How to - Land Rover 90 TD to Discovery 200TDi Engine Conversion

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well i found its no different to me didnt notice the swap round .but that might be that the gearbox is not as far back as some of us fit them..the checker plate box will do for now but think a trip to the scrap yard for a nice center box of something will do nice :)
 
300 is straight forward swap just needs new engine mount welding on at the front. Turbo is in same place on defender and disco so you don't need to swap the exhaust downpipe over. You willl need to fit the flywheel housing off a NA or TD engine to the 300 to get the LT77 gearbox to mate up.

Here's the definitive guide Landrover 110 engine page
 
redhand said:
300 is straight forward swap just needs new engine mount welding on at the front. Turbo is in same place on defender and disco so you don't need to swap the exhaust downpipe over. You willl need to fit the flywheel housing off a NA or TD engine to the 300 to get the LT77 gearbox to mate up.

Here's the definitive guide Landrover 110 engine page
Click to expand...

Which I knew that before fitting a disco 200 :doh:
 
Hi Richard - Excellent write-up, many thanks for taking the time. I've just started my conversion (engine came out this morning). I've got the same exhaust connector as you from the chap on eBay, which looks to be nicely put together. How much trouble did you have connecting up this to the rest of the 19J exhaust system? Was there much fiddling about?
Second question is - what did you do regarding the top of the radiator? I've read Patman's great thread and he welded some extra bits on and used the TD radiator top piece - did you do the same?
Thanks in advance! :)

Ian.
 
instantsquid said:
Hi Richard - Excellent write-up, many thanks for taking the time. I've just started my conversion (engine came out this morning). I've got the same exhaust connector as you from the chap on eBay, which looks to be nicely put together. How much trouble did you have connecting up this to the rest of the 19J exhaust system? Was there much fiddling about?
Second question is - what did you do regarding the top of the radiator? I've read Patman's great thread and he welded some extra bits on and used the TD radiator top piece - did you do the same?
Thanks in advance! :)

Ian.
Click to expand...

Hi Ian

Glad you're finding the write up useful - I tried to do it from a noddy DIY perspective (as that's what I am!) rather than a mechanic so hopefully it all makes sense :)

1. Exhaust - The downpipe is a different bore to the old TD system but luckily I had some pipe around that I could use as a reducer. The old TD system was on it's last legs though and I recently fitted a complete new 200TDi (Defender) exhaust. Again, this wasn't a straight fit to the downpipe so I used some steel flexipipe welded onto both the downpipe and system so there is some movement and flex for off road work.

2. Radiator - Using the 200TDi radiator I lowered it by cutting and rewelding the mounting brackets 3cm lower. I wanted to keep the existing TD bonnet stay etc which are connected to the top brackets so I kept these. I was going to reweld some pins on top for the rubber mounts but it sits snug enough anyway without them and I've not had a problem.

Hope this helps

Richard
 
Wow - that was quick! Thanks for the reply. Good news on the radiator - sounds like a plan. I'll have to go on the scrounge to sort the exhaust out I reckon.

Ian.
 
hi when i did mine i had a problem with the disco down pipe they only have 2 bolts to connect to the rest of the exhurst.the rest of the TD exhurst had 3 bolt connection .so i had to cut the end of the disco down pipe off and cut the end off the TD down pipe with a inch of rim to slot into the larger disco pipe and then i knock't the smaller TD pipe into it and welded round it for a strong fit.... its working a treat best thing for my 90 it make light work of a steady 70 now on the moterway and you can hear the cd player now ..ha ha!
 
Finally, finally started my TDi conversion today after much dilly-dallying.

Got the TD out of the 110 without much bother, got it hanging from the hoist. Now, I need to remove the flywheel housing to put it on the TDi, but which clutch will I put into the 110? The one from the TD or the one in the TDi Discovery? Also, when buying a 'rear crankshaft oil seal', I need to buy one for a Disco TDi lump, correct?

Cheers :D Will have some piccies up at some point.
 
Langers said:
Finally, finally started my TDi conversion today after much dilly-dallying.

Got the TD out of the 110 without much bother, got it hanging from the hoist. Now, I need to remove the flywheel housing to put it on the TDi, but which clutch will I put into the 110? The one from the TD or the one in the TDi Discovery? Also, when buying a 'rear crankshaft oil seal', I need to buy one for a Disco TDi lump, correct?

Cheers :D Will have some piccies up at some point.
Click to expand...


Normally the clutch plate is from the vehicle the gearbox was from (coz it has to mate with the input shaft) and the Clutch assembly is from the vehicle the engine is from (coz it has to mount on the flywheel). That is, of course if the clutch assy will take the clutchplate ;).

rear oil seal to match engine.
 
The Mad Hat Man said:
Normally the clutch plate is from the vehicle the gearbox was from (coz it has to mate with the input shaft) and the Clutch assembly is from the vehicle the engine is from (coz it has to mount on the flywheel). That is, of course if the clutch assy will take the clutchplate ;).

rear oil seal to match engine.
Click to expand...

Ok thanks. So that means I have to get the clutch plate out the 110, stick it into the clutch assembly from the Disco, and then bung the whole lot into the Tdi... I think? What exactly is the clutch assembly? :confused:
 
shouldn't the crank oil seal be the same for any 200tdi?

at least i hope so! just ordered one for mine yesterday and didnt notice anything about specifying the vehicle its from..:confused:
 
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