Disco 200Tdi in a Defender??

[graham2306]

Will it go ? What bits do I need?  

My engine expert says it will go, I'll just have to get a Defender radiator/intercooler, but he's an expert on Japanes engines.

I've read something somewhere about the turbo being too high.

Anyone done it?

Graham

[Edge]

Try a PM to Redlinemike :D , he's extremely clued up on all things landrover (perhaps cos hes a LR mechanic).

[datalas]

Will it go ? What bits do I need?  

My engine expert says it will go, I'll just have to get a Defender radiator/intercooler, but he's an expert on Japanes engines.

I've read something somewhere about the turbo being too high.

Anyone done it?

Graham

A Discovery engine into a defender isn't as easy as it might be as the turbo is in a silly place ISTR, or at least, it's in a silly place when you try to stick it in a defender....

[Xtremeteam]

hi there,i put a disco tdi into my 90 replacing the n/a,

to make it fit you need to mod the turbo downpipe,now you can chop it up & weld it back together like what i did or buy the steve parker 1 at circa £100,

know my work is currently doing this convo to a customers vehicle & the last batch of manifolds (12 of) didnt even hit the shelves,went straight out to punters,

anything else shout up or PM me

Mike

[gecko]

yep i got one need to put it in  on the wee wee or the out put shaft wont meet up proper  well i got a disco 300 in my defender  ill take a picky to moz to show

[Xtremeteam]

yep i got one need to put it in  on the wee wee or the out put shaft wont meet up proper  well i got a disco 300 in my defender  ill take a picky to moz to show

just as a side note

the disco 300 & defender 300 are identicle engines in fitment bar the air filter set up & front pipe for the exhaust (depending on age as some have fly by wire throttle controls )

[Landyash]

hi there,i put a disco tdi into my 90 replacing the n/a,

to make it fit you need to mod the turbo downpipe,now you can chop it up & weld it back together like what i did or buy the steve parker 1 at circa £100,

know my work is currently doing this convo to a customers vehicle & the last batch of manifolds (12 of) didnt even hit the shelves,went straight out to punters,

anything else shout up or PM me

Mike

Hi graham2306 you could buy my spare 300 Tdi defender turbo with manifold and down pipe for £100 :D  :D
It will make the transplant alot easyer
Cheers Landyash :)

[Xtremeteam]

hi there,i put a disco tdi into my 90 replacing the n/a,

to make it fit you need to mod the turbo downpipe,now you can chop it up & weld it back together like what i did or buy the steve parker 1 at circa £100,

know my work is currently doing this convo to a customers vehicle & the last batch of manifolds (12 of) didnt even hit the shelves,went straight out to punters,

anything else shout up or PM me

Mike

Hi graham2306 you could buy my spare 300 Tdi defender turbo with manifold and down pipe for £100 :D  :D
It will make the transplant alot easyer
Cheers Landyash :)

AFAIK (dont quote me) i dont think a 300 turbo & manifold fits a 200 engine,also the pipework is severly different,just fitted a 300 into an ex 200 90 & all the 200 pipewprk is now on mine as its now where near the 300,also the intercooler is slightly different

[plugger]

Will it go ? What bits do I need?  

My engine expert says it will go, I'll just have to get a Defender radiator/intercooler, but he's an expert on Japanes engines.

I've read something somewhere about the turbo being too high.

Anyone done it?

Graham

Just about to do same thing with mine, I'm told the disco rad and intercooler are better but The mountings need to be modified, but happy to be put right on that and anything else.The Steve Parker manifold is supposed to make things easier.There were a number of posts and pointers when I raised the issue a while ago if you look back a bit.
Keep me informed if you start it soon I'll pick youxr brains.

Good luck

[timberdog]

if you want any help i did one last year,,?.

[plugger]

Will it go ? What bits do I need?  

My engine expert says it will go, I'll just have to get a Defender radiator/intercooler, but he's an expert on Japanes engines.

I've read something somewhere about the turbo being too high.

Anyone done it?

Graham

Just found this link from my initial enquiry, well worth a look, lots of photos etc.

http://forums.lr4x4.com/index.php?showtopic=2394

[plugger]

if you want any help i did one last year,,?.

Where you at?   Local to Northants?

[timberdog]

I am in Nuneaton matey..pm me if you want to have a look at the one i did then maybye a bit clearer for you anytime?/

[stefan]

Feel free to have a browse on the conversion page of my website http://www.90county.co.uk too.

Stef

[graham2306]

Thanks for all the info guys, looks like Steve Parker pipe will do the job.  Now all I need to do is convince my mate he wants to break the Disco he bought for £50 last week.  Unfortunately there is a possibility that he will just get it MOTd and sell it for a huge profit.  Only bought it for the windscreen but it is so good it would be a shame to scrap it.  Engine needs a new cylinder head gasket but it's only done 97000.

If I get the engine off him I'll be back to let you know how it's going.

