Mud-club
Vehicle & Technical => Defender => Topic started by: graham2306 on April 20, 2006, 20:43:39
-
Will it go ? What bits do I need?
My engine expert says it will go, I'll just have to get a Defender radiator/intercooler, but he's an expert on Japanes engines.
I've read something somewhere about the turbo being too high.
Anyone done it?
Graham
-
Try a PM to Redlinemike :D , he's extremely clued up on all things landrover (perhaps cos hes a LR mechanic).
-
Will it go ? What bits do I need?
My engine expert says it will go, I'll just have to get a Defender radiator/intercooler, but he's an expert on Japanes engines.
I've read something somewhere about the turbo being too high.
Anyone done it?
Graham
A Discovery engine into a defender isn't as easy as it might be as the turbo is in a silly place ISTR, or at least, it's in a silly place when you try to stick it in a defender....
-
hi there,i put a disco tdi into my 90 replacing the n/a,
to make it fit you need to mod the turbo downpipe,now you can chop it up & weld it back together like what i did or buy the steve parker 1 at circa £100,
know my work is currently doing this convo to a customers vehicle & the last batch of manifolds (12 of) didnt even hit the shelves,went straight out to punters,
anything else shout up or PM me
Mike
-
yep i got one need to put it in on the wee wee or the out put shaft wont meet up proper well i got a disco 300 in my defender ill take a picky to moz to show
-
yep i got one need to put it in on the wee wee or the out put shaft wont meet up proper well i got a disco 300 in my defender ill take a picky to moz to show
just as a side note
the disco 300 & defender 300 are identicle engines in fitment bar the air filter set up & front pipe for the exhaust (depending on age as some have fly by wire throttle controls )
-
hi there,i put a disco tdi into my 90 replacing the n/a,
to make it fit you need to mod the turbo downpipe,now you can chop it up & weld it back together like what i did or buy the steve parker 1 at circa £100,
know my work is currently doing this convo to a customers vehicle & the last batch of manifolds (12 of) didnt even hit the shelves,went straight out to punters,
anything else shout up or PM me
Mike
Hi graham2306 you could buy my spare 300 Tdi defender turbo with manifold and down pipe for £100 :D :D
It will make the transplant alot easyer
Cheers Landyash :)
-
hi there,i put a disco tdi into my 90 replacing the n/a,
to make it fit you need to mod the turbo downpipe,now you can chop it up & weld it back together like what i did or buy the steve parker 1 at circa £100,
know my work is currently doing this convo to a customers vehicle & the last batch of manifolds (12 of) didnt even hit the shelves,went straight out to punters,
anything else shout up or PM me
Mike
Hi graham2306 you could buy my spare 300 Tdi defender turbo with manifold and down pipe for £100 :D :D
It will make the transplant alot easyer
Cheers Landyash :)
AFAIK (dont quote me) i dont think a 300 turbo & manifold fits a 200 engine,also the pipework is severly different,just fitted a 300 into an ex 200 90 & all the 200 pipewprk is now on mine as its now where near the 300,also the intercooler is slightly different
-
Will it go ? What bits do I need?
My engine expert says it will go, I'll just have to get a Defender radiator/intercooler, but he's an expert on Japanes engines.
I've read something somewhere about the turbo being too high.
Anyone done it?
Graham
Just about to do same thing with mine, I'm told the disco rad and intercooler are better but The mountings need to be modified, but happy to be put right on that and anything else.The Steve Parker manifold is supposed to make things easier.There were a number of posts and pointers when I raised the issue a while ago if you look back a bit.
Keep me informed if you start it soon I'll pick youxr brains.
Good luck
-
if you want any help i did one last year,,?.
-
Will it go ? What bits do I need?
My engine expert says it will go, I'll just have to get a Defender radiator/intercooler, but he's an expert on Japanes engines.
I've read something somewhere about the turbo being too high.
Anyone done it?
