Defender N/A to 200tdi Conversion Air filter problem

Hi all,

I recently started to convert my N/A 90 to a 200tdi, everything is in and we are almost at the end of the conversion, but we've ran into a few problems...

-The air filter box that the turbo pipe and crankcase breather connects to, well the N/A air box does not have the bit that the breather connects into, and i cannot find a 200tdi Air box anywhere on the internet to buy, are there any ways around this? because this type of air filter is mounted right where the inter cooler pipes go.

Anyone got any idea on what i can to do to continue using this airbox but have both the turbo and crankcase breather pipe plugged in?

Also if anyones got any diagrams for how the pipes are all arranged in a traditional 200, will be very appreciated!

Below photo is off my mates 200tdi camel, which i assume is the correct way for it to be positioned, is there any way i could get that smaller pipe into the same hole as the turbo one?

**EDIT** If anyone has a 200tdi fan cowling for a defender spare, send me a pm!

Any help is greatly appreciated!

T in above the air filter into the large od hose.

top drive said:

T in above the air filter into the large od hose.

Click to expand...

was just looking at t pipes, cheers!

I've just been through this. I used a 200 TDI disco airbox which has a plastic breather interface that fits on the end of the airbox. There should be loads of them around.

Be careful which rad cowl you choose as if you use a Disco TDI engine, the water pump is in a different position.

Btw, I mounted mine vertically and welded the housing onto the original TD legs. Check out the Glencoyne engineering website for details. Works well, but still tight for space.

DO NOT use the turbo diesel one.[ unless modified as by Britcyclerider] They have the engine breather inlet on the wrong side of the filter. This results in the air filter quickly becoming contaminated. Your mates set up looks standard 200tdi Defender although it is upsidedown, the squaire hole clips on top should be underneath located into the filter unit retainer.

Mine uses the Disco box as suggested above:

i dont have a tdi cowl but i have a couple of metal plates for mounting an electric fan on i could let go if thats of interest?

Britcyclerider said:

I've just been through this. I used a 200 TDI disco airbox which has a plastic breather interface that fits on the end of the airbox. There should be loads of them around.

Be careful which rad cowl you choose as if you use a Disco TDI engine, the water pump is in a different position.

Click to expand...

Probably a bit of confusion with my post, its a defender 200, not a discovery 200!

tottot said:

DO NOT use the turbo diesel one.[ unless modified as by Britcyclerider] They have the engine breather inlet on the wrong side of the filter. This results in the air filter quickly becoming contaminated. Your mates set up looks standard 200tdi Defender although it is upsidedown, the squaire hole clips on top should be underneath located into the filter unit retainer.

Click to expand...

So are you saying my original non turbo air filter and housing isnt a suitable thing to use?
or can it be used as a temporary until payday? im only a skint teen!
photo attached is the air filter + housing in question, was thinking i could remove those legs and mount the system in a good position

Matt Poiner said:

Probably a bit of confusion with my post, its a defender 200, not a discovery 200!



So are you saying my original non turbo air filter and housing isnt a suitable thing to use?
or can it be used as a temporary until payday? im only a skint teen!
photo attached is the air filter + housing in question, was thinking i could remove those legs and mount the system in a good position

Click to expand...

You can vent the breather to atmosphere if you want I.e don’t connect it to the air filter and leave it open-ended. You can attach it to a catch-can for a proper job.

You can adapt your housing to suit,it is the turbo diesel/V8 one that has the breather pipe in the wrong place. But you will have no where for the engine breather pipe. As a tempory fix just vent to atmosphere.

bluedog333 said:

You can vent the breather to atmosphere if you want I.e don’t connect it to the air filter and leave it open-ended. You can attach it to a catch-can for a proper job.

Click to expand...

tottot said:

You can adapt your housing to suit,it is the turbo diesel/V8 one that has the breather pipe in the wrong place. But you will have no where for the engine breather pipe. As a tempory fix just vent to atmosphere.

Click to expand...

okay ill vent it to atmosphere and have a catch-can, in the meantime i'll look out for the proper air box!

You can use that air filter box surely? As long as you tee into the inlet pipe side of the filter?

bluedog333 said:

You can use that air filter box surely? As long as you tee into the inlet pipe side of the filter?

Click to expand...

see this is my intention, and i have the pipe work to do that to, just want to make sure it wont cause any damage anywhere!

Matt Poiner said:

see this is my intention, and i have the pipe work to do that to, just want to make sure it wont cause any damage anywhere!

Click to expand...

Nah, it’ll be fine!

okay, thats cleared up now! thanks for your inputs everyone!

tottot said:

DO NOT use the turbo diesel one.They have the engine breather inlet on the wrong side of the filter. This results in the air filter quickly becoming contaminated.

Click to expand...

This is only the case if the cyclone breather is not in good condition. This is designed to spin out the oil and drain it back into the sump. I have the original TD air filter in mine and manage quite hapily not to cover the filter in oil despite the breather connecting on the intake side of the filter housing. I would just T the intake.
Also from memory (although stand to be corrected) venting to atmosphere is not legal, so if you are not mounting it to the intake pipework you would need a proper catch can arrangement.

A mate vents his into the chassis! That side will never rot.

Cheers for all the help guys! Got a t piece on order with some other bits, just looking for a 200tdi fan shroud now but theyre over £100 online! If you know of anyone who is getting rid of one then send them my way!

Matt Poiner said:

Cheers for all the help guys! Got a t piece on order with some other bits, just looking for a 200tdi fan shroud now but theyre over £100 online! If you know of anyone who is getting rid of one then send them my way!

Click to expand...

You won’t need the fan this time of year so no need to rush into buying one. If you still haven’t got one by next April then go to the 4x4 autojumble in Newbury, bound to be one there.