Disco 200TDi into 2.5TD Defender progress

Excellent! Nice to see my list of work to do is helping out others.
I am doing another 110 for a mate and it's made life so much easier just following my instructions. No nasty gotcha's on his.
I did find that putting the starter motor wiring on before lowering the engine into place and lining it up was much easier.

Sadly I only have Pirtec locally to do the hose extension so I have to pay the price. Still cheap as far as I am concerned. I am going to look at the TD oil cooler hoses and see if I can remove the oil cooler connectors from the TD cooler and swap them to the Tdi cooler. That'll save a few pennies.

Patman1200 said:

Excellent! Nice to see my list of work to do is helping out others.
I am doing another 110 for a mate and it's made life so much easier just following my instructions. No nasty gotcha's on his.
I did find that putting the starter motor wiring on before lowering the engine into place and lining it up was much easier.

Sadly I only have Pirtec locally to do the hose extension so I have to pay the price. Still cheap as far as I am concerned. I am going to look at the TD oil cooler hoses and see if I can remove the oil cooler connectors from the TD cooler and swap them to the Tdi cooler. That'll save a few pennies.

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Yep I've found your instructions to be invaluable while doing this conversion so a MASSIVE thanks for your write up. I've done things a little differently in a couple of places and also used some other guides for cross reference but it really is excellent.

So all this info and of course Landzone has made it possible for me to tackle something I probably wouldn't have managed otherwise.

Cheers to everyone who has helped me out!

That's what we're here for, to help and hinder

Yippee!!! I've finally completed the conversion today and test driven the 90 out of the garage and up and down the lane

I've just copied some pics off the camera as I know we all like piccies here

New downpipe fitted.


Old TD flywheel fitted to 200TDi


Britpart rear crank oil seal. Load of rubbish DO NOT USE!!!


Flywheel refitted


New clutch fitted


New heavy duty clutch fork fitted


Genuine Land Rover rear crank oil seal fitted.


200TDi bolted into 90


Extended oil cooler pipes and extended water pipe to expansion tank


Another water pipe shot, I'm not 100% happy with the angle of the pipe on the engine but it seems leak free so far.


Intercooler and radiator top pipes fitted


Lower intercooler pipe fitted


Another full engine bay shot!


Extended fuel pipe


Another extended fuel pipe


TD air filter fitted - just!


TD air filter just fits to 2 mountings at bottom still.


It's quite a squeeze but I got there in the end with oil breather, air filter pipes, and snorkel pipe


Another shot of air filter pipe routing




And finally a quick video of it all working. The exhaust wasn't fitted at this stage so with just a downpipe it's quite throaty

http://www.youtube.com/v/VMVwZ-lD5p8&hl=en&fs=1

A big thanks for everyone's help along the way :clap2:

I just need to get the MOT sorted now which ran out while doing the conversion and I'm back on (and off!) the road again.

Cheers

Richard

ave you been stealing the bread delivery mans trolleys ?

Sean said:

ave you been stealing the bread delivery mans trolleys ?

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That's exactly what it is so I guess you've nicked one in the past

(actually borrowed from my neighbour who probably nicked it - lol!)

richardjeaton said:

That's exactly what it is so I guess you've nicked one in the past

(actually borrowed from my neighbour who probably nicked it - lol!)

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I've got a few now, they have wheels on rated at 500Kg each ! - perfect for moving engines and boxes around

Excellent thread Mr. Eaton! The pictures are a massive help. I'll keep you posted with my conversion which will be starting on Monday -Pos

I did mine last year, best thing I ever did. Make sure you have a disco back axle fitted ! If not !
You will feel the difference !

666 george said:

I did mine last year, best thing I ever did. Make sure you have a disco back axle fitted ! If not !
You will feel the difference !

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Yep I'm really looking forward to seeing what it's like on a proper run

Re Disco back axle; Do you mean because of the disc brakes? My next job is to dismantle the Disco for parts so I may keep the axle for the 90...

Keep the diffs if you get rid of the axles...you never know

Disc's are a must, it will stop after fitting them ! Whole axle bolts straight on, fitted stainless hose's at the same time.

but not on a 110! - they have salisbury axles - rumour has it that disco axles aint man enuf for a fully loaded 110.

666 george said:

Disc's are a must, it will stop after fitting them ! Whole axle bolts straight on, fitted stainless hose's at the same time.

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I have no problems stopping my 110 with the drums on

I have a 110 axle on my 90 its all great when adjusted up but when you hit sandy water/water/mud they go very ****e and need a strip down clean re adjust, and they are good again. Fitting discs is a good idea if you want a little less maintainance although you will wear down discs quite quick on the above surfaces.
Salisbury axle disc conversion is quite simple but its about 120 quid worth of second hand parts which Im yet to source. Yes you can get away withoit the correct stub axles but if somthing went wrong then you'd be in nick. Me thinks.