Vehicle & Technical > Series Land Rovers

discovery 200tdi into 88"series,shopping list of parts i need.?advice please.

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DAVE V8:
hi ,got a rusty 200tdi discovery to use engine and maybe box into series 2a,dont want to start half arsed so was looking for helpfull advice .....will put new clutch on engine...at moment got an ancient 2.5 gutless non turbo daihatsu,fitted to 4 speed series box,rangy diffs 3.5s,265/70/16s............is it better to fit disco 5 speed box or just run series box?if i try to fit 5 speed what grief ,i.e props ,gear levers etc.whats pros and cons of either box,just wanting to get a shopping list together of parts i will need. so once i start i can really crack on.....................any useful  advice,personal experiences  that may help out really appreciated... cheers dave

NiteMare:
don't even bother trying to fit the disco box unless you want a passenger in the rear tub to change gear for you, the disco box/bellhousing is way too long...

my 200tdi is mated straight to the series 3 4 speed box, all i needed to do was use the 9.5 inch series friction plate, i mounted the alternator in the usual Series position using a series mount and spaced it all forwards approximately 30mm and put a double pulley on the alt'...

you have to remove one stud from the 200 flywheel housing along with a couple of locating pegs, there will be 4 bolts that you can't fit across the bottom of the bellhousing unless you drill and tap the flywheel housing to suit (i didn't and have been using it for nearly 2 years like this as a daily driver)....

use the series mounts on the 200 block but put 3.5-4mm spacers above and below the engine rubbers to lift the engine to help prevent the crank pulley hitting the front axle (i turned my pulley on my lathe) i used petrol rubbers on the engine...

you can "clock" the turbo to save you cutting the inner wing for your turbo piping (i didn't clock it), i trimmed my rad' panel to fit my i/cooler, i also turned the i/cooler upside down and trimmed 1-1.5 inch off the new top stub to allow the pipe to clear the radiator ...

i used a volvo 740 expansion tank as it's nice and small, a 90 airbox and cut the legs off and mounted that on the timing case (connector off the disco airbox with reducer) i cut and shut rad' hoses to suit, built my own exhaust  ...

a link to all the pictures i took as i built my 88"
http://s259.photobucket.com/albums/hh311/NiteMare_08/Zebedee/

fit 7.50 tyres, 3.54 diffs, an overdrive and you're geared for 90mph on the road if you're brave enough (i'm still on 10" single leading shoe brakes no servo single line system, will be upgrading that soon to dual line (servo) and 11inch SLS brakes on the front

DAVE V8:
thanks this is very useful,some really great tips,only thing ,i have a 3 piece new clutch kit will the 200tdi pressure plate not fit?,i will go down the standard series gearbox route and just sell the disco box..cheers

NiteMare:
series3, defender and 200tdi disco all use the same pressure plate and clutch release bearing ...

you just need to use the series3 9.5 inch friction plate as the splines are different

DAVE V8:
top man ,better get me shopping list sorted out and get cracking,lol....thanks for the help,really appreciated.

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