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Defender 200TDI converstion step by step with pics

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solihull-mick:
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:

--- 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?



--- End quote ---

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

Lumbering Jack:
Nice 1  :grin:

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