

hi mate i think you would have to use the 19 j bellhousing and the 19 j flywheel take flywheel from 19 j and remove housing . while its off change the crank seal in the casing bolt it to your 200 and use your 19 j clutch . you will find that a couple of the bolts in casing wont line up !! leave them out ! makes no difference at all !! as regards tutbo use the 200 tdi one its much better than the old unit! take out the three six mm bolts on back of the turbo turn the housing untill the outlet points forward and up!! drill the three holes in casing stick a six mm tap in and bolt up the turbo !! no swarf goes into turbo while drilling tapping the case is thick alloy !! put it all together and make a realy tight 90 exhaust fitting ! can be done easily with some tube a welder and a angle grinder !! if you plan to use the disco rad you will need to lower your bottom rad mounts by 25 mm or ya bonnet wont close !! hope this helps !! good luck..

why flywheel ,there identical apart from timing slot

right chaps done it ! i made a cardboard cut out of my bell housing, i removed the 1 stud not needed, i tapped the bottom three holes that are just unthreaded and used studs off of 19j one, 3/8 tap

the interesting bit is, you know where the 4 bolts are at the bottom, i bolted them in far enough, and then cut the heads of flush with casing, this way i still get streng into flywheel case ???

i hope this is good ??

Well its done now so dont worry about it.
Most people dont do any of this they just fit it and thats it done, but they always wonder why they have an oil leak afterwards!
I ran a 16mm drill down mine an inch or so, then used cap head bolts these sit under the mating face, then did as you did tapped out the existing holes, we did the same with a mates 200 disco in an old 90.


Lynall

you say its done, but it doesnt fit in the hole !
cant get them to couple, iv tried another series bell housing and that fits ok ..... help haha

Look at the spigot bush in the middle of the flywheel, less than a quid from bearmach
The engines can be real sods to line up, mine was tight even though i had greased the bush and shaft i still had to pull it in the last 1/2 inch or so, this was into a series 2.
Ps dont just get the nuts on and try and wind it in if its real tight as you dont want to break something


Lynall

right so what should i buy for a few quid ?? as i dont understand shouldnt it just fit ? or do you think shaft could have moved forward ?? not to sure on this one, have a look at my other post for details

lynall said:

even though i had greased the bush and shaft i still had to pull it in the last 1/2 inch or so,

Click to expand...

not something I would advise as it is common practice to grease a bush to push it out. Also bushes are commonly oil impregnated. this can be easily carried out on a domestic cooker.

come again mate (in english this time )

an what amazing thread... hard to sense make

haha i appreciate your enthusiasm, im just trying to get back on the road !

lordluke1995 said:

right so what should i buy for a few quid ?? as i dont understand shouldnt it just fit ? or do you think shaft could have moved forward ?? not to sure on this one, have a look at my other post for details

Click to expand...

Sorry what you need to look at is the spigot bush located in the centre of the flywheel, if is smooth its entire length theres nowt wrong any step means its worn, the bush is a quid.
By greasing it i mean a wipe over with a greasy hand not slathered on.
The engine should be a straight fit, remove the engine rubber mounts and try again, then when in and secured to the gearbox lift it up and refit the rubber mounts.
Did you remove the studs not needed for the housing?


Lynall



Lynall

yeh i have removed aload of studs just in case, nightmare !