200 tdi porn

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dr pepper said:
Cheers fenners,

that doesnt look so hard, I dont have any 1 bi 2, but I've loads of flat bar, a chunk of 6mm bi 50 should take care of that.
I nearly bashed the crap out of mi front panel, but looking at yours its not necessary.
I did have to cut away a load more of the battery tray, as the oil cooler pipes would not go in, looks like you have too, did you have some more pipes made up or re they the originals, I think I might just be able to get them to reach original lengths.
I wanted a bit of reassurnace with all the work I've put in so I lashed mine up today and had her running, sounds cool, nearly as good as a common rail, cant wait to go for a razz, wont be doing any off roading straight away, theres no clearance under mi exhaust for now.
Click to expand...

The battery tray had to go, but the original Disco oil cooler pipework just about fits - I'll need to fabricate some supports for it though. I wouldn't have thought you'd have enough room to put the intercooler where mine has gone because all those ancilliaries on the nearside of your engine are taking up a lot of space. I think that putting a 300tdi intercooler infront of the main radiator would be a better bet for you. I think you might be able to mount it by drilling a couple of holes in the top of the front X-member and another couple in the slam plate of the front pannel, for the locating pegs on the intercooler.

Better than common rail I'd say - no ECU to go wrong when wading.
 
TheSmiths88 said:
Yeah - just! Between the rad and the motor - a Pacet slim 'leccy one. There was no way the viscous fan was going to fit.

I'm very slightly in love with your air filter mounting bracket. Brunel would have been proud.
Click to expand...

Yeah I might have got a bit carried away with that filter bracket... One of the boys in work said the filter looked strong enough to support the weight of the whole engine!
 
I'll bear that in mind, messin wi it last night though, I think there might just be enough space to have it like yours, the ancills are well back, speaking of which if I lean on the engine while its goin the alty rattles on't chassis, so I need to address that, I was thinkin if I make a extension braket for the altys single lug mount that'd get me away from the chassis and may also negate for the need of the steering pump as an idler.
The turbo makes interesting noises without any pipework on the induction side, not a good idea I know but nothing got in there whilst I was playing 'cept for a moth, which isnt gonna fly again.
 
199.jpg


199_2_.jpg


You were right then fenners, there is a shortage of space, even width wise, did you not have issues with the steering bellcrank on the top of the relay clouting the rad?.
I can get the cooler in front of the rad with a slight overlap, and a very tight fit for the leccy fan, the issue I have is the lower water pipe, its right up against the steering pump pulley, the other issue is the alty smacks the chassis when you stop the motor, so I'm thinking of removing the steering pump and shifting the alty, this'll give room for the rad pipe and lift the alty away from the chassis (to take up exra length without the pump pulley), it'd jsut be a bit tricky leading the pipe up and behind the alty.
Is there a right and wrong way up for the intercooler, I'd have an easier life if I was to turn it upside down, the pipes 'd point just the right way then.
 
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dr pepper said:
You were right then fenners, there is a shortage of space, even width wise, did you not have issues with the steering bellcrank on the top of the relay clouting the rad?.
I can get the cooler in front of the rad with a slight overlap, and a very tight fit for the leccy fan, the issue I have is the lower water pipe, its right up against the steering pump pulley, the other issue is the alty smacks the chassis when you stop the motor, so I'm thinking of removing the steering pump and shifting the alty, this'll give room for the rad pipe and lift the alty away from the chassis (to take up exra length without the pump pulley), it'd jsut be a bit tricky leading the pipe up and behind the alty.
Is there a right and wrong way up for the intercooler, I'd have an easier life if I was to turn it upside down, the pipes 'd point just the right way then.
Click to expand...

I just positioned the main rad far enough over to the nearside to avoid problems with the arm on top of the steering relay. Overlap between the radiators should not cause a problem as most car manufacturers do it that way. I've turned the intercooler upside down on mine and it works just fine. It should be easier to do the turbo pipework if you can work out a way of removing the power steering pump and repositioning the alternator.
 
didnt know the 200 was single groove, ayways looked into the positioning, and I'm gonna make a bracket and put the alty on topof the injector pump, and do away with the steering pump, fan idler pulley and the tensioner, and still be avle to use the original fan belt.
 
Well the steering pump pulley gets right in the way so I removed it and moved the alty to above the pump, it runs ok like this, but the run of the belt which is standard tdi is about 24" and flaps a bit when cold, was wondering whether this'd be ok or not.
 
in case you're not aware, the 200Tdi crank pulley will hit the front axle tube when traversing the rough stuff

Picture005.jpg


Picture009.jpg


my solution
Picture010.jpg


i even turned a couple of mm off the front pulley lip
Picture012.jpg


i started with about 1.5 - 2" of clearance, after removing the rear groove i've nearly got 3" i reckon
 
Mine wont, its a 300 and the crank is longer than the 200, and therefore is out of the way, the axle hits the bumpers first, the axle oil breather gets fairly close.

I must admit I'm having trouble finding a place for the rad, everywhere is in the way of something else, the fan belt is now in the way of the bottom hose, its touching the boss for it.
 
I think that's a Defender front pulley. The discovery ones have only 1 groove and they are made of pressed steel. It looks like mine has just about got enough clearance for the front axle to hit the bump stops, but it's a bit hard to tell exactly because the front axle moves backwards as the suspension compresses. I'm planning on fitting 5mm spacers above and beneath the rubber engine mounts to lift the engine 10mm, and I might put some 10mm spacers under the bump stops too.
 
if it was a Defender pulley then it was retro-fitted as i pulled this engine out of a Disco myself...

the spacers on the mounts are worth a try, had a glimpse myself with that thought in mind
 
Rover were known for using odd bits, so its possible it had a diffo pulley.

Thats a good idea about packing up the suspension buffers, My axle would have to move laterally about an inch to be an issue, I hope I'm right in assuming thats unlikely.
 
Well we'll see, if the pulley looks like its done a round with tyson, then its time to address it, anyways I think I'll lose the axle breather doofer first.
 
dr pepper said:
anyways I think I'll lose the axle breather doofer first.
Click to expand...

i fitted extended axle breathers (robbed them out of the disco) it didn't touch the banjo and bolt, it just cut the plastic tube in half where it followed up the side of the diff housing, so you'll miss the actual breather by a good margin...

i've now routed the breather up the nearside wing so it'll not get touched again
 
Thats good advice, I didnt know the disco had a remote breather.

Is that a myford further up, I have a super 7 lying about my shop.
 
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