200Tdi Conversion

2.5td -> 200tdi.

Can some give any advise on how to do the bottom hose + which header tank to use?

I how tried offering both disco an td hose up but neither look like the will work even using extension pieces. Am I missing something?

Cheers Ian

have yer looked in patman's write-up fred?

Have yer looked on ere Ian...
Putting a Disco 200TDi engine in a 90 - LR4x4 - The Land Rover Forum
Not sure if i PMd you the link the other week?

Treworgey 90 said:

have yer looked in patman's write-up fred?

Click to expand...

no yet, i've read it threw before and cannot remember seeing it, will look again tho

odenne said:

Have yer looked on ere Ian...
Putting a Disco 200TDi engine in a 90 - LR4x4 - The Land Rover Forum
Not sure if i PMd you the link the other week?

Click to expand...

its not covered in that link thanks anyway

There's a bit in there which says that all the radiator hoses were made from bits they had available from both engines so one of them should fit!

when i did my 300 from a disco i made all the water hoses reach. I used the tdi bottom hose to the old expansion tank, with a joint in it to mek it fit over the hole, and i used the NA top hose, cut short to reach the rad at the right angle.

odenne said:

There's a bit in there which says that all the radiator hoses were made from bits they had available from both engines so one of them should fit!

Click to expand...

Found the line, its very vauge on how he did it.

cheers Ian

I have a disco 200 in mine, but the engines moved foward so the hoses fit. Is it possible to move the rad back by fabricating some mounts?

its much easier 2 make the pipes reach.

Ok. I dont know how far out they are. My engines about 15 cm foward I think. To move the radiator would only take a couple of plates and a little welding, and you could keep the origional pipes as they are, so it looks tidy. Just a thought.

Well...

If you are putting the TDi onto the existing gearbox, the engine sits in the same place as it did before - the blocks are all basically the same, they all bolt to the 'box in the same way, etc.

The mounts gotta be moved cos the TDi engine mounts are bolted further back on the block.

The pipework problem is'cos in the disco the rad is a lot closer. Also, cos of 200TDi's being a pain, the intercooler pipes are all odd too.

Other problem is, at least with my 300 it is, the radiator outlet pipe is on the same side as the inlet, whereas the old one was on t'other side. In a way i do agree, moving the rad back will make it look tidier, and make the intercooler pipes much easier to fit. My main concern would be bolting the top bit to the wings - you would have to make some custom brackets, as the wing inner panel, i think, won't go back far enough.

The old coolant pipes, with a bit of bodgery, will reach though, but you will probably need to replace one of the interior heater pipes - i still gotta do that bit.

I wish LR kept the mounts in the same place... so much easier...

boydy1989 said:

The old coolant pipes, with a bit of bodgery, will reach though, but you will probably need to replace one of the interior heater pipes - i still gotta do that bit.

Click to expand...

You had batter get that done, winters a'comin!

boydy1989 said:

I wish LR kept the mounts in the same place... so much easier...

Click to expand...

Yea same, on the 200tdi, you dont have to mave any mounts, it goes strait on the mounts and gear box of a 19J as is. The reason mine are moved is because i also went for the disco gear box, which means cutting holes in the floor and bodging an exhaust pipe, though the pipes do then fit.

I used the Disco header tank and the longer Disco lower raditor hose. I used a 10cm length of metal water pipe from the TD engine and cut another 20cm length of header tank hose from the TD lower radiator hose and sliced them together to reach.
You can just make out the jubilee clips on the header tank hose in this photo.
Grippa mounted the Disco header tank so it sits quite high in the bay but it is well below the bonnet.
PM me if you want any further help.

thank pat! have you got any more piccys of the pipe?

on mine i used the td bottom hose to give you the bend round the steering box from the rad and then used the disco hose from the waterpump and to the expansion tank and joined them with some metal pipe. put both pipes on roughly in position if you can, you will see where they meet up and where you will need to cut and sleeve them. They will need joining somewhere at the side of the steering box. Also use the disco header tank, had problems with mine forcing water out the cap on the stock td tin header tank. no problems with the proper tdi one.

Thats brilliant nizzer, I will try that way, sounds good.

boydy when you did your conversion, where did you aquire your exhaust from as its no too good to use the existing N/A exhaust right?

i took the disco downpipe, de cat it, welded in a section to make it a bit longer again, and then mated it to a 300tdi system i bought on ebay

Itll probably be for sale also soon, if you want it. Has only been on for a few weeks, want a side exit one though.

Search for 300TDi upgrade - i have a thread showing everything i have done.