Disco 200Tdi in a 90 - Changing the starter motor?

[stefan]

The starter motor has packed in on my 90 (the solenoid engages, but the motor won't spin) but it doesn't look an easy job as it's a Discovery 200Tdi fitted in my 90.

There is not enough room between the engine and chassis for the starter motor to drop down, I've tried that, the only way I can see is to remove the manifolds and turbo, anyone with the same setup agree with that, or is there an easier way?

Stef

[MTyrrell]

Did mine just after Christmas

Hears what i did:

Remove the elbow pipe from the turbo outlet to allow the turbo to be pulled back
Remove the pipe from the intercooler to intake manifold.
Remove intake manifold
Unbolt the exhaust manifold
Unbolt the strut that holds the turbo to the engine block
If using the steve parker exhaust conversion remove the lower 90 degree bend.
Slide the exhaust manifold back off the block, pry bar helps here
There should be enough room for the turbo to move back.

You should be able to lift the starter between the manifold and the block with a but of fettling and a lot of swearing. It's fiddly but it will fit.

[stefan]

Matt,

Thanks, that's kind of what I thought, although I am contemplating undoing the oil feed and return pipes and lifting the whole assembly clear.

Stef

[MTyrrell]

Removing the whole thing would make the job a lot easer, didn't want to deal with the mess of removing oil pipes when i did mine.
Although i did try and remove the manifold from the turbo assembly, three of the bolts had been nicely rounded by someones previous attempt , that idea was rapidly abandoned.

[stefan]

I've looked at that option, but the manifold to turbo bolts are VERY tight, and as you've found, easy to round off, still think I'll go for the whole assembly out option, must check about re-priming the turbo with oil, I'm sure I read about that somewhere.................................

Stef

[extreme90]

no dont start ripping the engine 2 bits, i have a 200 disco in my 90, startor seized what you do is jack the engine and gearbox up, loosen the engine mountings but dont take the nuts off ! i found that it gave me just enough room 2 fiddle it around and out and fit it back in 30 mins l8r....but with a lotof cursing goin on tho :roll:

[extreme90]

remember kiss......keep it simple stupid..stand back and think there is always a solution ! i nearly gave up on fitting this disco engine but i stud back and thought. fitted it without any fancy conversions but found it sluggish. so i fitted a disco gearbox in with brought the origional downpipe back in2 play....now it it kills my grandads disco in a straight line even with grizzlys on

[Xtremeteam]

i had to take the turbo manifold off mine & then remove the studs to get the starter out BUT now got a defender 200 so not a problem now

[stefan]

Job all done. I did remove the manifolds and turbo, actually wasn't that bad, once the intake manifold was removed I then took the exhaust manifold and turbo out as one complete unit, no oil dripped from the 2 pipes, in fact the hardest bit was getting the oil feed banjo connection on the turbo to line up again once I'd primed it with fresh oil, and tightening the bolt underneath the centre of the manifold.

Let's hope this new starter lasts for quite a while!!

Stef