Yet another Series 3 200TDI project

Another one jumped on the bandwagon...thought it was about time I made a thread....

So I bought this a couple of months back....




1982 Series 3 109" Hi-capacity pickup, needs some welding to the bulkhead and its outriggers, and the rear crossmember, and both door tops are shot, but seems alright-ish - so far.

Engine runs but smokes alot, have also recently noticed coolant crystallised near the rocker cover so assuming something untoward there - not to worry, as I took the plunge and went for a 200TDI from a Disco...

After collecting bits for a while, decided to start work on the weekend just gone, firstly by borrowing a trailer from Bump to shift the Landy to my workshop.....which didn't happen as fixing my mate's 110 in the cold took longer than expected....so instead I just shifted the engine and dragged the girlfriend in to help out...




I've been reading into how to get around fitting the turbo into a 109" chassis for a good while, and was pretty settled on having an adapter made up to kick the turbo out to clear the rail, until I found out about using a 300tdi manifold. Seems to be shorter and not at an angle so should (hopefully) be OK. We'll see - but it only cost 20 quid and according to the internets it works.





Started work tonight on stripping the manifolds down to swap the turbo across, but that stopped when I realised my nice shiny new spanner set from work didnt include a 13mm :doh:

I'm assuming the 'hole' at the top of the 300tdi manifold is for EGR - is there a stock blanking plate I can buy or do I need to make one?

Interested in any comments and suggestions and will be following everyone elses threads closely

u can buy the blanking plate anywere m8

discowayne said:

u can buy the blanking plate anywere m8

Click to expand...

Nice one

As you may allready know I have a 300tdi in a 109.
The exhaust fanimold is in a better position to fit, however the pressure outlet from the compressor side of the turbo fouls on the bracket for the wing, at least on mine, the 300tdi turbo has a clamp that can be loosened and the turbine/compressor housing can be rotated so the angle can be changed so as not to interere with the wing bracket.
The 200 turbo might be diffo.
The mounting bolts for the egr valve on my engine broke off, so to save faffing about I cut the sae flange of one of the egr pipe fittings welded a blank to the centre and then welded this to the fanimold using dissimilar metals welding rods, as the fanimold is cast iron, see the pic, you'd be better with a plate if the bolts do come out.



My mrs helps me shift stuff aboot too:

This is what I love about doing this conversion - every time I think I've found a way round something, another thing crops up Looks like it shouldn't be too bad though fortunately, thanks for the advice.

Fortunately there's no crap stuck where the EGR plate would be, and it just came as a bare manifold anyway so buying one of the cheap eBay blanking plates should work alright hopefully

Trying to defer too much head scratching over the rad/oil cooler/intercooler setup until I get to have a look at Bump's setup but that'll be the next challenge!

Well got the Landy to the workshop, but my pass card to get in has knackered up so that's stopped work for a while.

In the mean time I decided to play with the bits I had in the house still, chopped down the Disco rad housing to do away with the intercooler, I'll bolt/weld the bottom of the frame to something or weld a length of unistrut across the chassis and bolt it to that.

Plan for the intercooler is to use the td5 one as done by dr pepper, just got to make up some brackets to atach it up to the housing but leaving that until i've got the rad in so I can make some adjustments if I need to...

Got the week off work next week to do the Landy so hopefully decent updates coming soon.

TheKeymeister said:

Well got the Landy to the workshop, but my pass card to get in has knackered up so that's stopped work for a while.

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Is it still sat on the grass then?

I'm sure its just the way you have pictured it, however you want the intercooler out front before the rad, otherwise warm air out the rad will ehat the induction air, contradicting the whole idea.
Be interesting to see how you pipe it up.

Nice looking project - but buy your girlfriend some decent overalls. It's romantic gestures like that that really cement a relationship.

The project is interesting as are the photos (how do you do it?) however the lack of PPE and suitable clothing on the young lady is scandalous! put your hand into your wallet!
My good lady is on her third pair of rigger boots, has two sets of overalls , one of which is padded for spanner passing in cold weather! she has at least 3 different types of gloves and her own hard hat and goggles.
She can't weld tho'.

Bump said:

Is it still sat on the grass then?

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Nah I pulled it in with the Transit when someone let me in during the day, but nobody is there after work/at the weekend. However, my card has now arrived and works, so work will commence on my week off next week

dr pepper said:

I'm sure its just the way you have pictured it, however you want the intercooler out front before the rad, otherwise warm air out the rad will ehat the induction air, contradicting the whole idea.
Be interesting to see how you pipe it up.

