Topic: Defender 200TDI converstion step by step with pics (Read 16408 times)

solihull-mick · « **on:** December 13, 2008, 11:06:44 »

Few people have expressed interest in how to fit a disco 200TDI into a defender, Heres a few pics to start you off

Old Engine removed, cant see any point in showing how to remove the engine as its straight forward

200TDI waiting to go in, changing the cambelt and a few seals before it gets fitted,

By using the 200 tdi the N/A engine mounts bolt to the TDI in the correct place so chassis mount removal is not needed, will show this in later pics,

The 200 fuel inlet from the tank is the same as the N/A union, so no modds needed here, the inlet is the highest pipe centre,

Heres the pipe on the 110 from the tank

This is the old CAV fuel filter housing, this need to be replaced with the disco Bosch system,

The bosch system, keeps the fuel pipes correct for the 200TDI and easyer to replace filter in the future

This is the fuel return from the injection pump back to the tank on the 200TDI,

This is the old N/A return pipe which used to go to the injector leck off pipe, this will go when the filter is removed, identify which pipe on the old filter head goes back to the tank, then using a length on rubber, connect this to the return on the 200 injection pipe,

Drivers side disco engine mount, remove and bin this, its held on with one m10 bolt, and two M12 bolts

Drivers side engine mount on the N/A or TD, held on with 2 M12 bolts, this will bolt back on to the 200 with no problems,

This is the 200 mount holes, the disco used the two front holes, you need to bolt the N/A mounts to the rear two holes

This is the N/A mount holes, the TD uses the same block ,

This is the N/A mount on the 200 TDI block

More will follow

Artwigwa · « **Reply #1 on:** December 13, 2008, 11:52:50 »

Quote from: solihull-mick on December 13, 2008, 11:06:44

Few people have expressed interest in how to fit a disco 200TDI into a defender, is that somthing you guys would be interested in?

O yes!

I have a old 90Td and have been thinking of doing a 200Tdi conversion but not sure where to start. :-k

Lumbering Jack · « **Reply #2 on:** December 13, 2008, 16:45:42 »

I'd be interested too - I've a disco sat there ready to be chopped up and the 110 NAD is needing an engine :dance:

solihull-mick · « **Reply #3 on:** December 13, 2008, 17:05:53 »

Ok guys, im doing a 110 N/A to 200 disco tdi this week coming, will take pics as i go,

Lumbering Jack · « **Reply #4 on:** December 13, 2008, 22:30:29 »

Nice 1

Les Henson · « **Reply #5 on:** December 14, 2008, 09:22:45 »

Putting a 200TDi Disco engine in a 90 (previously a TD lump).

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

Les :)

solihull-mick · « **Reply #6 on:** December 14, 2008, 16:26:23 »

Not exaclty a detailed thread there les, im sure i can make it all clear with my fitment guide, no mention of how to fit the electronic glow plug timer, or wiring changes, watch this space guys,

Les Henson · « **Reply #7 on:** December 21, 2008, 08:44:35 »

Do you think it's necessary to fit the timer Mick? Tdi's tend to start without plugs anyway so the vehicles original system will just plug and play. A matter of choice I suppose and if you have a complete disco donor for all the fiddly bits.
I just bought an engine and a few other bits and pieces to the job.

Les.

davidlandy · « **Reply #8 on:** December 21, 2008, 12:29:31 »

done a few of these now and from the outset was always wanting to put the glow plug timer on , and like Les says I have found it to be completely unecessary.

solihull-mick · « **Reply #9 on:** December 21, 2008, 17:10:21 »

Well thats your choice not to fit it, me i like to do the job as landrover intended, nice touch when you turn the key on, customers if done this for in the past have loved it, so cant be a bad thing,

craig_midz · « **Reply #10 on:** December 21, 2008, 19:42:04 »

ive just done the same conversion on my 110 took 2.5td out an put 200 tdi in i didnt use glow plug timer either i just use same method as land rover used for the td where u turn ignition key just pass 2nd position an glow plugs come on but to be fair engine starts without glow plugs as the disco it came out of the glow plugs wernt even connected an bloe had it for a few years like that with no probs what so ever but i connected em up just in case we get a very cold mornin

stuntman · « **Reply #11 on:** December 22, 2008, 14:31:03 »

Come on Mick, I'd also like to wire my glow plug timer in, where I live is a frost pocket and it does get well below zero on the frosty mornings.

Les Henson · « **Reply #12 on:** December 24, 2008, 07:48:06 »

Me too - I might get a fussy customer

Les.

davidlandy · « **Reply #13 on:** December 24, 2008, 21:50:08 »

would also find useful any alternative air filter setups

Mark Y · « **Reply #14 on:** February 10, 2009, 21:13:42 »

how do i print all this out, as I am just about to commence the conversion and the wi fi will not reach the garage ?.

Artwigwa · « **Reply #15 on:** February 10, 2009, 22:08:30 »

Quote from: solihull-mick on December 13, 2008, 17:05:53

Ok guys, im doing a 110 N/A to 200 disco tdi this week coming, will take pics as i go,

How's the conversion going? Watching with interest, pls more pics [-o<

thompjas · « **Reply #16 on:** February 11, 2009, 12:41:23 »

I have just fitted a Glow Plug Timer relay to my 2.5 NAD, it looked as though it was going to be a right pain, instead it turned out to be almost straight forward !!

I bought a glow plug Timer relay of ebay quite cheap and the fitted as follows

Click on this Thumbnail for a picture of the Terminals of the relay as a reference

PIN 1 - I connected this via 10mm cable direct to the Battery Positive (6mm is Minimum that you need)

PIN 2 - I used 10mm cable and connected this to Glow Plug 4 (nearest Bulkhead)

PIN 6 - Connect this to the Chassis Ground

PIN 4 - Connect to any White Wire in Wiring loom, I fed via Bulkhead into Dash panel and connected in there.

I left all of the original wiring for the glow plugs in situ, so this also provides a back up way of using the glow plugs should the timer fail, also this also back feeds the glow plug light on the dash panel

here are a couple of Images of the relay all wired up and in situ -

davidlandy · « **Reply #17 on:** February 11, 2009, 19:29:53 »

how long does it allow the plugs to stay on for?

thompjas · « **Reply #18 on:** February 11, 2009, 21:36:58 »

Seems like ages when you are waiting for it to go off, probably 10Secs

davidlandy · « **Reply #19 on:** February 12, 2009, 22:13:56 »

is that enough time for an NA ? mine used to need 20secs or so

thompjas · « **Reply #20 on:** February 13, 2009, 14:07:31 »

At the moment I need a minimum of 2 lots of timer, maybe 3 lots

solihull-mick · « **Reply #21 on:** February 13, 2009, 16:40:15 »

Sorry guys jobs been done and gone from the shop, been to busy to post pics, will carry on when i get the next one in,

Smokydiesel · « **Reply #22 on:** February 16, 2009, 19:54:52 »

Hi,

Also working on my conversion (seems popular these days... :)..)

I'm keeping the Disco flywheelhousing and the Defender gearbox and belhousing (LT77).
The different conversion-threads on here don't seem to mention the two short metal well.....stumps (5 mm long) on the edge of the Disco's flywheel housing, just between the m10 thread-ends. Looks like it is used for mating flywheelhousing to belhousing on a Disco box, but it doesn't match the Defender belhousing.

What did you do with them ? just grind them of or...?

Thanks !

Edwin.

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AuthorTopic: Defender 200TDI converstion step by step with pics (Read 16408 times)