200tdi 3 door Disco's (& other ramblings...) also '86 Ninety 200tdi hybrid...

decided it was time to remove the (aftermarket) clock as it was draining the battery


also fit the Lucas turbo / boost gauge I've had stashed for such an occasion


also decided to replace the horribly crimped terminals on the illumination bulbholder with nicer items..

now need to fit the 200tdi so the gauge can do something

Rich.

been driving the Ninety around & comuting so ~55 miles a day without issue....

so I've parked it up and will give it a good going-over as something is about to fail catastrophically


in other news, bought a Garret GT2062V turbo


(ebay, from a 2004 Audi A4 Avant TDI Sport MK2 with the 2.5L BDG code 161BHP V6 diesel engine) as...


I've memories of reading their compatablity with the 200tdi manifold bolt-pattern.


can confirm it will bolt to a Disco 200tdi exhaust manifold so hopefully will fit the Defender 'top-mount' turbo manifold

these have a vacuum actuator operate vnt ring so either I need to sort some electronics to controll this or find a suitable pressure operated actuator to replace it.

^^ this is irrelavent as I've not fitted the tdi engine in the Ninety so another 'one-day' project (was cheap)

more ideas & fiddlin to follow....

Rich.

Brought tears to my eyes - I had a disco exactly the same as J609MUT. I eternally regret having sold it. Now I have 93 200TDI 2 door and a 95 300 TDI five door that I am working on. I'll post my project in a day or so.

subject of J609MUT, J610MUT is on these forums....

https://www.landyzone.co.uk/land-ro...y-gradually-improving-my-daily-driver.344243/

subject of, I must get around to doing some Disco'ing.....

Rich.

minor update...


new tyres & 'old' D1 wheels for the ninety


full set (4) of 205/80/16 COOPER A/T3 SPORT 2, seriously smaller diameter and circumference to the previous 7.50x16 so maybe helpfull to the 2.5d pOwErHaUs


also, visited Farmfoods and captured 4 x 10Litre tubs of veg oil (2 x 10 Litre tubs for £25 so £1.25 / Litre) - obviousaly I'm NOT intending to use this as fuel

honest

Rich.

Zed. said:

minor update...

also, visited Farmfoods and captured 4 x 10Litre tubs of veg oil (2 x 10 Litre tubs for £25 so £1.25 / Litre) - obviousaly I'm NOT intending to use this as fuel

honest

Rich.

Click to expand...

But if you were, say, to be intending on using this as fuel - and of course you are not - how would you do it? Just spit balling, as the yanks would say...

Dave Sherry said:

But if you were, say, to be intending on using this as fuel - and of course you are not - how would you do it? Just spit balling, as the yanks would say...

Click to expand...

erm, open fuel tank cap, open veg-oil can, pour veg oil into fuel tank & drive

although I wouldn't use veg oil in anything newer than a 300tdi as they (newer) don't like it

allegedly of course

Rich.

Zed. said:

erm, open fuel tank cap, open veg-oil can, pour veg oil into fuel tank & drive

although I wouldn't use veg oil in anything newer than a 300tdi as they (newer) don't like it

allegedly of course

Rich.

Click to expand...

Ahhhh! that obvious? With diesel getting going up from stupid to stupid prices, might be the way to go!

okey, I'm fitting a 200tdi in the Offender (Ninety) starting tomorrow hopefuly and there was one item I've been searching for - the Defender 200tdi rad / fan shroud


couldn't find one in Newbury or locally - found this one on ebay and it was delivered today


it had a section cut off & re-fixed - easily tidied if needed but I'll look at that another time

anyway, 2.5d out tomorrow & hopefully the 200tdi in place

Rich.

more Diesel, Tesco £1.20 / L....


started dismantling the 2.5d before the 200tdi goes in (hopefully tomorrow?)


had a fight with the floorpans, 20 different fasteners and most rusted solid

more fun to follow

Rich.

Looking forward to seeing the write-up on this.

Knappster said:

Looking forward to seeing the write-up on this.

Click to expand...

Christ!

that means I've got to take loadsa photo's then

Rich.

Zed. said:

Christ!

that means I've got to take loadsa photo's then

Rich.

Click to expand...

No pressure!

okey, a few photo's


the 200tdi, out of the garage (it's still full!) and readied for action


new oilpressure switch fitted.


the turbo side showing a mostly complete heatshield - first one I've ever seen & I'd thought they were something of legend


jetwashed inside the bellhousing (& everything else) then new clutchfork / release bearing and liberal coating of cv grease where needed


image showing the fuel pipework.
will be changing to the newer (simpler) fuel filter setup...
the feed from tank / sedimenter to the engines lift-pump is common between the 2.5d and 200tdi engines so will stay, the return is a different matter....


so bought the 'proper' 200tdi (maybe 300tdi also?) return pipe @ great expense - from LR direct.