Graham
Just found this link from my initial enquiry, well worth a look, lots of photos etc.
http://forums.lr4x4.com/index.php?showtopic=2394
-
if you want any help i did one last year,,?.
Where you at? Local to Northants?
-
I am in Nuneaton matey..pm me if you want to have a look at the one i did then maybye a bit clearer for you anytime?/
-
Feel free to have a browse on the conversion page of my website http://www.90county.co.uk too.
Stef
-
Thanks for all the info guys, looks like Steve Parker pipe will do the job. Now all I need to do is convince my mate he wants to break the Disco he bought for £50 last week. Unfortunately there is a possibility that he will just get it MOTd and sell it for a huge profit. Only bought it for the windscreen but it is so good it would be a shame to scrap it. Engine needs a new cylinder head gasket but it's only done 97000.
If I get the engine off him I'll be back to let you know how it's going.
Graham
-
Got myself a 200tdi out of a disco. Does anybody know how much I'll have to modify the engine mountings?
You see I have a galvanised chassis and don't really want to hece to cut and weld the chassis. Can it be done without?
Ta
Graham
-
fit the n/a or TD engine mounts to the disco engine in the defender mounting holes & throw the disco mounts in the bin,puts the engine in the corect location aswell
-
Thanks Mike
Graham
-
Hi Graham
How's the conversion plans going, or is it done and dusted?
Bob
-
we did, or rather started this job last year, then a defender spec 200Tdi came along for a good price.
you'll need longer pipes to reach the oil cooler, either get the ones you've got made longer or source defender ones.
you will need a new fan shroud.
you may need to play with the wiring and glow plug relay set up, depending on what engine you've removed.
the exhaust is best done with the steve parker pipe.
the Rad frame will need modifying slightly.
some of the air and water pipes will need lengthening/ altering slightly.
you will need to think about the position of the air filter/ intake set-up.
the pipe from the clutch master cylinder to the slave cylinder is very close to the new exhaust downpipe, you may need an exhaust heat shroud.
this swap is do-able, but its a fiddly job. there are a few people around who have done it, and every conversion seams to end up slightly different.
take your time, don't listen to anyone who hasn't actually done it, and don't throw anything away until its completely finished.
-
The 200 tdi lump is out of the Disco, I want to get the head off and have a good look at it. One core plug was leaking and the keyway in the crank may be damaged, so few jobs to do on it before the swap takes place. have just renewed my insurance and the insurance company say they will still insure it once it is done, so that's one problem less.
On the heater plug point, do 200Tdi engnes have a relay? All my previous diesel Land Rovers have been turn the key for 20 seconds then start it up. You aren't suggesting that Land Rover have gone all upmarket and have a relay to turn them off are you?????
Graham
-
Have got the lump in bits and bottom end is knackered. Wooodruff key has gone, taken cam gearwheeel with it. Have found another bottom end from a friend of a friend but am missing the pulley and gear wheel so if anyone has them in good nick let me know as new price is around £150.
Graham
-
Does anyone out there know If I can use the Disco Bell housing, gearbox and Transfer box easily? It looks like the Disco box is a recent re-build and with the clutch being on the other side that would solve the exhaust/clutcg pipe problems. I also see from others comments that the 90 bellhousing doesn't have the same hole pattern as the Disco engine and some messing about is needed so as a bare minimum we thought we might use the disco bell housing. I am off out to do some measuring, but all input from you lot greatfully recieved.
Ta
Graham
-
how is the conversion going or has it gone.....no body has replyed about the disco gearbox is it fit..... I am just about to get into all this job so any help on your conversion would be greatley recieved....
-
if you use the disco box you will either have to either chop the seat box to fit or fit a defender rear remote casing so the gearstick is in the right place,
if you use the disco box you will need to remount the gearbox,tbox & make new engine mounts,
if you use the defender box you fitthe TD engine mounts tot he disco enge & it all lines up bar the hoses :wink:
-
Thanks for that info re gearboxes. Went in to my local independent Land Rover dealer, EH Douglas, yesterday for some engine bits and other odds and ends. Neil was very helpful and spent 20 minutes talking to me about the best way to do it. He said use the defender gearbox and bellhousing, he thinks there is one stud that is in the wrong place but he hasn't done one for a while so he may be wrong. He also said the Steve Parker downpipe works a treat.
