200Tdi upgrade begins

Patman1200 · Jul 30, 2008

Thursday should be OK, I'll check with 'er indoors. Might be a bit of a squeeze getting past all the landys now

Patman1200 · Aug 1, 2008

I got all the pipework fitted last night. Stuck the rad/intercooler in, filled up the water, PAS and oil, attached the battery then though, why don't I test the electrics to make sure it's all OK.
So I removed the starter solenoid then turned the key and it span over!!
I span it over until the oil pressure light went out to make sure that the oil pipe to the turbo was full. Then I though........ wonder how easily it will start??
So stuck the fuel solenoid lead back on turned the key to glow for 5 seconds and hit the starter...... instant noise! STARTED FIRST TIME

Wow, much quieter than the 2.5TD and no smoke on starting.
Stuck it in gear and moved forward a few feet to make sure the new clutch and slave were ok. All ok at crawling speed. I changed the gearbox oil with that expensive (£45) Difflock stuff and the gearbox at cold is very much slicker and easier to move around. Wether this is due to just having new oil in or that fact that it is the Difflock stuff I cannot say.

Only issues seen were the lower water pipe to the radiator is constricted too much and leaking so I will have to cut that pipe back a cm or so and the heater matrix is ****sing water, so a new one of those is needed before winter.
Also got to put in the air filter somewhere/somehow.

Test drive Saturday afternoon when I've got the front end back on.
YAHOOOOOOO

Piccies below.
Welded up exhaust made to fit

Rad goes in nicely

Lower intercooler pipe from Darton Fabrications. The 90 degree bend needed cutting back so it wasn't folded over by the inner wing

Lower water pipe that is folded over by the angle it takes

Upper rad mounting from the TD attached to the 200Tdi rad with new welded on posts and painted a rather nice Hammerite hammered grey

De engine, she is running boss!

I'm a very happy bunny

The Mad Hat Man · Aug 1, 2008

where the pic of the noo proud owner then?

Patman1200 · Aug 1, 2008

Didn't want to spoil the happy event with a view of my ugly mug

TheVengefulElephant · Aug 1, 2008

woo! Good job pat

I'll wager you're dead eggsited about taking her out fer a proper test run

Patman1200 · Aug 1, 2008

Yup looking forward to the extra power. Might even be able to get up the hills at more than 20mph!

MadBikerGoth · Aug 1, 2008

Patman1200 said:
Didn't want to spoil the happy event with a view of my ugly mug

I second that!

MB x

choppa · Aug 1, 2008

Patman1200 said:
Yup looking forward to the extra power. Might even be able to get up the hills at more than 20mph!

you will be amazed at the difference , well done that man ...

Patman1200 · Aug 2, 2008

I've got it all done (well apart from final fettling like tapping 3 new stud holes in the bottom of the bellhousing and a new heater matrix)
And I've taken it out for a slow run 40mph max. She's nice when the turbo comes in and the gearbox is very smooth.
Also had time to mount the Tdi airbox above the alternator and it gives easy access to the oil dipstick, PAS bottle and water washer bottle.

Going for a proper run tomorrow but for now enjoy some photos.

Le fin

choppa · Aug 2, 2008

good on yer fella , good work ..... i know the feelin well and it just gets better from now on.....

boydy1989 · Aug 3, 2008

Mr Patman Sir...

once more an excellent thread! What did you pay for your donor disco, and what should I expect to pay for one thats going the same way? Cos now i've seen it done in piccies, i want one too! Thankee

Patman1200 · Aug 3, 2008

I got my Donor Disco "Dento" for £315

and he delivered it to me for nothin

I shall be uploading my spreadsheet of jobs I did, the order I did them in, parts needed and the cost of the parts some time soon. This is the way I did the conversion and due to the very nature of Land Rovers every one will be different and probably require different parts.

boydy1989 · Aug 3, 2008

Sounds good to me! I think i have just picked up me a 300tdi for £350 too, all in a disco to nab any parts off too. Ill be interested in that spreadsheet too!

Patman1200 · Aug 4, 2008

Went out for a longer test drive Sunday morning to make sure nothing fell off, smacked into somthing else or otherwise could destroy the hard work.
Wow, lots more power. On the sttp hill where my TD could barely get make it to the top at 30mph in 2nd the 200 keeps pulling up the hill at 50!
Top test speed 70mph without trying. Cruising without effort at 60 and even able to OVERTAKE!!
It's like driving, dare I say it, a modern car!!
Absolutely worth removing a working TD for a 200TDi.

Just got the last bits to do like ensure the viscious fan doesn't chop the lower water pipe up and hit the PAS unit casing and cover any pipes and hoses to stop chafing.

It's back on the road!

The Mad Hat Man · Aug 4, 2008

chances are, Pat - you wont need a fan at all - bigchap runs his in France without one, and my electric one hardly ever comes on.

yu gonna change you name to "Gonzales" now?

Patman1200 · Aug 4, 2008

Very true but sods law also dictates that if I don't bother it will overheat. The temp gauges runs at 3/4 with the fan in. The rad is due to be replaced sometime in the near future as all the fins are like rice paper and the heater matrix is not connected so all of these will stop the cooling effect.
For the miniscule amount of power that a working viscous fan uses to aid air circulation I'll keep it in until I can get some 'leccy fans for less than £20

It'll be coming on the BBQ!

The Mad Hat Man · Aug 4, 2008

sound move - wot with an iffy radiator.

Patman1200 · Aug 4, 2008

You have totest drive it somehow.... and how better than to destroy it over the rocks, through the thorn bushes and against the trees on the lanes. I will have the boot filled with BBQ and all the spare left over bits from the engine upgrade just in case!

Dorset VogueSE · Aug 4, 2008

Well done Pat, enjoyed readingthis thread an will see you on the BBQ. Don't worry about the rad too much thou, yours is in pristine condition compared to mine - You'll see.

Patman1200 · Aug 4, 2008

Speedy Gonzales? I'll have you know I drive my Landy in a responsible and caring manner..... on my bikes though that is a different story.
So to any Landy drivers who use the M3 northbound inna mornin' Sorry!
And everyone else, nah nah na na nah

200Tdi upgrade begins

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