200tdi conversion

yeah i looked at the steve parker stuff buts it seams alot more expensive than everywhere else, be nearing on £190 from there but i prefer the blue silicon pipes to the plane black from him. it worth me getting a slave cylinder? easy enough to change?

Not if yours is ok.



How mine looks

i like that, looks like a bit more thought has gone into it

Used the brackets from the disco for airbox and fettled them fitted to wing. There are several pipes used. I am going to make a pipe out of same as that intercooler pipe so very few joints.

oh yeah i didn't even notice the air box lol. I've seen a picture where the pip runs sort of round the back of the engine to the air box at the other side. Sure a few people would buy a pipe if you get one made to fit

Haha ok.

Might see what I can sort out

Just picked up the disco, starts first turn of the key. bit of a leaky rocker cover gasket but all looks good apart from that.

Removed the engine from the disco yesterday with a little help from the forklift at work


Also made myself a little cradle to sit it in, save my buying and engine stand


all went well except i managed to damage the rad slightly hopefully not too bad.

On the little guide thing, it say extended oil cooler pipes? dont think i asked already but do i need to buy them or just extend existing?

You can get away with swopping the oil filter housing off td and using the old oil pipes. Need to make sure you swop the brass fittings from td rad onto the disco rad. Is your td rad good? Some people leave that in and fit alternative intercooler.

Ah is see, i thought thats what you ment before but i thought i better ask again. the td rad i fine, think i might just stick to the disco one for now, fingers crossed it will be alright haha. Thanks for your help again, if all goes well it will be going in my fender next saturday. hows yours going? thought anymore about making a pipe for the air box?

Yeah. Am going to do it. Just thinking on how I can anchor the pipe so it runs along the chassis. I can see it just being uber huge cable ties and a pad of the thick closed cell foam I have. Will measure the pipes this weekend.

Just realised the disco had air con, how hard is this to fit to the fender? Guessing its best to just take the pump off while I'm doing the belts?

Anyone know a way to break the crank bolt off while the engine is out? Obviously jut turning at the moment

Little update engines in and she's alive! only problem is where I joined one of the power steering pipes it keeps blowing apart :/ any ideas?

Ptfe tape? Which pipes did you use. Old ones or new ones. If new try the old ones. I used the ones that had originally been with the steering box

I used a mixture of both, read it on the guide thing I printed off. Obviously it being high pressure fuel pipe isn't enough haha. Think I will get pirtek to make me some new ones. You know if they come out to you? Seen the vans so I assume they do. What did you do with your exhaust? I had to cut mine haven joined it up properly yet but it doesn't seam like a great join

Good to see another Tdi conversion. Did you retain the original TF box and bell housing?

Yeah I did, seamed the easier way of doing it. Glad to finally hear it run, first time I tried I just got click, quick swap of the starter motors and it went first time

Nice.

Did you tap and bolt the bell housing on the lower studs? We found out that on a Tdi the lower bell housing bolts only reach as far as the cover not into the block. This means the weight of the engine and box could cause movement and cause the crank seal to fail and leak.

Sorry not a very good pic, but you can just make out the allen bolts at the bottom:

No I didn't we had a good fixing all the way around the housing. Obviously we used the td housing which was bolted to the block and torqued up correctly