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How to - Land Rover 90 TD to Discovery 200TDi Engine Conversion

Discussion in 'Technical Archive' started by richardjeaton, Nov 29, 2009.

?

Approve or not??

Poll closed Dec 17, 2011.
  1. It was Great

    80.0%
  2. Utter ****e

    0 vote(s)
    0.0%
  3. I've had better

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  1. storm99

    storm99 Spreading Joy & Harmony

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    It may be worth taking the gearbox out, attatching the whole thing together, then putting it in. Thats how mine was done.

    Not an ideal solution but if you can't get it to fit one way..try another.
     
  2. Pikey

    Pikey Dummy Ejection Facilitator..

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    Fit 3 lengths of threaded bar to the bottom holes in the block then slide the gearbox over the threaded bar. This ensures that the box is lined up properly with the mainshaft sproket also make sure bush is inplace and that the seal is on square,
     
  3. Terra Ero

    Terra Ero Member

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    Thanks for those, will give the threaded rod method a try tomorrow - will save the gearbox out method for if all else fails - but would be a sound method thanks.
     
  4. Terra Ero

    Terra Ero Member

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    Update - it was a matter of taking the engine mountings off completely, (which I'd been advised not to do) and then the usual shaking and wobbling it home!
    An early set back was my local independent Landy place gave me the wrong mounts and despite my insistence were adamant they were the correct ones for anyone changing a 2.5 n/a to a 200TDi - (turns out they were for 300TDi on a later vehicle anyway apparently I'm told - square shaped rubbers) and a new set of my old ones was what I needed - which is actually what I asked them (the round ones) to get me - but one of the staff, on hearing I was doing the upgrade thought he knew better and got me the other ones! When I went to collect them insited they were correct and what i really needed. Trying to help, but in second guessing me wrongly, set me back by a week. I won't name them as normaly they are very helpful, and anyone can make a mistake, - but it caused me no end of problems to be without transport an extra week.
    I think what I've learned is that sometimes you have to question what "experts" tell you - this guide on here was excellent help though, and the only duff info I've been given has been from people I've spoken to in person!
     
  5. larrynumber1

    larrynumber1 New Member

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    for me i removed the drivers side rubber mount completely, then jacked up gearbox slightly and slid engine in, tightened up bell housing then used hoist to lift drivers side mount as much as possible and insert rubber

    this was so easy i even decided to leave one of the little pivoting things off the clutch fork so i could do it all again! :doh:

    iv a question as well, i have my 200tdi in which is replacing a 2.5 petrol. my pas pump connections are a little different, the high pressure side bolt thing is of a different diameter to the petrol one, i dont have the donor disco i only have the engine! does anyone know the part number for this? although its may be easier to find it in a scrappys, anyone else came across this problem??
     
  6. richardjeaton

    richardjeaton New Member

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    Hi Guys

    Not been on Landyzone for a while so only just caught up with this thread.

    I had a nightmare getting the engine back onto the box too as it just didn't seem to line up. I could get one side all lined up and bolts in etc but would then end up with an inch gap at the other side that just wouldn't close up. I definitely didn't have the rubber engine mounts on though which gives more room. In the end I got mine lined up by jacking up the gearbox end. If I did it again I'd definitely use an adjustable engine lifting bracket!

    Really glad people are making use of the guide I put together anyway :)

    Cheers

    Richard
     
  7. Langers

    Langers Well-Known Member

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    No, thank you sir - I used it from start to finish, literally read it word-for-word - it saved me a lot of time.

    :D
     
  8. richardjeaton

    richardjeaton New Member

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    No worries and glad it's been useful :)

    When I did mine I'd done stacks of research beforehand but of course lots of people do it different ways and have different ability levels! As I'd not done anything like this before I wanted the simplest method so had to take advice from all the other write ups and it made sense to then put this into one document. If I ever do one again (I probably will at some stage when I get another Landy!) then I'd follow my document again with the only difference being the use of an adjustable carrier fitted to the engine hoist.

    Cheers

    Richard
     
  9. Langers

    Langers Well-Known Member

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    Yep same here, it would have saved a lot of jiggery-pokery. I spent about two hours trying to get the engine to line up with the gearbox so that it would just slide on, but simply couldn't get it to work. So I went indoors, had a cup of tea, watched 10 minutes of Top Gear and went out to try again - amazingly, I got it to slide on on my first attempt and I still don't know exactly what I did differently. She's going great now though, have done approx 250 miles since the conversion and not a problem yet. :)
     
  10. scotia900

    scotia900 New Member

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    is there a thread somewhere where i can work out what clutch kit to get? i got the 200tdi motor i'm going to fit the 2.5td bellhousing and fit onto the lt77 gearbox (110 model)? disco or defender clutch? pressure plate? etc,
     
  11. oil dripper

    oil dripper Well-Known Member

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    Have you compared part numbers?:rolleyes:
     
  12. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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    As a general rule of thumb.....
    Clutch matches engine.
    Clutchplate matches gearbox.
     
  13. Sean

    Sean Banned

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    subtle, very subtle ;)
     
  14. oil dripper

    oil dripper Well-Known Member

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    Well its more polite than standard reply number 1:D,we might need to borrow an aircraft carrier or summit offum soon:eek:
     
  15. billy-friday

    billy-friday New Member

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    Where do i get hold of a heavy duty clutch arm ?
     
  16. Langers

    Langers Well-Known Member

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    Here is always a good place to start :rolleyes:
     
  17. tombardier

    tombardier Well-Known Member

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    how does one report spammers?
     
  18. storm99

    storm99 Spreading Joy & Harmony

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    One presses the ! in the red triangle on the right of each post, one does. :p
     
  19. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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    click on the red triangle on the right of their post.
     
  20. tombardier

    tombardier Well-Known Member

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    well, one has just done that one has :)
     
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