Fitting disco 200tdi to defender..

[whitewolf]

Ok decided not to go with the V8 option, so i've bought a tdi motor from an early disco, complete  :D .....is there any nasties I need to be aware of when fitting this engine??
looks like my clutch will be ok as will my starter motor ( according to parts manual ) am i correct here?

anyone else fitted this th their defender???
advice and pics woulkd be really helpful, thanks.

[Xtremeteam]

im doin the same conversion hopefully bloody soon,so far the only thing ive noticed that you have to do is cut the corner of the pas side footwell on the bulkhead & chop n weld  the downpipe of the turbo si it points down inside the chassis rails,also have to get a different hose for the turbo outlet that is more of a V shape insteap of a 90' elbow,when u plannin on fitting urs as mine should be goin in next week when im on hols aslong as i get the disco finished

[whitewolf]

Hopefully I'll be p[icking up the engine from yorkshire next weekend, I'll probably wait untill after Billing to fit it now thoug.

are you going to take pics when you fit yours??..be very helpful if you could :)

cheers......Heres to TDi power :D

[Xtremeteam]

since u asked really nicely i will take some pics,next time a see my mate ill take some o his 2 trucks as hes fitted disco tdis to 2 different motors of his,1 a 90/88 & the other a 110 csw with td5 intercooler,im on my hols from next mon 11th so "hopefully" ill b able to get started then,im using the starter of the existing engine unless my boss comes upwith a new 1 at a good price,also need an alternator but think ive got 1 of a sierra(100 amp) for runnin my ICE that im fitting,gonna make the exhaust up as i go cos im thinkin side exit through the wing but no sure yet  :lol:

[Topple]

Stanton Boy has just fitted a 200tdi disco engine into his series 3, so may have some advise.

[whitewolf]

since u asked really nicely i will take some pics,next time a see my mate ill take some o his 2 trucks as hes fitted disco tdis to 2 different motors of his,1 a 90/88 & the other a 110 csw with td5 intercooler :lol:

Nice one V8...cheers M8. :D

[whitewolf]

Stanton Boy has just fitted a 200tdi disco engine into his series 3, so may have some advise.

cheers topple, I'll have to collar him :)

[Xtremeteam]

Stanton Boy has just fitted a 200tdi disco engine into his series 3, so may have some advise.

cheers topple, I'll have to collar him :)

 i wanted to do that when he beat me to that tdi  :lol:  :lol:

[cstokes]

Sorry i beat you to the TDI, how is yours going now?

When i fitted the disce engine to the series 3, i didn't have to cut out the bulkhead.
I just sawed the downpipe in half, just after the turbo and twisted it about 1" , welded it back together so that it cleared the chassis, this brings the downpipe very close to the starter, which means thet to have to lose the starter heat shield and bracket.  What i did was the wrap the starter in a heat reflective blanket. You should be able to get the blanket from demon tweaks, i got mine from graham goodes about £20 square meter.

As mine is in a series 3 i had to move the radiator backwards, so i had to lose the viscous fan.

Hope this helps

chris

[davidlandy]

Rumour has it that a down pipe from a Saab car will fit , not sure which Saab model it is though so will need to do some diggin.

I wonder how easy (or not ) it is too rework the inlet manifold to raise the turbo up to where it normally is on defender 200tdi.

[Porny]

I wonder how easy (or not ) it is too rework the inlet manifold to raise the turbo up to where it normally is on defender 200tdi

Or even the exhaust manifold???

As the turbo sits on the exhaust manifold, not the inlet one... due to the turbo being driven by exhaust gas?????  :roll:

But in rasing the turbo (defender exhaust manifolds are £58 I think from Craddocks) you would need to alter the inlet manifold...

If you try and fit the defender stuff you also need the defender front cover, pas pump brackets/alternator brackets and a few other bits....


Ian

[davidlandy]

I wonder how easy (or not ) it is too rework the inlet manifold to raise the turbo up to where it normally is on defender 200tdi

But in rasing the turbo (defender exhaust manifolds are £58 I think from Craddocks) you would need to alter the inlet manifold...

Ian

thats what I said
 :-k

[whitewolf]

Hey Stanton Boy, you got any pics I could have a look at??

My engine came complete with everything, and was removed properly which makes a change!

Is it worth getting a disco down pipe of just hack my defender one around to fit the turbo outlet pipe?

cheers

[cstokes]

I cut the exhaust front pipe just after the flange and welded it back together.