Click to expand...

It is just the way I pictured it, if it was the other way it'd have emptied any more of the remaining oil/water onto the cardboard and then floor
I'm also interested to see how I pipe it up to be fair...

oxides said:

Nice looking project - but buy your girlfriend some decent overalls. It's romantic gestures like that that really cement a relationship.

Click to expand...

Scratch that, I'm with a different girlfriend now who just so happens to be a mechanic, that had nothing to do with me being in a relationship with her

Managed to get the bloody thing started, was just a really cacked up battery, stuck another one on and glowed up for a good while and it started straight up - winner! Even took it for a celebratory drive round the yard at work, stopped it, then thought I'd killed it when in actual fact I'd locked the stop solenoid lever- doh! All tucked up inside the workshop now, and had a couple of hours free today so done a little bit of dismantling, and realised I'll need a bulk buy of nuts and bolts to replace the ones that have either disintegrated or sheared......



Bulkhead is better than I imagined so far, both footwells are gone which I knew about, and I'm a bit concerned about the bit above the 'air conditioning flaps'




One thing I noticed is that there's an expansion tank of sorts bolted onto the side of the radiator in a sort of 'holster', as I understood it series rads didn't have an expansion tank and one had to be added on? Have I got some crazy other radiator? The rad itself has a cap on it as well, and there's a small pipe from under that cap going to the bottle, the other hose on the bottle was disconnected though.....

As I'll be doing a 200TDi conversion with the disco rad, will this be suitable? It'll be easier to hide somewhere than the 'fish bowl' mk3 Golf one I've been given. I didn't even know series' had expansion tanks (I was expressly told they didn't) so if anyone can 'expand' on this (ho ho) it'd help...Cheers

not sure about late s11as but all s111s had an expansion tank early s11as had a big expantion tank built in on top of the radiator but later s11as the radiator was discontinued and use the new s111 radiator instead.

graham
_______________
98 d1 300tdi auto.

cornish rattler said:

not sure about late s11as but all s111s had an expansion tank early s11as had a big expantion tank built in on top of the radiator but later s11as the radiator was discontinued and use the new s111 radiator instead.

graham
_______________
98 d1 300tdi auto.

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Nice one! That'll be where the confusion came from then,
Saves me putting german parts in it, and also saves me spending 6 quid on a rad cap for the vw one

These may help with your conversion. . .









This conversion has been done on a LWB using the 200 disco manifolds, we have sculpted a small groove in the chassis rail to allow the turbo to clear, the air filter is the standard round discovery type sealed up and working backwards (inlet is now outlet) and is fitted over the P/S footwell.

The Series 3 type expantion tank is not suitable for use with the 200.

Chris

Very very useful pics - thanks for that!

Already invested in the 300tdi manifold now so may as well persevere with that! Should hopefully end up with an easier to route exhaust with that method.

Spot on with the intercooler though, very useful! I've got a 19j defender airbox and a 300tdi defender snorkel to bodge together at some point....

I'll revert to plan A, and persevere with my fishbowl vw golf expansion tank, thanks for that mate!


Edit to add, managed a couple of hours today, just a small amount of dismantling, front panel and rad off, got to grind off a couple of bolts on the passenger side wing. Passenger side bulkhead has a tiny tiny hole where the windscreen hinge bit is, may be rescuable, will poke it soon to see how bad it is.

Have also noticed that the steering gear that sits by the rad, the rubber bits had split, I'll grab some pics tomorrow but I'm assuming I'll need to replace these bits, no idea how the steering really works on one of these though!

Handy things those vw spaceship expansion bottles.

dr pepper said:

Handy things those vw spaceship expansion bottles.

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I was going to persevre with the mk3 fiesta one that I've got rolling about, but the vw looks far easier to mount with it having 2 holes for a bracket as opposed to the fiestas one plus sitting on a bit of bar...

Slow progress again today, generator ran out of juice resulting in no lighting! Bugger!

Task one next time will be to wire up some of the 5ft fluorescent fittings instead of the huge twin floodlights, probably be much easier to work in as well!

Did manage to get a pic of the steering part that looks knackered, not sure what it's called though and how much needs replacing, any ideas anyone?

its a track rod end / drag link end.
probably right hand thread on that as its on a drag link.
can be interesting to seperate from the arm, unscrews from the tube after loosening the clamp. may be easier to remove other end to do the unscrewing.