200 TDI Conversion (90)

Hey guys, I bow to your experience and wisdom!

Just about to put a 200tdi into my 2.5td 90. Just running past you guys a few questions on items that i think I still need to get!

I have purchased the new manifold pipes and also the intercooler pipes, do I still need:

1. Do I need a new power steering kit?
2. Water pipe kit
3. Temp Sender
4. Fan, existing one is tight fit.. thinking of just taking off half an inch to ensure it doesnt touch body


Appreciate your help!

Sorry guys, can i get away with using the resevoir and air filter from the 2.5td instead of buying a new one!

hey fella, just done all this meself today, but youve made it easier for yourself by purchasing the conversion parts so that will save some time.


1, you can mix n match the existing td and disco pipe work to sort that out, threaded joint to pump is female on td and male on disco so just swap this one over.

2, dont know if you can get that off shelf for conversion? but not that hard to fab yourself, just needs some extensions and alter the angle on bottom rad hose.

3,depends on how old your td is, mine was a turner rebuild jobbie and had the new type fitted anyway so just swapped it over.

4,yes fan is tighter than a nuns with the existing steering box, thinking about swapping mine for the box off the doner disco and make some room. alternatively eletric fan.

which resevoir do you meen? if water expansion tank then yes you can keep that in place.

you can use the air filter assembly from the td but it does make fitting lower intercooler pipe work tighter, but def doable, iv junked mine as iv got a k&n instead.

have fun with it matey, hope thats some help.

Much appreciated,....great advice!

I joined the Disco power steering pipe (pump end) to the TD pipe (steering box end) using a small compression joint.
I used the Disco air filter housing and made up a couple of little brackets to fix it to the inside of the wing.
I didn't swap the temp sensor over and it seems to be about right. I was prepared to change it if it was reading too high (Steve Parker sell both types as there are two different threads).
I've left the fan off for the time being and had no problems yet. At a later stage I may fit an electric fan with either a thermostatic switch on the water pipe or just a switch on the dash.

Ian.

no worries fella, hope to get mine finished today so any help i can give while its fresh in me mind

What have you guys done about the exhaust system? I Can't get the old 2.5TD exhaust to fit with an adapted down pipe, but the 200tdi defender back box will not fit the mount on the bottom of my defender?

The temp sender from the td will fit the 200tdi so everything matches.

I bought the exhaust downpipe off the chap on ebay - his is designed to fit over the TD exhaust. So I just cut the TD exhaust off and clamped the new downpipe over it.

What downpipe are you using?