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

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It may be worth taking the gearbox out, attatching the whole thing together, then putting it in. Thats how mine was done.

Not an ideal solution but if you can't get it to fit one way..try another.
 
Fit 3 lengths of threaded bar to the bottom holes in the block then slide the gearbox over the threaded bar. This ensures that the box is lined up properly with the mainshaft sproket also make sure bush is inplace and that the seal is on square,
 
Update - it was a matter of taking the engine mountings off completely, (which I'd been advised not to do) and then the usual shaking and wobbling it home!
An early set back was my local independent Landy place gave me the wrong mounts and despite my insistence were adamant they were the correct ones for anyone changing a 2.5 n/a to a 200TDi - (turns out they were for 300TDi on a later vehicle anyway apparently I'm told - square shaped rubbers) and a new set of my old ones was what I needed - which is actually what I asked them (the round ones) to get me - but one of the staff, on hearing I was doing the upgrade thought he knew better and got me the other ones! When I went to collect them insited they were correct and what i really needed. Trying to help, but in second guessing me wrongly, set me back by a week. I won't name them as normaly they are very helpful, and anyone can make a mistake, - but it caused me no end of problems to be without transport an extra week.
I think what I've learned is that sometimes you have to question what "experts" tell you - this guide on here was excellent help though, and the only duff info I've been given has been from people I've spoken to in person!
 
Update - it was a matter of taking the engine mountings off completely, (which I'd been advised not to do) and then the usual shaking and wobbling it home!
Click to expand...

for me i removed the drivers side rubber mount completely, then jacked up gearbox slightly and slid engine in, tightened up bell housing then used hoist to lift drivers side mount as much as possible and insert rubber

this was so easy i even decided to leave one of the little pivoting things off the clutch fork so i could do it all again! :doh:

iv a question as well, i have my 200tdi in which is replacing a 2.5 petrol. my pas pump connections are a little different, the high pressure side bolt thing is of a different diameter to the petrol one, i dont have the donor disco i only have the engine! does anyone know the part number for this? although its may be easier to find it in a scrappys, anyone else came across this problem??
 
Hi Guys

Not been on Landyzone for a while so only just caught up with this thread.

I had a nightmare getting the engine back onto the box too as it just didn't seem to line up. I could get one side all lined up and bolts in etc but would then end up with an inch gap at the other side that just wouldn't close up. I definitely didn't have the rubber engine mounts on though which gives more room. In the end I got mine lined up by jacking up the gearbox end. If I did it again I'd definitely use an adjustable engine lifting bracket!

Really glad people are making use of the guide I put together anyway :)

Cheers

Richard
 
richardjeaton said:
Hi Guys

Not been on Landyzone for a while so only just caught up with this thread.

I had a nightmare getting the engine back onto the box too as it just didn't seem to line up. I could get one side all lined up and bolts in etc but would then end up with an inch gap at the other side that just wouldn't close up. I definitely didn't have the rubber engine mounts on though which gives more room. In the end I got mine lined up by jacking up the gearbox end. If I did it again I'd definitely use an adjustable engine lifting bracket!

Really glad people are making use of the guide I put together anyway :)

Cheers

Richard
Click to expand...

No, thank you sir - I used it from start to finish, literally read it word-for-word - it saved me a lot of time.

:D
 
Langers said:
No, thank you sir - I used it from start to finish, literally read it word-for-word - it saved me a lot of time.

:D
Click to expand...

No worries and glad it's been useful :)

When I did mine I'd done stacks of research beforehand but of course lots of people do it different ways and have different ability levels! As I'd not done anything like this before I wanted the simplest method so had to take advice from all the other write ups and it made sense to then put this into one document. If I ever do one again (I probably will at some stage when I get another Landy!) then I'd follow my document again with the only difference being the use of an adjustable carrier fitted to the engine hoist.

Cheers

Richard
 
richardjeaton said:
No worries and glad it's been useful :)
If I ever do one again (I probably will at some stage when I get another Landy!) then I'd follow my document again with the only difference being the use of an adjustable carrier fitted to the engine hoist.

Cheers

Richard
Click to expand...


Yep same here, it would have saved a lot of jiggery-pokery. I spent about two hours trying to get the engine to line up with the gearbox so that it would just slide on, but simply couldn't get it to work. So I went indoors, had a cup of tea, watched 10 minutes of Top Gear and went out to try again - amazingly, I got it to slide on on my first attempt and I still don't know exactly what I did differently. She's going great now though, have done approx 250 miles since the conversion and not a problem yet. :)
 
is there a thread somewhere where i can work out what clutch kit to get? i got the 200tdi motor i'm going to fit the 2.5td bellhousing and fit onto the lt77 gearbox (110 model)? disco or defender clutch? pressure plate? etc,
 
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