]
BUT.....

there was a problem.......




different threads...
guessing imperial on the '86 Ninety & metric for the Bosch pump 200tdi

so, I've refitted the origonal return pipework onto the tank (untill I get a suitable stub or metric 'nut / olive' to remedy) and bodgedcut the pump end and TEMPORARLY joined onto the pump with rubber fuel hose / pipe clamps


looks like this

Annoyed as I tried to do this properly but failed due to a thread missmatch that I couldnt combat with the contents of my workshop

anyway....

more to follow....

Rich.

more that follows


nearly in the bay.


getting closer....


oooooh!


it's in, straight on the gearbox / input shaft & a little jiggling for the (new Genuine LR) mount rubbers to fit the chassis

about this time was dinnertime so bonnet on & a cuppa.....


then the saga of powersteering....

everyone says that a disco pas box fits...

it does BUT nobody mentions that the non-pas box has (4 off) imperial bolts & nuts securing ot to the chassis whereas the pas box uses METRIC bolts screwed into the casing
need to find bolts now (M12 x 90mm long I think)

also, disco & Ninety / defender steering arms are interchangable


pas pipework fitment fun - I'm playing with the pipe routing to get a neat fittment across the crossmember....


and failing


more tangles! the air / oil cooler was a temporary fittment to run the engine on the floor - 1/2"bspp threads on the engine pipework.


fitted a new / aftermarket 200tdi type throttlecable & spent ages trying to route it neeatly


theres more fun lurking on this side


starting to look more complete...


started playing with the intercooler & rad hoses....
I'd bought new 200tdi rad hoses (& they SHOULD fit) and managed to buy a new / genuine LR top intercooler metal pipe (huge cost from LR Direct) but need to make the lower pipe...

subject of rad-pack, need to fit one


BUT theres another issue...

I bought a 200tdi Disco radpack (£30 in newbury) as they're cheaper & easier to find than the Defender 200tdi type....

but they need altering

Call for the Anglegrinder


side mounts trimmed & removed then it fits in the hole


but now it's too tall
I'm going to remove the channel-shaped risers & hopefully it'll be correct - I've seen some people alter the chassis's mounts to lower but I'm going to fettle the rad frame.


bought a 200tdi Defender turbo - airfilter hose....
I'm intending to use a spare 200tdi Disco airfilter case in the 'standard Defender position so this should join the 2 - need to sort mounts for it I suppose


curiosity had a poke at me, would the bonnet close???
yes but it rests on the turbo heatshield


another view...

the Ninety has the strengthening ribs fitted to allow carrying a spare wheel on the bonnet - I was sorta expecting these to clash....


thats my progress so far, I have found the front axles number - will check the heratige cirtificate but dont expect it to match on this squaddy-charriot (TUL,FFW)

more tomorrow after I've visited Foundary4x4 to hopefully get some bits....

Rich.

Looking good! Great write-up too!
But one of the Land Rover curses. A mix of metric and imperial threads…

Knappster said:

t one of the Land Rover curses. A mix of metric and imperial threads…

Click to expand...

Yup

somewhat annoying

Rich.

test-fitting rad-shroud / top hose & intercooler pipe to gauge the possibility of D1 200tdi airfilter fitment.
pair of D1 @00tdi 3 door (non-sunroof) in background for effect


another view - looks promising


drivers side looks sorta empty @ front

more to follow....



like trying to fit the downpipe now the engine is in

Rich.

Looking good!

more wombling around today

went for a roadtrip in the t4 van heap to Foundary4x4 - my Local parts supplier (~50 miles away) hunting for goodies...

they dont do counter-service but 'collection' or postage, somewhat different to my last (pre-covid) visit

they were helpfull & sorted a few bits so not a wasted journey

way home the long / slow way over the mountains so probably 100 miles return

then to Halfords to sort a replacement 17mm ratchet-spanner and bought a few other spanners like 33mm open-ended (£9.99?) and a 33mm socket - both to tighten the pas steeringbox drop-arm nut


played with the pas pipework and routed them accross the crossmember as best I could see, probably completely wrong but hey-ho


the steeringbox end, 2 hoses & 1 metal hard-pipe.


pump end...


this is an important photo as it shows (sorta) the area that the lower intercooler pipe needs to rum, I've spread the pipes to give more clearance - but it might not be needed?


the routing across the erm, crossmember
theres 2 plain holes in the crossmember's vertical face and I'll fit rivnuts to secure the pipes...

more faffin tomorrow...

Rich.