Hello All.
I'd like to say thank you to everyone who has posted info about converting a Series 3 to 200tdi - I've now finished my conversion and I couldn't have done it without you!
Following much planning and eBaying I've successfully managed to fit a Discovery 200tdi into my 1984 Series 3. The car has been in my family since 1988 and was my first car so has a lot of sentimental attachment. The 2.25 diesel was getting tired so I either needed to sell it and trade up to a 90, take the 2.25 out and overhaul it or fit a 200tdi. I am so glad I went the with the 200tdi option! Its made a huge difference and puts a smile on my face every time I drive it.
I am quite chuffed with how it turned out as I managed to do the conversion without really modifying anything from the original. The only non-reversible changes are two 3" square cutouts in the inner wing and radiator panel which aren't visible unless you look for them. The rest is as-built or bolted on.
I used the series radiator with a 10 core oil cooler mounted behind. The intercooler is mounted in front of the radiator and is from a Fiat Multipla with an electric fan in between (it has the inlet and outlet on one end and is 96% the same core volume). I clocked the turbo as per normal, but had to relieve the inner wing as mentioned to get the waste gate actuator to fit. I even managed to keep the battery under the bonnet. The oil cooler pipes are the only made-to-measure parts. The rest of the hoses and bits came from eBay. Most of the engine conversion parts and exhaust came from Steve Parkers - who were very helpful and gave great advice.
Luckily mine already had a cable throttle so a slightly modified Discovery cable is all I needed. The fuel filter uses the same bulkhead fixings and even the washer bottle fits on the holes left by the vacuum tank. I apologize in advance for the bad-boy air filter - I wanted to use the Discovery one but just couldn't find the space. The heater control valve was a nice find, I think its from a black cab.
The wiring is very simple, I didn't bother with the glowplug relay and the only extra wire I had to run is a switched live for the stop solenoid. The stop solenoid also gets a feed from the start signal when cranking - I used two diodes to stop any back feeding.
If I did it again I would use a slightly smaller oil cooler as the one fitted is very close to the water pump pulley.
Unfortunately I must have damaged the rear crank seal when fitting the modified flywheel housing, so it all needs to come out again. But at least I know all the fixings are new!
I've added some photos for anyone who's interested. I'm afraid they were taken at night so aren't the best quality.
If anyone is interested in more info just let me know.
Cheers, Ric
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I'd like to say thank you to everyone who has posted info about converting a Series 3 to 200tdi - I've now finished my conversion and I couldn't have done it without you!
Following much planning and eBaying I've successfully managed to fit a Discovery 200tdi into my 1984 Series 3. The car has been in my family since 1988 and was my first car so has a lot of sentimental attachment. The 2.25 diesel was getting tired so I either needed to sell it and trade up to a 90, take the 2.25 out and overhaul it or fit a 200tdi. I am so glad I went the with the 200tdi option! Its made a huge difference and puts a smile on my face every time I drive it.
I am quite chuffed with how it turned out as I managed to do the conversion without really modifying anything from the original. The only non-reversible changes are two 3" square cutouts in the inner wing and radiator panel which aren't visible unless you look for them. The rest is as-built or bolted on.
I used the series radiator with a 10 core oil cooler mounted behind. The intercooler is mounted in front of the radiator and is from a Fiat Multipla with an electric fan in between (it has the inlet and outlet on one end and is 96% the same core volume). I clocked the turbo as per normal, but had to relieve the inner wing as mentioned to get the waste gate actuator to fit. I even managed to keep the battery under the bonnet. The oil cooler pipes are the only made-to-measure parts. The rest of the hoses and bits came from eBay. Most of the engine conversion parts and exhaust came from Steve Parkers - who were very helpful and gave great advice.
Luckily mine already had a cable throttle so a slightly modified Discovery cable is all I needed. The fuel filter uses the same bulkhead fixings and even the washer bottle fits on the holes left by the vacuum tank. I apologize in advance for the bad-boy air filter - I wanted to use the Discovery one but just couldn't find the space. The heater control valve was a nice find, I think its from a black cab.
The wiring is very simple, I didn't bother with the glowplug relay and the only extra wire I had to run is a switched live for the stop solenoid. The stop solenoid also gets a feed from the start signal when cranking - I used two diodes to stop any back feeding.
If I did it again I would use a slightly smaller oil cooler as the one fitted is very close to the water pump pulley.
Unfortunately I must have damaged the rear crank seal when fitting the modified flywheel housing, so it all needs to come out again. But at least I know all the fixings are new!
I've added some photos for anyone who's interested. I'm afraid they were taken at night so aren't the best quality.
If anyone is interested in more info just let me know.
Cheers, Ric