So the engine is being rebuilt at the moment and will probably go in in the next couple of weeks.
Graham
-
Put the flywheel housing off of your old engine onto the disco lump. That way all studs will line up. Good idea to replace the crank rear seal when doing this job, as well as clutch slave, clutch and operating fork (reinforce it as well).
I'm the author of the thread in LR4x4 Tech archive.
http://forums.lr4x4.com/index.php?showtopic=2394
All the information to do this conversion is there, including mods to the rad, other pipework, exhaust fabrication, wiring, etc etc.
This conversion is well worth it.
Les.
http://www.LR4x4.com
-
Thanks Les, very useful.
Graham
-
I have a old 2.5TD in the garage and on the end of the turbo is a cast exhaust elbow which fire the exhaust down. Is this another option for getting the exhaust to fit. I can take a photo if you wish and post it.
-
The disco turbo has to have the downpipe removed or modified because of the available room. The exit from the turbo has to be a tight curve immediately due to the limited room (115mm). I don't know if the TD downpipe will fit the Disco turbo. The Steve Parker dowpipe doesn't look all that good for what it costs I think. I understand it's not a direct fit, and some clamping modification is still needed. The reason I made my own downpipe was so that I could connect to the rest of the TD system and it was significantly cheaper too.
Les. :)
-
I've just taken delivery of the Steve Parker pipe, not yet tried it on the engine or in the engine bay. It looks well made and they assure me it does the job with no other mods than cutting the exhaust system to the right place. I have to say £137 including delivery is a lot of money for what is essentially a bit of bent and welded pipe. I just wish I had the skill to make them.
I'll let you all know how it goes.
Graham
-
Good aint they...saves a allot of faffing around..
i spoke to S.Parker oin the phone he is a great guy and helped me behond what was the norm as i had problems with somthing else..
Close to the chassi though..
-
yes expencive but will do the job you need it for thats why you bought it.
I will make my own for about £10 sorry but I had to say it....he he
-
Well it all started today, we put in about 5 hours and have the old lump out and the new lump almost ready for its test fit, hope to get it test fitted, reuired mods done and final fit onto mountings tomorrow. Can then get it out the workshop and back home on the drive for all the plumbing and electrics to be done next week. That'll leave the workshop free to earn money.
Pictures and more info to follow when it's over.
Graham
-
Wow man now how is that for a strange day. I today have been to newcastle for my 200tdi discovery. So now I have mine at the garage waiting to be taken out BUT...... :cry:
The engine sounds like its chuffing abit like head gasket gone between cylinders or valves leaking so on monday we are going to do a compression test....
-
Wow man now how is that for a strange day. I today have been to newcastle for my 200tdi discovery. So now I have mine at the garage waiting to be taken out BUT...... :cry:
The engine sounds like its chuffing abit like head gasket gone between cylinders or valves leaking so on monday we are going to do a compression test....
dont bother with the comp test,
start it up & take the oil filler cap off,if its chuffing out there the ehadgasket will have blown between No4 cylinder & one of the pushrod holes :wink:
-
Already done that its fine. I was thinking more of a burnt out exhaust valve or inlet valve
-
could be injection pump timing out as mine did that when i first rebuilt it
-
May be but this has been run as a family car for the last year. Dont you think a compression test would be a good idea first before I go down the line of messing with the pump timing. What ya think.
-
Hi all, just to add a bit on the subject of downpipes, when we put a disco 200 into my old na we trimmed two inches off the corner of the passenger footwell and got longlife exhausts to make us a three inch stainless system that exited out the side behind the passenger door, they also made me up some turbo and intercooler pipes, all for under 200 squid... It sounded real sweet and went like stink... still see it being driven around everyday too :wink: cheers all...
