Converting 1985 LR90 2.5n/a to Disco 200tdi

derodster · Apr 6, 2021

Hello, as the heading says that's the plan, however....
I thought it might be a good idea to use Defender 200tdi inlet & exhaust manifolds to get over that upper exhaust pipe problem.....it wasn't...
Because now I have a very slippery belt setup on power steering pump. Ideally I will have to move ps pump back and alternator forward...problem is how...
I thought it might be easier to put Disco inlet & exhaust manifolds back on and go find the right brackets for alternator and ps pump.

A photo might explain my current setup

So I guess the question is...where might I buy these manifolds, if still available !!!

Thanks for reading
R

tottot · Apr 6, 2021

It is a good idea to stay with the defender exhaust set up as you can still use the standard down pipe which is a hell of a lot cheaper than a Steve Parker Disco to Defender conversion pipe. Plus you have to purchase a manifold.
Your setup was never going to work, not enough contact with the crank pully as you know.
On the Defender set up it is the inner groove of the crank pully that drives the water pump and alternator. I recon the Defender water pump pully has a deeper inset for the groove to line up.
Power steering pump has a short belt direct from the crank.
Some mount alternator on the o/s of engine where air con pump would have gone.
It may be possible to move alternator back some as there is a spacer there [ I think]

derodster · Apr 27, 2021

tottot said:
It is a good idea to stay with the defender exhaust set up as you can still use the standard down pipe which is a hell of a lot cheaper than a Steve Parker Disco to Defender conversion pipe. Plus you have to purchase a manifold.
Your setup was never going to work, not enough contact with the crank pully as you know.
On the Defender set up it is the inner groove of the crank pully that drives the water pump and alternator. I recon the Defender water pump pully has a deeper inset for the groove to line up.
Power steering pump has a short belt direct from the crank.
Some mount alternator on the o/s of engine where air con pump would have gone.
It may be possible to move alternator back some as there is a spacer there [ I think]

Thanks for that Tottot,
Yes I think I may be able to move the alternator up and forward and then i hope to try move the ps pump back and as you say on it's own short bwlt

time will tell, lot's done, more to do.

lynall · Apr 27, 2021

I would do pas belt as std ie belt from crank straight to pas pump, even then it can be a pita!
Alt more tricky, I have my series alt mounted high where the disco a/c pump would go, belt wrap not perfect around the water pump, in fatc it literally skims the pulley but its been on there a few years now.
Only pics I have sorry!

derodster · Apr 27, 2021

Thanks for those.
I did think i might try the alternator up there but i will have to look at the mounting of the ps pump too
i have been gathering photos from various other places and trying to decide what bit and pieces i need to make it happen
Am getting there, albeit slowly ;-)

zeaphod · Apr 27, 2021

Just my 10p worth, i have changed my 1985 na to a disco 200tdi. If you stick with the disco manifolds, its easy enough, and there's a guy on ebay who sells the conversion downpipe for much less than steve parker. Make sure you have a good look at the glencoyne engineering website for the process, and have a look at a couple of my posts for the fiddly bits. The NA exhaust makes excellent intercooler pipes.

lynall · Apr 27, 2021

More pics, cannot for the life of me find one of it all installed.

zeaphod · Apr 28, 2021

A few shots of my install:

[GALLERY=]

[/GALLERY]

derodster · Apr 28, 2021

they are great to have, thanks
I am working towards putting the alternator as in yours , but I did wonder about the ps pump
I may not have room there as there are pipes in situ, but then again !!!
is the pale thaqt the alternator is on a part or did you make it ?

derodster · Apr 28, 2021

or maybe it is the ps pump on the plate with the alt above !!!

flat · Apr 28, 2021

Why can’t you just run the alt and pas pumps as designed on the tdi? Have you put your NA crank pulley on the tdi?

srandard defender 200 setup is for the rear pulley on the crank to drive the alternator and the water pump then then front pulley drives the pad pump only.

will take a photo of my 200tdi setup in my previously 2.5na 90

flat · Apr 28, 2021

Not a great photo as I can’t faff with taking the fan shroud off right now but you can *just* see my belts

Converting 1985 LR90 2.5n/a to Disco 200tdi

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