Hi guys had a a quick search but couldn't find all the answers


I guess before putting new engine in clutch,sump and rocker cover gasket as the is a lot of oil on top of rocker cover.. And just give the engine a good clean.

Also what exhaust is recommended I hear Steve parker are good but you have to move certain parts around and other stuff just wondered if there is any alternative exhaust solution.

Looking to take a week off work and Aim to do it within the week and be running for the weekend if possible will be my first time doing anything this serious


Many thanks


Martyn

Hi,

I guess your talking about a disco 200. I'm in the process of converting my 2.5d to 200 TDI. Just got the engine in today as a matter of fact.

You can buy a pre-welded exhaust downpipe off ebay for about £70. I can't vouch for mine yet - it's on the engine but not connected to anything. I would not fancy trying to make one myself, but if your a talented welder...

I've not done the sump gasket but that should be easy with the engine in situ if required. I changed all the timing gear, the rear crank oil seal & flywheel seal. I also swapped over the oil filter housing so that I can reuse the cooler pipes from my 2.5D. I also modified the bellhousing so that I could bolt through to the ladder frame on the new engine. You also need the engine mounts off your old engine.

Are you converting from a 2.5D or a 2.5TD? If the former, you will also need a full new exhaust.

I pretty much followed the advice on this sticky thread: http://www.landyzone.co.uk/lz/f7/how-land-rover-90-td-discovery-200tdi-engine-conversion-90679.html

I currently have a2.5 d non turbo ..... Are the crank and flywheel cover hard to do ??

And yes it is a disco engine

James Martin reckons it's not necessary to do the flywheel housing mods. I already had the bits and the job in hand, so I did it anyway.

There are two methods. Drill and counterbore the flywheel housing or drill the bell housing. I went for the later as it means you can remove the bolts if you need to drop the ladder frame for any reason.

Glencoyne has a lot of detail on the conversion 200TDi into Defender - some useful info - by Glencoyne Engineering .

I wanted to clock my turbo as he describes but I could not remove the circlip that holds the housing on, so I gave that up in the end before I ended up destroying the bloody thing. I don't have power steering anyway so there should be more room for me to work in.

For the rear crank seal, I've read too many stories about them failing shortly after conversion, so it seems daft not to do it whilst the engine is out. I must admit it was not a job I enjoyed, hopefully I got it right otherwise it's engine out time again.

I bought a new Borg & Beck clutch but I ended up reusing the one from my old engine as it looks to be in perfect condition and has no signs of wear.

I moved my clutch pipe around to the side of the bulkhead - space is very much at a premium around the exhaust outlet.

I bought the steve Parker exhaust very good. Top hint cut the little bracket that holds the clutch line it will be mm off exhaust and needs moving aside. Much easier to do before exhaust on.( ask me how i know) Also do not throw anything away till your all plumbed in takes lots of bodging usually.

Meant to say, biggest pains by far were all related to doing the timing. Getting the dognut off, getting the pulley balancer off, getting the waterpump bolts out without shearing them.