I don't see a problem with altering the standard front pipe, but you would have to make a flange up to fit it, also is the pipe bore diameter the same and the heat generated by the turbo may affect the mild steel exhaust pipe so close to the turbo.
Here is a link to my gallery, i have taken a few photo's of what i did to the exhaust.

http://members.mud-club.com/profiles/Stanton%20Boy/gallery/exhaust1

[whitewolf]

hows the engine swap going V8????

[Xtremeteam]

dont even go there,     still finishin of the disco i was doin the welding,was somewhat sidetracked when fitting the lift kit to it yesterday & me dad came out n gave me  hand,1/2 hour for the back,2 n a bit hours for the front cos i wanted to get on with it n he was swithering,anyhow if the disco is finished for tonight so it can go for its test 2 moz i can go n pick the engine & motor up either 2 moz or fri  :lol:  :lol:  :lol: Bout bloody time

[whitewolf]

dont even go there,     still finishin of the disco i was doin the welding,was somewhat sidetracked when fitting the lift kit to it yesterday & me dad came out n gave me  hand,1/2 hour for the back,2 n a bit hours for the front cos i wanted to get on with it n he was swithering,anyhow if the disco is finished for tonight so it can go for its test 2 moz i can go n pick the engine & motor up either 2 moz or fri  :lol:  :lol:  :lol: Bout bloody time

LOL, ya got it yet m8?.......I'm hopefully gonna start getting my engine in next week, still not sure what to do with the exhaust though. :roll:

[Xtremeteam]

well,when my dad gets up were gonna go n get the trailer & go n pick my 90 up & bring it back to my house n get started on it  :twisted: well wash it first inside & out,i no roughly what im gonna do with my exhuast but ill need to have a bit more of a closer look before i announce it as its still bit hazy,

although i do like stanton boys side exit on his s3  :lol:  :lol:

[whitewolf]

although i do like stanton boys side exit on his s3  :lol:  :lol:

whats he done?....didnt see a pic of that in his gallery, has he got it going through the side panel?

[Xtremeteam]

it comes down off the turbo,under the chassis,through a silencer & out behind the front wheel  :lol:  :lol:

[Xtremeteam]

NEWS FLASH:
the 90 is now washed & striped & was last seen heading for the workshop,just need doors,seats & a seat box,came on here to find the forum switched off so went & did that instead,been washing it for the last say 6 hours    & its still dirty in places

[Xtremeteam]

UPDATE:
its now washed AGAIN & is currently sitting in the drive with the front o/s wing off along with the bonnet to allow easier acces to the engine bay & also to patch the small hole in the footwell & repair the bulkhead pillar which is somewhat full of catty,all non vital hoses have been removed along with the radiator & all water has been drained,so far the welding stands at a small patch on rear xmember,small patches on the footwell panels & the o/s/f door pillar neding remodeled as the hinges have ben pulled out through the metal & fixed with catty

[Xtremeteam]

wakey wakey the engine will be ready for starting ion around 15 min,just spent thelast few hours working through the loom & repairing any burnt/split wires,just got to fill it with oil N turn the key,oooooo  cant wait  8)

[Xtremeteam]

whoooo ha ha ha cough cough (bit smokey now its goin in the garage)
just got it kindled up as it wouldnt start & the starter has decided to throw in the towel & discover a fuel leak last night,it starts & stops now but sounds good with no exhaust or intake pipes

[landyman Ash]

Well done mate!!!!

Doing my 300tdi this weekend!

I'll take loads of pics and let you all know how it goes!

Wish me luck, next time Im on here Im hoping to have lost myt roar and found my chuger chug...   :shock:  :roll:  :shock:

[Xtremeteam]

loose the roar & get a big diesel noise by removing the silencers & having plain pipe  :twisted:  :twisted:

refitted the front wings & welded the footwells & repaired the door pillar last night,

gonna dfo the front bushes & brakes to nite & hopefully remove the seat box so i can fix it

[Xtremeteam]

woo haha,now have a 200tdi-300tdi-td exhaust with only 1 silencer at the back,gonna fit the rad n intercooler tomoz & remove the seat box then im away out for a night on the town as im knackered n need some time out  :lol:  :lol:  :lol:

[stefan]

If you are looking for a solution to putting a disco 200 Tdi in your 90, then Steve Parker does the downpipe, bit pricey though, but an 'off the shelf' solution!

Should picking my engine up tomorrow and hopefully making a start over the next few weekends.

http://www.steveparkers.co.uk

Stef

[Xtremeteam]

thats what my choped up & remodeled 1 looks exactly like

[stefan]

Unfortunately I don't have access to a welder, so I may need to bite the bullet and buy one, must be a market for a cheaper version though?

Stef