200 TDI Conversion Pics

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sp00k

sp00k

Well-Known Member
Posts
1,530
Location
Washington, County Durham, UK
I just wanted to post a thank you to all the people who helped with their advice on my 200 TDI conversion :D. I had a lot of fun along the way and I’ve learned so much.


The difference from my tired old 2.5 NA to this is like night and day. I’m still having fun getting used to it and am amazed by the performance, given the weight of the beast.


I’ve still got some odds and ends to sort out.


An electric fan or adapt my shroud so that I can reuse my viscous (I would prefer to do this, but I’m not sure how successful my adaptions would be).


Cable tie all the electrics – all are routed clear of danger, but I want to tidy it up.


Secure oil cooler pipes – they are lying against the chassis leg at the moment.


Here are a few pictures:


engine-in.jpg

New engine in the beast for the first time and my first chance to hear it run.



overhead.jpg

Overhead shot of the engine plumbed in. [FONT=&quot]. I retained the 2.5 NA fuel filter setup.[/FONT]


rad-bracket.jpg

I reused the existing 2.5 NA rad mounts by tapping the top of the rad frame and locking M8 threaded bar in with stud lock. Seems to be holding well.


pinched-bottom.jpg

My bottom rad hose is a little pinched. Think I’ll shorten it a bit and get a support bracket on it.


air.jpg

I had to make do with my existing 2.5 NA air cleaner. Not really visible in the picture, but I had to tilt the airbox about 20 degrees towards the bulkhead so the hose to the turbo reaches. Brackets on the box are poor so I double up with a bungee to be sure it stays in place. Breather is not connected as I’m waiting for pipe to be delivered.


exhaust.jpg

Exhaust is an ebay special. Works well. I moved the clutch pipe and cables.
 
Last edited:
Surprisingly it still works! I've been using it everyday for work which is just a few miles. I keep expecting it to blow up though :)

Traditionally I threaten to take her to see oldseadog and then suffer some catastrophic failure before getting there, so I'm not making any arrangements yet!
 
looks good. i did roughly the same with my air box. i made a bracket to hold it in and still use the intake from the wing and the breather pipe goes to chassis. for the rad mounts i used the old ones like you but welded a nut to the rad housing and then just bolt it on
 
what did you use for your intercooler pipes?

Ive got my engine in today and started the pipework, the lower water pipe has more of a kink in mine than yours and the intercooler lower pipe is just sooooo tight
 
trax said:
nice, do you have a rough idea of the cost? and where did you find the donor engine?
Click to expand...

Engine was £400 from ebay. It seemed very well maintained. I changed the rear crank seal, rocker seals, leak off pipes, full cam belt kit, full exhaust, new engine mounts, power steering delete kit, clutch kit (which I never fitted). I probably spent almost the same again but that included one off tools such as engine crane.

Only problems I've had since fitting it were the disco alternator bearings were shot, so I got a new alternator. I had a drip from the temp stat on my oil filter housing (this was the one I swapped over from the old engine) which needed a new 'o' ring. Last week my fuel lift pump failed - the existing one looked crap when I got it, so I really should have changed it anyway. All very minor stuff - touch wood.
 
IamRobbie said:
what did you use for your intercooler pipes?
Click to expand...

The old exhaust with 51mm silicone connectors. 135 degree one works well for the bottom pipe out of the engine with a 90 degree one on the intercooler.

Ive got my engine in today and started the pipework, the lower water pipe has more of a kink in mine than yours and the intercooler lower pipe is just sooooo tight
Click to expand...

I used the bottom pipe from my 2.5NA. It had a really nasty kink in it but still allowed water flow - I would not have been happy to leave it like that long term. The kink was completely removed by fitting the inline stat shown in my other link about the radiator fan. Having an extra cut in the pipe allowed everything to line up perfectly.

Also, I was running with a brand new radiator so my cooling was optimum.
 
Well this is an ongoing dispute..

Whats your views on it?

I was going to do it on the top as i was pretty convinced by MHM that it should go on the top, after all is it not better to chance it being too cool than too hot?
 
It needs to be on the bottom - the idea being that the radiator on it's own will be able to provide the cooling as long as there is airflow over it. So the coolant should be very hot in the top pipe and much cooler in the bottom pipe. On rare occasions that there is not enough airflow to cool the coolant in the rad, the temp of the bottom pipe will rise indicating that the airflow is insufficient - at that point, your fan comes on and blasts some much needed air through the radiator. The coolant temp drops and the fan switches off.

99% of the time, the fan will not come on. Mine has only switched on a couple of times for a handful of seconds.
 
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