Bell housing wise we just removed one stud and tapped a new one in the right place.....
-
Hi all, just to add a bit on the subject of downpipes, when we put a disco 200 into my old na we trimmed two inches off the corner of the passenger footwell and got longlife exhausts to make us a three inch stainless system that exited out the side behind the passenger door, they also made me up some turbo and intercooler pipes, all for under 200 squid... It sounded real sweet and went like stink... still see it being driven around everyday too :wink: cheers all...
Bell housing wise we just removed one stud and tapped a new one in the right place.....
-
The 200tdi lump is in on the mounitings and bolted up, just the plumbing and electrics left to do. In les's version of events he says to cut the radiator mountings down 28mm to get the radiator in, but in other versions of the conversions I've not seen anything about this.
Anybody that has done it know a better way than cutting the mountings down as I have a galvanised chassis and really don't want to break the galv or risk the fumes from welding it.
Looks like it might be possible to get some of the 28mm from the brackets on the radiator housing, by cutting them off and welding the pegs straight onto the casing.
Also where is the best place to put the air cleaner?
Cheers
Graham
-
The 200tdi lump is in on the mounitings and bolted up, just the plumbing and electrics left to do. In les's version of events he says to cut the radiator mountings down 28mm to get the radiator in, but in other versions of the conversions I've not seen anything about this.
Anybody that has done it know a better way than cutting the mountings down as I have a galvanised chassis and really don't want to break the galv or risk the fumes from welding it.
Looks like it might be possible to get some of the 28mm from the brackets on the radiator housing, by cutting them off and welding the pegs straight onto the casing.
Also where is the best place to put the air cleaner?
Cheers
Graham
on the disco rad there is an extension on the bottom to lift the whole frame up,thus giving you the 28mm,on mine did awayeith the spacer type bit & welded the pins on the bottom of the frame giving the correct height,
for the air filter i took the original box & welded a flat plate on the bottom doing away with the normal legs,
Pm yer mobby No & ill send a piccy over
-
The 200tdi lump is in on the mounitings and bolted up, just the plumbing and electrics left to do. In les's version of events he says to cut the radiator mountings down 28mm to get the radiator in, but in other versions of the conversions I've not seen anything about this.
Anybody that has done it know a better way than cutting the mountings down as I have a galvanised chassis and really don't want to break the galv or risk the fumes from welding it.
Looks like it might be possible to get some of the 28mm from the brackets on the radiator housing, by cutting them off and welding the pegs straight onto the casing.
Also where is the best place to put the air cleaner?
Cheers
Graham
Graham,
Check out my website http://www.90county.co.uk for an alternative way, I basically cut the brackets off the bottom of the radiator bottom plate, drilled holes to line up with those brackets fitted on the chassis, then used long bolts and nuts to create new 'pins'. The pics on the 200tdi conversion page should also give you an idea about air filter location. I have some straps bolted to the inner wing which hold the air filter in place close to its original location.
Stef
-
Does anybody know if and old series 3 mounting plates are the same as the standard 90 N/A. I have to fit my new 200tdi onto the new chassi but have no plates but I do have an old series diesel....???
-
Thanks Stefan, forgot I had read that some time ago!!!!!!!!!!!
Have cut the side brackets off today and got the rad shell in place to see how much hight I need to get rid of. Looks like removal of the bottom brackets will do it, I plan to cut them off and get the locating pins out then drill the mounting shell and weld the pins in it.
Graham
-
Oh did u get the pics i sent over to your mobby?
-
Yes thanks mike, I did. Very useful. I have got the lugs off of the side and 'test fitted' it in to check so next step is to cut the brackets off of the bottom.
