200TDi from a disco

[zulublue]

Hi all, yes ive jumped from the Range Rover page to the Defender, which is my new toy, unfortunatly I locked the engine up after 3 day's in Packington ford, Dont ask I am still trying to calm down, must be a leak on the snorkel!!!!

Anyway I have purchased a 200Tdi engine from a disco, I think the turbo manifold is different? do I need to do any mods to fit it, or will it go straight in?

Any help as always appreciated, hands on help even more so :D

Mark.

[extreme90]

take the old downpipe off and bolt up the steve parker conversion to it
  fits in then
or do like i did and keep the origional pipe.....and didnt cut the chassis nor bulkhead  
dan

[90sam]

I think a saab turbo downpipe can be used and is a lot cheaper than steve parkers!

[disco steve]

if u got the  old defender engine there just change over the bits off the one engine on to other saves a lot off  messing about thats wot i did with mine

[zulublue]

Hi Steve which bits?

The alternator, power steering pump and the water pump are in different places!

does this mean removing the W pump take the front cover off, remove the cam belt and cogs, and remove the back plate from the cam belt housing, then fit it to the disco block ?

Unfortunatly due to my inexperience, I have chaged the rear cam gasket, refitted all the cogs cam belt front gasket water pump gasket and so on put it all back together fitted the inlet and exhust manifold from the 90 then to see that the alternator from the disco sits right in front of the inlet pipe into the manifold.
Talk about good day bad day

So I dont know waht to do for the best now, if I put the disco inlet manifold on what else do I need to do to fit it into the 90?

Plus I take it I will need an electric fan as the viscous will be out of line?

HELP please :(  :(  :(  :(  :(  :(  :(

[extreme90]

fit a td inlet manifold

[Porny]

fit a td inlet manifold

He already has...  

...... fitted the inlet and exhust manifold from the 90 then to see that the alternator from the disco sits right in front of the inlet pipe into the manifold.

[Xtremeteam]

fit a td inlet manifold

He already has...  

...... fitted the inlet and exhust manifold from the 90 then to see that the alternator from the disco sits right in front of the inlet pipe into the manifold.

from the sounds of it he has fitted a TDi defender inlet manifold,
the Td one comes out the sode

[Porny]

Just re-reading this...

Mark,

Being 1992 I gather you 90 was a Tdi??

In which case, although you have already done the seals, personally I'd convert your Disco 200Tdi to Defender spec...

So you need to change the front cover (different idler set-up on the cambelt too) - which would also allow you to fit the defender type water pump, hoses etc etc etc.  

It also means you could run the Defender intake and manifold set up without fouling the PAS or alternator - you will also need to fit the Defender pully/damper set-up.


The other advantge is that all the pipe work will remain strandard Defender, rather than being a Disco/Defender sepc hybrid.  You can also keep the Defender fan cowl etc etc.

On top of the ease factor, if you ever sell your 90, it would be better to have a proper 'standard' set-up, than a hybrid mix of bits.

Also, have you fitted the engine yet??

If you use the Disco rear engine cover you will have to drill and tap a couple of the stud holes!

Give me a shout if you want a hand.


Ian

[extreme90]

ian hes still got the disco timing case afink, and thats why the alt is in the way  :?

on another not on the offchance, can you program 2 button key fobs ?
its a 300 tdi R reg so i believe it runs on a 10as unit ? but i aint sure so im happy to be corrected  8)
its giving us jip and wont work some times  :roll:
changed battery to no avail

dan

[zulublue]

ALL, Thank you so much for your input it means  a lot, I am totally frustrated by this as you can tell, the 90 has been in the garage for over a week now and I have been helping out when I can.

I have learnt the hard way today with about 3 inlet and exhaust manifold changes trying to get it to fit, I then got to the point of saying to the mechanic that I think the best way to go is to fit all of the alloy front end of the defender engine to the block of the disco, I knew it meant removing the cam belt and cogs etc, but at least it would be original fittings, he said we could make it fit and to put the disco manifold on etc etc, so that's what we did, yes you are probably all guessing the next bit where the exhaust manifold hits the bulk head, I did tell him I had been warned about this but he thought better of it.

Anyway I said that's enough so we have taken the engine out again stripped it back taken the cam cover and inner cover water pump and thermostat off the defender and are now ready to fit it to the disco block, I need to go and get a few gaskets in the morning then I am back to work having booked 3 day's off to help out and got no where.

so as it stands I have a disco block with a defender front end to refit, if there is anything I need to be aware of please let me know.

Ian I will Pm my mobile number to you.

thanks again

Mark.

[extreme90]

yes, you will need a defender timing belt as the disco and defender ones are different sizes
also, what you doing with the scrap block ?
whats the damage as i need a engine block as ive got a 200 here with a cracked block between 2 and 3 cyls as usual  :roll:
dan

[zulublue]

I have both timing belts, but as I am using the disco block, I take its a disco cam belt thats needed? or is the tensioner in a different place etc, it looks like the cam belt housing fits the disco block OK.

As for the block, I have had 3 people PM asking if its for sale, I am not sure yet, I just want to get this one done first.


Mark.

[Porny]

Nope....

Defender cam belt, and Defender idler.

The actual base engine (i.e block and head) is exactly the same between the Disco and Defender (apart from a different engine number sequence).... it is only the ancil. and dress items that are different.


Ian

[extreme90]

the timing case will bolt straight up

however you will need a new timing belt, a defender one as its shorter
on a discovery you not only have a tentioner pully but a idler pully aswel, on a defender there isnt a idler, just the tentioner as the belt isnt long enough to need one, plus the design of the timing case eliminates the need as its quite compact

hope this helps
dan

[Porny]

on another not on the offchance, can you program 2 button key fobs ?
its a 300 tdi R reg so i believe it runs on a 10as unit ? but i aint sure so im happy to be corrected  8)
its giving us jip and wont work some times  :roll:
changed battery to no avail

dan

Yep... can do them
Sure we can sort it out... could just put it into a base mode.


Ian

[redhand]

Might be a bit late for you but here's a step by step guide to fitting a disco engine into a defender.

http://www.llawnroc.f2s.com/200tdi_conversion.htm

[extreme90]

on another not on the offchance, can you program 2 button key fobs ?
its a 300 tdi R reg so i believe it runs on a 10as unit ? but i aint sure so im happy to be corrected  8)
its giving us jip and wont work some times  :roll:
changed battery to no avail

dan

Yep... can do them
Sure we can sort it out... could just put it into a base mode.


Ian

now ive got the landy moving again by using the emergency disarming procedure in the owners man

when you say base mode, does that mean get rid of it all together, because i hate it full stop  :roll:

dan

[zulublue]

Thanks Redhand,

I has helped a little, the garage did have the issue with the stud been in the wrong place, they had the engine in and out 3 times and have had to take the clutch housing?? off the defender engine to match it up, just waiting for a coupl of gaskets tomorrow, then fingers crossed :?  :?

[zulublue]

Give me a shout if you want a hand.
Ian

Im Shouting

[extreme90]

whats the problem ?
mine is a 200 disco engine
with origional downpipe fitted
i used the disco box
dan