Vehicle & Technical > Series Land Rovers
200TDi in me lightweight, update on build! :)
12LDA28B:
I've done this using a Disco engine and have had it up and running since January so I can tell you the basics and dispel the myths. This is based on a lights in the grille 2a and not a lightweight though.
Disco 200Tdi will fit straight onto the existing engine mounts on a 2 or a 3.
The series 'box will bolt straight on but you will have to remove one stud from the engine.
The series diesel clutch fits onto the Tdi flywheel.
You can buy a ready made exhaust from Steve Parker if you are minted (£280 plus VAT) or you can make one as you progress. Mine is made from Disco and 90 parts. The rear section of a 90 system fits over the back axle and the rest is made up to follow the original line of the series system. The cast (or malleable iron?) section that bolts onto the turbo is binned and a new flange made. This means the pipe exits downward. It is a tight fit but avoids the need to cut the bulkhead footwells.
Despite what has been said on other forums there is absolutely no need to turn or modify the turbo in any way.
The intercooler can be fitted alongside the standard series radiator by cutting a section out of the inner wing and remaking the section to keep the muck out. Pop rivets will suffice.
The series radiator if in good condition to begin with seems to be able to cope with the cooling. I have driven mine off road and done long motorway trips and it has been OK so far.
Fit an electric fan. There is no space for the viscous fan and altough there is clearance between the nose of the water pump and the rad, it is better to grind the nose down as far as the end of the thread for the fan. You won't need it anyway.
If you cut out the standard air filter base and move the battery tray forward by cutting an re-welding you can keep the battery under the bonnet.
Do fit an oil cooler. I have heard of people doing away with it but Land Rover didn't spend all that money developing this engine to run at its best with an oil cooler only for it to be binned! The Disco rad/intercooler/oil cooler comes as one so you will need either an aftermarket cooler, one from a Rover 800 series car or, as I have, one from a military 90.
ian_s:
by the sounds of it, both engines have their drawbacks
with the defender engine you have to change an engine mount,
with the disco engine you have to do fancy things with the exhaust
lightweight-love:
thats why im trying to source a disco engine but fit the defender manifolds, but then you apparently have to re-site the alternator, will see.
12LDA28B - did you drill and use the lower 4 bolts thru gearbox? also do you find you need the electric fan much? good to get another point of view on here, cheers!
12LDA28B:
I didn't have to drill anything on the gearbox but it may depend on what gearbox combination you have. Although I have a series 2 gearbox it is the later (suffix C) type with the larger bearings and so can take a series 3 bellhousing. The series 3 bellhousing didn't need any modification but I can't say whether or not the series 2 bellhousing would or not. The fan comes in only on motorway runs but as the temp gauge shows only a 3rd the way up it could be thta it's coming in too soon and the fan thermostat needs adjusting.
One other thing... You should fit bump stop extenders on the front from a military 109 between the chassis and the bump stop itself. This will prevent the Tdi crankshaft pulley from hitting the axle on extreme travel. I found this out the hard way when I took a chip out of the pulley and put a groove in the axle.
Resiting the alternator: You should do this anyway. The Disco 200Tdi engine has the alternator driven from the power steering pump, which is driven by the crankshaft. If you don't resite the alternator you have a useless PS pump that will need some lubrication i.e. a pipe circulating the PS fluid. It's more to go wrong, requires two drive belts and it saps power unneccesarily. Take an alternator mount from a 2.25 petrol or diesel and weld it to a plate so it can be made to bring your alternator in line with the crankshaft pulley. You will need to make an adjuster out of some threaded bar.
ian_s:
--- Quote from: lightweight-love on April 20, 2008, 18:52:41 ---thats why im trying to source a disco engine but fit the defender manifolds, but then you apparently have to re-site the alternator, will see.
12LDA28B - did you drill and use the lower 4 bolts thru gearbox? also do you find you need the electric fan much? good to get another point of view on here, cheers!
--- End quote ---
that sounds like a damn good idea with the manifolds, best of both worlds
i found that i only needed a fan when i was sat in traffic, stop start kinda thing.
on a run, backing off slightly to protect my ears, i never had any problems even on hte hottest days last year
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