Topic: Disco 200Tdi in a Defender?? (Read 18229 times)

graham2306 · « **Reply #30 on:** June 14, 2006, 16:16:42 »

I've just taken delivery of the Steve Parker pipe, not yet tried it on the engine or in the engine bay. It looks well made and they assure me it does the job with no other mods than cutting the exhaust system to the right place. I have to say Ã‚Â£137 including delivery is a lot of money for what is essentially a bit of bent and welded pipe. I just wish I had the skill to make them.

I'll let you all know how it goes.

Graham

timberdog · « **Reply #31 on:** June 14, 2006, 19:09:35 »

Good aint they...saves a allot of faffing around..

i spoke to S.Parker oin the phone he is a great guy and helped me behond what was the norm as i had problems with somthing else..

Close to the chassi though..

Miniman · « **Reply #32 on:** June 15, 2006, 02:09:24 »

yes expencive but will do the job you need it for thats why you bought it.
I will make my own for about Ã‚Â£10 sorry but I had to say it....he he

graham2306 · « **Reply #33 on:** June 17, 2006, 21:21:00 »

Well it all started today, we put in about 5 hours and have the old lump out and the new lump almost ready for its test fit, hope to get it test fitted, reuired mods done and final fit onto mountings tomorrow. Can then get it out the workshop and back home on the drive for all the plumbing and electrics to be done next week. That'll leave the workshop free to earn money.

Pictures and more info to follow when it's over.

Graham

Miniman · « **Reply #34 on:** June 17, 2006, 22:19:31 »

Wow man now how is that for a strange day. I today have been to newcastle for my 200tdi discovery. So now I have mine at the garage waiting to be taken out BUT......

The engine sounds like its chuffing abit like head gasket gone between cylinders or valves leaking so on monday we are going to do a compression test....

Xtremeteam · « **Reply #35 on:** June 17, 2006, 22:58:49 »

Quote from: "Miniman"

Wow man now how is that for a strange day. I today have been to newcastle for my 200tdi discovery. So now I have mine at the garage waiting to be taken out BUT......

The engine sounds like its chuffing abit like head gasket gone between cylinders or valves leaking so on monday we are going to do a compression test....

dont bother with the comp test,

start it up & take the oil filler cap off,if its chuffing out there the ehadgasket will have blown between No4 cylinder & one of the pushrod holes

Miniman · « **Reply #36 on:** June 17, 2006, 23:01:57 »

Already done that its fine. I was thinking more of a burnt out exhaust valve or inlet valve

Xtremeteam · « **Reply #37 on:** June 17, 2006, 23:07:09 »

could be injection pump timing out as mine did that when i first rebuilt it

Miniman · « **Reply #38 on:** June 17, 2006, 23:10:32 »

May be but this has been run as a family car for the last year. Dont you think a compression test would be a good idea first before I go down the line of messing with the pump timing. What ya think.

CJ · « **Reply #39 on:** June 18, 2006, 16:55:14 »

Hi all, just to add a bit on the subject of downpipes, when we put a disco 200 into my old na we trimmed two inches off the corner of the passenger footwell and got longlife exhausts to make us a three inch stainless system that exited out the side behind the passenger door, they also made me up some turbo and intercooler pipes, all for under 200 squid... It sounded real sweet and went like stink... still see it being driven around everyday too

cheers all...

Bell housing wise we just removed one stud and tapped a new one in the right place.....

CJ · « **Reply #40 on:** June 18, 2006, 16:55:41 »

Hi all, just to add a bit on the subject of downpipes, when we put a disco 200 into my old na we trimmed two inches off the corner of the passenger footwell and got longlife exhausts to make us a three inch stainless system that exited out the side behind the passenger door, they also made me up some turbo and intercooler pipes, all for under 200 squid... It sounded real sweet and went like stink... still see it being driven around everyday too

cheers all...

Bell housing wise we just removed one stud and tapped a new one in the right place.....

graham2306 · « **Reply #41 on:** June 18, 2006, 20:20:15 »

The 200tdi lump is in on the mounitings and bolted up, just the plumbing and electrics left to do. In les's version of events he says to cut the radiator mountings down 28mm to get the radiator in, but in other versions of the conversions I've not seen anything about this.

Anybody that has done it know a better way than cutting the mountings down as I have a galvanised chassis and really don't want to break the galv or risk the fumes from welding it.

