Preparing for my 200tdi conversion!

Ok so i ruined my 2.5 TD engine... (don't ask how..)

I have brought a lovely 200tdi with a snapped timing belt, I've replaced the belt and luckily the only damage I could find were 5 of the 8 bent push rods!

Ive read manual after manual on how to convert a 19j to 200tdi, and I'm pretty confident that if i follow a guide i can do this..

I am going to buy the steve parker conversion exhaust to make things easier because my welding isn't the prettiest if I'm honest.

Im just wondering who has done this and what problems did you guys/girls come across that I can expect to see?...

Thanks! and wish me luck

easy job, look at glencoyne site, .... can get the exhaust downpipe cheaper on ebay

cheers steve

thank you buddy, I've had a look around, 107 on steve parker and seems to be around 123 on ebay.

hope all goes well and its in before the snow comes!

I will see if I can look through my ebay history, the guy I bought mine off was only £60ish quid and it was an excellent bit of kit, although this was 2 years ago so maybe he isn't doing them anymore

Cheers Steve

This the one?



http://www.ebay.co.uk/itm/defender-90-110-exhaust-conversion-for-discovery-200tdi-/321259847767?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item4acc944057

Thats the badger.... saved me searching when I get home lol

Cheers Steve

awesome! just paid for it, and all under £80!

Did anyone buy the intercooler pipes ect? of did you make them up yourselves

Ive got the 200tdi still that I've taken the engine from so I have the opportunity to take off any bits of pipe I may need.

i take it your tdi is a disco one. change the oil filter housing keeping your 19j one that way the pipes fit. the power steering pump is different so you can only use one of the pipes off the 19j i think and the other one is only slightly shorther but it does fit it just cuts the corner coming around the chassis i cant remember if its the high or low pressure side and its too dark for me to go out looking now but if you need it clearing up i'll look 2mrw. fit an electric fan and ditch the big cowling cover. have you come up with a plan for your air filter

thats the first I've heard about the oil filter housing, does it bolt straight off and on?



This is what my manual says about the power steering pump:

19. Fit the power steering pipes. I used the low pressure one from the TD and the high pressure one from the Discovery. The TD one still fits the bracket on the rear of the crossmember but the Discovery one is the wrong shape so you need to make a bracket to secure it to the chassis rail


How do you tell the difference between the low and hi pressure pipes by any chance?..


If I'm honest about my current setup it has a snorkel and the air filter is in the top of that, it goes straight into my turbo however i know this isn't best practice so i may see what room is left and attempt to fit the 200tdi filter?...

Any pictures or info would be great, thank you.

Ill start taking pictures as i take it apart tomorrow and so on..

started it yesterday for a few hours, took all the floor pans out, all the front centre bit, rad ect ect.

Just got to drain the power steering fluid and remove them pipes and then the earth straps..

Maybe i should have jet washed the engine bay before i started, very muddy truck in the engine bay and underneath lol...


Im next off on wednesday so i think ill have a day on it then if weather permits.

quick question:

My clutch pipe that goes down to the passengers side, I've read you have to relocate it to the right by 6inch..

has anyone got experience of this? or pics?


old engine is now out and new one is being prepared to go in. I'm finding it steady but rather much easier than i expected it to be.

That is a pic of mine I have just finished my conversion

Mine....



I followed the advice on 200TDi into Defender - some useful info - by Glencoyne Engineering excellent info & very thorough.

Titch thats where mine is at the moment this is what is confusing me lol...

IamRobbie said:

Titch thats where mine is at the moment this is what is confusing me lol...

Click to expand...

You want it as far from the exhaust as possible. I did mine similar to Arc above. My thread with pictures here: http://www.landyzone.co.uk/lz/f7/200-tdi-conversion-pics-230884.html . You can clearly see the clutch pipe arrangement in my last photo.

and you simply move it over to the right? no need for pipes to be extended ect?

I'm moving it over more towards the passenger side...?

Titch1987 said:

That is a pic of mine I have just finished my conversion

Click to expand...

what did you use for your intercooler pipes dude?

I got the kit of ebay
discovery 200tdi into defender 90/110 conversion kit | eBay
I also got the top rad water pipe from there as well

I cut up my old exhaust for the itnercooler pipes and bought silicone hoses off ebay. Sprayed up it looks fine.

135 degree bend hose works very well for the disco engine intercooler output (which is very tight for space between the engine and inner wing). 51mm width silicone pipes work fine with good quality 45-60mm clips.