Graham

[graham2306]

Got myself a 200tdi out of a disco.  Does anybody know how much I'll have to modify the engine mountings?

You see I have a galvanised chassis and don't really want to hece to cut and weld the chassis.  Can it be done without?

Ta

Graham

[Xtremeteam]

fit the n/a  or TD engine mounts to the disco engine in the defender mounting holes & throw the disco mounts in the bin,puts the engine in the corect location aswell

[graham2306]

Thanks Mike


Graham

[plugger]

Hi Graham

How's the conversion plans going, or is it done and dusted?

Bob

[freeagent]

we did, or rather started this job last year, then a defender spec 200Tdi came along for a good price.

you'll need longer pipes to reach the oil cooler, either get the ones you've got made longer or source defender ones.

you will need a new fan shroud.

you may need to play with the wiring and glow plug relay set up, depending on what engine you've removed.

the exhaust is best done with the steve parker pipe.

the Rad frame will need modifying slightly.

some of the air and water pipes will need lengthening/ altering slightly.

you will need to think about the position of the air filter/ intake set-up.

the pipe from the clutch master cylinder to the slave cylinder is very close to the new exhaust downpipe, you may need an exhaust heat shroud.

this swap is do-able, but its a fiddly job. there are a few people around who have done it, and every conversion seams to end up slightly different.

take your time, don't listen to anyone who hasn't actually done it, and don't throw anything away until its completely finished.

[graham2306]

The 200 tdi lump is out of the Disco, I want to get the head off and have a good look at it.  One core plug was leaking and the keyway in the crank may be damaged, so few jobs to do on it before the swap takes place.  have just renewed my insurance and the insurance company say they will still insure it once it is done, so that's one problem less.

On the heater plug point, do 200Tdi engnes have a relay?  All my previous diesel Land Rovers have been turn the key for 20 seconds then start it up.  You aren't suggesting that Land Rover have gone all upmarket and have a relay to turn them off are you?????

Graham

[graham2306]

Have got the lump in bits and bottom end is knackered.  Wooodruff key has gone, taken cam gearwheeel with it.   Have found another bottom end from a friend of a friend but am missing the pulley and gear wheel so if anyone has them in good nick let me know as new price is around £150.

Graham

[graham2306]

Does anyone out there know If I can use the Disco Bell housing, gearbox and Transfer box easily?   It looks like the Disco box is a recent re-build and with the clutch being on the other side that would solve the exhaust/clutcg pipe problems.  I also see from others comments that the 90 bellhousing doesn't have the same hole pattern as the Disco engine and some messing about is needed so as a bare minimum we thought we might use the disco bell housing.  I am off out to do some measuring, but all input from you lot greatfully recieved.


Ta

Graham

[Miniman]

how is the conversion going or has it gone.....no body has replyed about the disco gearbox is it fit..... I am just about to get into all this job so any help on your conversion would be greatley recieved....

[Xtremeteam]

if you use the disco box you will either have to either chop the seat box to fit or fit a defender rear remote casing so the gearstick is in the right place,

if you use the disco box you will need to remount the gearbox,tbox & make new engine mounts,

if you use the defender box you fitthe TD engine mounts tot he disco enge & it all lines up bar the hoses  

[graham2306]

Thanks for that info re gearboxes.  Went in to my local independent Land Rover dealer, EH Douglas, yesterday for some engine bits and other odds and ends.  Neil was very helpful and spent 20 minutes talking to me about the best way to do it.  He said use the defender gearbox and bellhousing, he thinks there is one stud that is in the wrong place but he hasn't done one for a while so he may be wrong.  He also said the Steve Parker downpipe works a treat.

So the engine is being rebuilt at the moment and will probably go in in the next couple of weeks.

Graham

[Les Henson]

Put the flywheel housing off of your old engine onto the disco lump. That way all studs will line up. Good idea to replace the crank rear seal when doing this job, as well as clutch slave, clutch and operating fork (reinforce it as well).
I'm the author of the thread in LR4x4 Tech archive.
http://forums.lr4x4.com/index.php?showtopic=2394
All the information to do this conversion is there, including mods to the rad, other pipework, exhaust fabrication, wiring, etc etc.
This conversion is well worth it.


Les.

http://www.LR4x4.com

[graham2306]

Thanks Les, very useful.

Graham

[Miniman]

I have a old 2.5TD in the garage and on the end of the turbo is a cast exhaust elbow which fire the exhaust down. Is this another option for getting the exhaust to fit. I can take a photo if you wish and post it.

[Les Henson]

The disco turbo has to have the downpipe removed or modified because of the available room. The exit from the turbo has to be a tight curve immediately due to the limited room (115mm). I don't know if the TD downpipe will fit the Disco turbo. The Steve Parker dowpipe doesn't look all that good for what it costs I think. I understand it's not a direct fit, and some clamping modification is still needed. The reason I made my own downpipe was so that I could connect to the rest of the TD system and it was significantly cheaper too.


Les. :)