Looks like it might be possible to get some of the 28mm from the brackets on the radiator housing, by cutting them off and welding the pegs straight onto the casing.

Also where is the best place to put the air cleaner?

Cheers

Graham

Xtremeteam · « **Reply #42 on:** June 18, 2006, 20:56:52 »

Quote from: "graham2306"

The 200tdi lump is in on the mounitings and bolted up, just the plumbing and electrics left to do. In les's version of events he says to cut the radiator mountings down 28mm to get the radiator in, but in other versions of the conversions I've not seen anything about this.

Anybody that has done it know a better way than cutting the mountings down as I have a galvanised chassis and really don't want to break the galv or risk the fumes from welding it.

Looks like it might be possible to get some of the 28mm from the brackets on the radiator housing, by cutting them off and welding the pegs straight onto the casing.

Also where is the best place to put the air cleaner?

Cheers

Graham

on the disco rad there is an extension on the bottom to lift the whole frame up,thus giving you the 28mm,on mine did awayeith the spacer type bit & welded the pins on the bottom of the frame giving the correct height,

for the air filter i took the original box & welded a flat plate on the bottom doing away with the normal legs,
Pm yer mobby No & ill send a piccy over

stefan · « **Reply #43 on:** June 19, 2006, 14:42:20 »

Quote from: "graham2306"

The 200tdi lump is in on the mounitings and bolted up, just the plumbing and electrics left to do. In les's version of events he says to cut the radiator mountings down 28mm to get the radiator in, but in other versions of the conversions I've not seen anything about this.

Anybody that has done it know a better way than cutting the mountings down as I have a galvanised chassis and really don't want to break the galv or risk the fumes from welding it.

Looks like it might be possible to get some of the 28mm from the brackets on the radiator housing, by cutting them off and welding the pegs straight onto the casing.

Also where is the best place to put the air cleaner?

Cheers

Graham

Graham,

Check out my website http://www.90county.co.uk for an alternative way, I basically cut the brackets off the bottom of the radiator bottom plate, drilled holes to line up with those brackets fitted on the chassis, then used long bolts and nuts to create new 'pins'. The pics on the 200tdi conversion page should also give you an idea about air filter location. I have some straps bolted to the inner wing which hold the air filter in place close to its original location.

Stef

Miniman · « **Reply #44 on:** June 19, 2006, 15:50:39 »

Does anybody know if and old series 3 mounting plates are the same as the standard 90 N/A. I have to fit my new 200tdi onto the new chassi but have no plates but I do have an old series diesel....???

graham2306 · « **Reply #45 on:** June 19, 2006, 16:21:29 »

Thanks Stefan, forgot I had read that some time ago!!!!!!!!!!!

Have cut the side brackets off today and got the rad shell in place to see how much hight I need to get rid of. Looks like removal of the bottom brackets will do it, I plan to cut them off and get the locating pins out then drill the mounting shell and weld the pins in it.

Graham

Xtremeteam · « **Reply #46 on:** June 19, 2006, 20:09:45 »

Oh did u get the pics i sent over to your mobby?

graham2306 · « **Reply #47 on:** June 19, 2006, 22:06:50 »

Yes thanks mike, I did. Very useful. I have got the lugs off of the side and 'test fitted' it in to check so next step is to cut the brackets off of the bottom.

graham2306 · « **Reply #48 on:** June 29, 2006, 21:07:15 »

Well there is so much plumbing! I haven't decided exactly where to put the air filter yet, the old 2.5 NA one was knackered, case split, so I am going to use the Disco one. Thinking about putting it on the roof above the passenger and piping it up as a snorkel. Remember seeing a Royal Marines one done like it for deep wading. Havin g it well out of the way makes plumbing up the turbo and intercooler so much easier.

Power steering and oil cooler are plumbed in and have made up mnost of the bottom hose. Need to get some heater hose and some hose to make up a top hose from. Anyone know any good hose suppliers near Banbury???

It's taking much longer than I planned :-)
:) :D :D :D :)

Miniman · « **Reply #49 on:** June 29, 2006, 21:25:31 »

I have my disco donor and have just been given yes GIVEN a complete disco 300tdi gearbox and transfer case.....R380 is it....now then recon that and fit it along with the 200tdi engine ya think......??????