-
Well there is so much plumbing! I haven't decided exactly where to put the air filter yet, the old 2.5 NA one was knackered, case split, so I am going to use the Disco one. Thinking about putting it on the roof above the passenger and piping it up as a snorkel. Remember seeing a Royal Marines one done like it for deep wading. Havin g it well out of the way makes plumbing up the turbo and intercooler so much easier.
Power steering and oil cooler are plumbed in and have made up mnost of the bottom hose. Need to get some heater hose and some hose to make up a top hose from. Anyone know any good hose suppliers near Banbury???
It's taking much longer than I planned :-)
:) :D :D :D :)
-
I have my disco donor and have just been given yes GIVEN a complete disco 300tdi gearbox and transfer case.....R380 is it....now then recon that and fit it along with the 200tdi engine ya think......??????
-
dont bother fitting the r380 unless u want to mod like you would to fit the disco LT77,same length o box,get a defender gearbox & use the disco T box to up the gearing
-
Just after I fitted mine to my Defender box someone showed me one with the Disco box fitted, leaving loads of room behind the engine and bringing the fan up against the radiator. They say it was fitted on the original gearbox and engine mounts, but as they didn't do it themself I'm not sure. Had a good look round and all it seemed to be in about the same place as mine except the engine was well forward.
Graham
-
HEY its mikey how ista....... :lol:
I was thinking about the lt77 box being so soft and the r380 being so good that it would be a good idea... What mods are I looking at. I have to make a exhaust manifld drop pipe and get the power steering pipe extended by 30cm ect ect so if the r380 box is used all that goes out the window.....so what dont I know or have I forgotten..... If I want ti fit the r380 what probs have I to face......
-
HEY its mikey how ista....... :lol:
I was thinking about the lt77 box being so soft and the r380 being so good that it would be a good idea... What mods are I looking at. I have to make a exhaust manifld drop pipe and get the power steering pipe extended by 30cm ect ect so if the r380 box is used all that goes out the window.....so what dont I know or have I forgotten..... If I want ti fit the r380 what probs have I to face......
ill have a think n post up the morra
-
Cheers fella. All good info. I do give my Gbox alot of stick......
-
Spoke to Steve Parker Land Rovers on Friday about there Intercooler pipe kit.
Here is their reply.
Hi Graham,
We are suppling intercooler kit which include all the pipe work for the air intake/intercooler, top rad hose, bottom rad coupling pipe, temp sensor and a new or s/hand air filter box. this will cost you £350.15 new filter box or £298.00 for s/hand one, plus 13.98 carriage for main land UK.
Thanks
Dave
Think I am going to make my own intercooler pipes up then.
I am also looking at cutting the air out nozzle offf the turbo and tig welding a right hand bend on so that it clears the wing and can be piped straigh up to the intercooler.
Graham
-
what i did was before the engine went in was adjust the inner wing with a 2Ib hammer so there was more space just where the turbo outlet comes out,what u need is a 300 tdi turbo outlet hose as its just slightly tighter than a 90 degree bend,if not buy a samco one whict is tighter than a 90,if u want any more infor drop me a pm N ill give you my No to fone me
-
Thanks for that info Mike, my turbo expert and I have just been looking at it again and the turbo is having surgery.
Graham
-
Spoke to Steve Parker Land Rovers on Friday about there Intercooler pipe kit.
Think I am going to make my own intercooler pipes up then.
Graham
Yeh I recon that will be my idea aswell...
£350 god d*m................
-
Having removed the turbo and started to dismatle it ready to weld a 90 degree elbow on it we dicovered that there is no locating peg on the snailhousing so it can be positioned at any angle on the turbo. So no need for welding, we are just going to turn the snail housing through 90 degrees and it will pipe into the intercooler using a couple of 90 degreebends and some of the old pipe. It will also miss the inner wing completely.We will have to drill and tap a couple of new holes for the waste gate mechanism and jobs a good 'un.
Also looking at the possibility of using the airbox off of something like a Subaru Impreza Turbo or Nissan Primera as these are neat flat boxes with loads of airflow. They can be fitted in almost anywhere.
Graham