This is the list of jobs and the order I did them in with parts prices.
Hope this helps anyone who thinks this is a large job. It is but by breaking it down into little sections it makes it easier to cope
Step order - 2 May 2008 with parts required.
Complete driveable Discovery 1 with 200Tdi £315 on ebay.
Solve water leak from rad top hose. Radweld in rad and tank- Water leak stopped
New radiator cap. 99p from Challenger 4x4
Remove Rad/intercooler. Disco/Done
Replace cam belt, gaskets and oil seals. 200 tdiCam belt kit/Done (£60 From Paddocks)
Remove exhaust. Done
Keep power steering bottle and pipes on engine. Yes, done
Remove anything in engines way. Yes, done
Remove all cables and pipes and label them all. Done 2 elec cables with connectors. Fuel filter and fuel return pipe
Remove floorpan and tunnel to get at clutch bellhousing bolts. No need
Remove bellhousing bolts. Done
Remove glow plug system. 1 cable removed.
Remove bonnet.
Remove 200tdi engine. Engine crane, removed (£200 for crane and load leveller brand new. Ebay)
200TDi outside vehicle.
Replace clutch and output oil seal. Done clutch plates and cover and output seal (£80 Paddocks).
Cleaned inside housing no oil leaks.
Mount exhaust downpipe - Used all studs, replaced 1 nut. Exhaust downpipe - £80 on ebay
Undo engine mounts. Use a long breaker bar and 19mm socket. New rubbers £6
110 2.5TD
Remove anything in engines way. Front slam panel and top rad mounts removed.
Remove front bumper
Remove radiator
Remove exhaust from lower joint Done
Undo engine mount lower bolts Done
Undo bellhousing bolts. Lift and remove engine rubber mounts. Drop onto chassis and undo all the bellhousing studs and starter motor wiring.
Remove all cables and pipes, leave loom in the bay Done
Remove fuel filter and pipes strap to engine Done
Remove PAS pump pipes from box leave on engine Done
Remove bonnet.
Remove TD engine. When out remove the engine mounts.
110 with no engine
Remove exhaust front section so it can modified to fit later.
Check gearbox rubber mounts OK.
Jetwash engine bay, check for welding and waxoil.
Clean bellhousing and check clutch fork for wear. Welded strengthening plate across back. All coeated in grease and grime and rust free.
Change Clutch slave cylinder . Lubed up ball joints with copper slip (£10)
Bleed clutch
Change gearbox oil for Difflock stuff. New Difflock gearbox oil. Looks like ATF- £45 for 3 litres
200TDi and 2.5TD out of vehicles.
Seal exhaust upper mounting and wrap with heat tape.Seal exhaust joint with firepaste and wrapped with heat wrap £12
Check engine studs for ones to be removed. 2 removed as they do not line up with gearbox bellhousing.
Check out for hole for dowel in gearbox bellhousing.No hole so dowel removed.
Flush out cabin heater. Done and clear
Tidy up engine bay wiring and axle breather pipes. Done
Transfer engine mounts to 200tdi using rear block mounts under alternator. Tighten nuts on mounts to block but do not fit rubbers. Done
Replace fan and PAS belts with new. New PAS and fan belt (£10 Paddocks)
Change clutch release bearing. Placed new one in
200TDi fitting.
Lift engine into bay and adjust for fit. Lower until starter motor wires can be connected.
Earth lead to chassis.
Lower engine and adjust until studs line up and push engine in.All studs done up. Need 3 lowest bolts tapping
Do up bellhousing studs.
Glow plug system leave as was, remember to only hold for 5 seconds.
Fuel stop solenoid.
Throttle linkage. Attached and adjusted.
Lift engine and gearbox until you can put in the engine mount rubbers. Lower engine onto rubbers and tighten.Done.
Remove 2 small lugs either side of the radiator frame
Cut down Radiator/intercooler lower mounts by 3cm - Welding
Weld 2 pins to top of rad for mounts. Done and painted with hammerite
Remove Tdi oil cooler pipes and get extended by 30cm Pirtek 30cm longer for £60
Fit oil cooler pipes into filter.Done
Check new rad/intercooler fits.
Flush out radiator and intercooler
Turbo heat shield.
Internal heater pipes- steel pipe feeds rear, pipe nipple feeds front. Used old ones out of Disco.
Swap Temperature sensor on front of engine and wire up.
Change alternator wiring. 2 thick brown cables to large stud.
Oil pressure sensor .
Mount Tdi PAS pump pipes. Fill with PAS fluid.
Replace water expansion tank from disco.
Mount exhaust front section. Will need adjusting to fit 110. 6cm cut out.
Mount disco fuel filter and pipes and heater system. Need 8mm and 10mm id fuel hose. £2 per metre from Camberley Auto Factors.
Connect up intercooler pipes. In at bottom out of top. Darton fabrications £120
Radiator hoses made up from all the bits. TD ones are long enough. Added section to expansion tank pipe
Mount rad/intercooler and upper bracket from disco or BBB
Fill up with water and anti freeze and radweld into rad. Anti freeze £5
Mount air filter and pipes- Mounted on RHS above alternator using Disco filter and holders.
Mount viscous fan.
Check water, oil, PAS levels .
Prime fuel system with hand pump.
Remove fuel solenoid wire and run on starter to prime fuel and oil sysytem.
Start and run
Move steering from lock to lock and top up PAS bottle
Replace bonnet
Replace bumper