Xtremeteam · « **Reply #50 on:** June 29, 2006, 21:48:16 »

dont bother fitting the r380 unless u want to mod like you would to fit the disco LT77,same length o box,get a defender gearbox & use the disco T box to up the gearing

graham2306 · « **Reply #51 on:** June 29, 2006, 21:56:57 »

Just after I fitted mine to my Defender box someone showed me one with the Disco box fitted, leaving loads of room behind the engine and bringing the fan up against the radiator. They say it was fitted on the original gearbox and engine mounts, but as they didn't do it themself I'm not sure. Had a good look round and all it seemed to be in about the same place as mine except the engine was well forward.

Graham

Miniman · « **Reply #52 on:** June 29, 2006, 22:05:49 »

HEY its mikey how ista....... :lol:
I was thinking about the lt77 box being so soft and the r380 being so good that it would be a good idea... What mods are I looking at. I have to make a exhaust manifld drop pipe and get the power steering pipe extended by 30cm ect ect so if the r380 box is used all that goes out the window.....so what dont I know or have I forgotten..... If I want ti fit the r380 what probs have I to face......

Xtremeteam · « **Reply #53 on:** June 29, 2006, 22:43:41 »

Quote from: "Miniman"

HEY its mikey how ista....... :lol:
I was thinking about the lt77 box being so soft and the r380 being so good that it would be a good idea... What mods are I looking at. I have to make a exhaust manifld drop pipe and get the power steering pipe extended by 30cm ect ect so if the r380 box is used all that goes out the window.....so what dont I know or have I forgotten..... If I want ti fit the r380 what probs have I to face......

ill have a think n post up the morra

Miniman · « **Reply #54 on:** June 29, 2006, 22:52:20 »

Cheers fella. All good info. I do give my Gbox alot of stick......

graham2306 · « **Reply #55 on:** July 02, 2006, 19:33:21 »

Spoke to Steve Parker Land Rovers on Friday about there Intercooler pipe kit.

Here is their reply.

Hi Graham,

We are suppling intercooler kit which include all the pipe work for the air intake/intercooler, top rad hose, bottom rad coupling pipe, temp sensor and a new or s/hand air filter box. this will cost you Ã‚Â£350.15 new filter box or Ã‚Â£298.00 for s/hand one, plus 13.98 carriage for main land UK.

Thanks

Dave

Think I am going to make my own intercooler pipes up then.

I am also looking at cutting the air out nozzle offf the turbo and tig welding a right hand bend on so that it clears the wing and can be piped straigh up to the intercooler.

Graham

Xtremeteam · « **Reply #56 on:** July 02, 2006, 19:38:28 »

what i did was before the engine went in was adjust the inner wing with a 2Ib hammer so there was more space just where the turbo outlet comes out,what u need is a 300 tdi turbo outlet hose as its just slightly tighter than a 90 degree bend,if not buy a samco one whict is tighter than a 90,if u want any more infor drop me a pm N ill give you my No to fone me

graham2306 · « **Reply #57 on:** July 02, 2006, 20:17:16 »

Thanks for that info Mike, my turbo expert and I have just been looking at it again and the turbo is having surgery.

Graham

Miniman · « **Reply #58 on:** July 02, 2006, 22:26:20 »

Quote from: "graham2306"

Spoke to Steve Parker Land Rovers on Friday about there Intercooler pipe kit.
Think I am going to make my own intercooler pipes up then.

Graham

Yeh I recon that will be my idea aswell...

Ã‚Â£350 god d*m................

graham2306 · « **Reply #59 on:** July 10, 2006, 22:36:34 »

Having removed the turbo and started to dismatle it ready to weld a 90 degree elbow on it we dicovered that there is no locating peg on the snailhousing so it can be positioned at any angle on the turbo. So no need for welding, we are just going to turn the snail housing through 90 degrees and it will pipe into the intercooler using a couple of 90 degreebends and some of the old pipe. It will also miss the inner wing completely.We will have to drill and tap a couple of new holes for the waste gate mechanism and jobs a good 'un.

Also looking at the possibility of using the airbox off of something like a Subaru Impreza Turbo or Nissan Primera as these are neat flat boxes with loads of airflow. They can be fitted in almost anywhere.

Graham

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AuthorTopic: Disco 200Tdi in a Defender?? (Read 18229 times)