Mechanic to fit 200tdi into a Series 3 near Worcester

Bump · Jun 20, 2012

chunkymunky said:
I think its possible, but wont be at my location. Scrappyloz and I are days from starting my conversion of a td to 200tdi.

Don't know how much is involved with doing it to a series 3. Haven't spotted a blow by blow guide yet but only on my phone.

Pm where you are. Etc. There is a guy I can give you a number for but aint cheap. Was gonna be bout 1300 for mine with me providing donor.

There are 100's of guides around, it's quite straight forward to make it a 200tdi or 200di - i left the turbo on mine but didn't put the intercooler in so i guess it sits somewhere between the two! Definitely not a £1300 job though

You don't need to buy fancy expensive exhausts either, just get a 200tdi exhaust and an angle grinder and adapt it to fit!

scrappyloz · Jun 20, 2012

mjdelahunty said:
Unfortunately N/A engine is shot, my mate has a 200tdi incl turbo in his 2A & everyone seems to think it is an easy conversion. I had picked up some diffs to be fitted but this was before I realised the engine was shot.

Fair enough. Its not a difficult conversion it is just an awful lot simpler with the turbo left off, but its not too difficult with it on.

The other thing i would recommend is 109 twin cylinder front brake setup, or someone might be here to correct me and discs may be needed.

with some diffs it should drive very well.

Spunka · Jun 20, 2012

Is a TDI with out a turbo a tried and tested convertion? Useally if you take a turbo off an engine wots disignd for one they are realy numb,
You dont want to have to gun it in eavery gear

Just asking coz im intrested

scrappyloz · Jun 20, 2012

Spunka said:
Is a TDI with out a turbo a tried and tested convertion? Useally if you take a turbo off an engine wots disignd for one they are realy numb,
You dont want to have to gun it in eavery gear

Just asking coz im intrested

The 200tdi without a turbo makes it a 200di. Its a very popular conversion fitting a 200Di in a series as it is pretty much a straight swap in and out.

It produced more power than the standard engine 2.25 diesel, and without the turbo they are pretty much unbreakable due to being so under stressed. If your not happy without the turbo you can always refit it at a later date.

Bump · Jun 20, 2012

scrappyloz said:
Fair enough. Its not a difficult conversion it is just an awful lot simpler with the turbo left off, but its not too difficult with it on.

I disagree, leaving the turbo on makes it easier, you don't have to remove it + block up the odd hole, the exhaust isn't an issue, engine just drops in.

You don't need discs - not an easy conversion, either very expensive, or, you have to adapt disco axles, but, you can upgrade the drum breaks

scrappyloz · Jun 20, 2012

Bump said:
I disagree, leaving the turbo on makes it easier, you don't have to remove it + block up the odd hole, the exhaust isn't an issue, engine just drops in.

You don't need discs - not an easy conversion, either very expensive, or, you have to adapt disco axles, but, you can upgrade the drum breaks

Thanks bump its good to know that the upgraded 109 drums will cope ok.

With the turbo left on you have to rotate it so a custom oil line needs to be made (i think).

A different exhaust is needed, also the disco rad and intercooler has to be fitted if the turbo is kept.

All of these things arnt needed with the turbo removed so it must be easier without the turbo.

mjdelahunty · Jun 20, 2012

Thanks for all the Pro's & con's, however back to the original question. Does anyone know of a Mechanic in the Worcestershire/Herefordshire area to fit a 200tdi?

scrappyloz · Jun 20, 2012

I would be happy to do it. Me and chunkymunky are doing a 200tdi swap into his defender this weekend. So after thats out of the way im sure we could do yours for you.

Bump · Jun 20, 2012

scrappyloz said:
With the turbo left on you have to rotate it so a custom oil line needs to be made (i think).

A different exhaust is needed, also the disco rad and intercooler has to be fitted if the turbo is kept.

Only if it is a 109 - If it is a 88" the engine drops straight in with the turbo in tact, you can then exit the exhaust out into the N/S front wheel area, under the chassis rail and under the passenger seat area.

Apparently you can just get the disco rad + intercooler into the space, but, i opted for just the disco radiator and run the turbo with no intercooler. You can also apparently fit the intercooler behind the radiator, but, it all gets very tight!

**
Just remembered, i'm on my second 200tdi engine now and this one, although has the turbo there, it has all the inards taken out so doesn't actually do anything, so, i'm technically running a 200di!

scrappyloz · Jun 20, 2012

Bump said:
Only if it is a 109 - If it is a 88" the engine drops straight in with the turbo in tact, you can then exit the exhaust out into the N/S front wheel area, under the chassis rail and under the passenger seat area.

Apparently you can just get the disco rad + intercooler into the space, but, i opted for just the disco radiator and run the turbo with no intercooler. You can also apparently fit the intercooler behind the radiator, but, it all gets very tight!

**
Just remembered, i'm on my second 200tdi engine now and this one, although has the turbo there, it has all the inards taken out so doesn't actually do anything, so, i'm technically running a 200di!

Ahh yes as the 109 is an inch higher.

I think the OP might want to run the exhaust so it comes out the back as if its a short stubby exhaust he might not like it. I think he already has the exhaust part though

chunkymunky · Jun 30, 2012

Our conversion is now done.

lordluke1995 · Jul 9, 2012

sorry to bring up the past gents, i have a 19j in mine, what if i swapped the inlet and exhaust manifold to 19j, withj the 19j turbo, then it would have less stress but still have a turbo !, and then i could fit my already modified 19j exhaust ??

any ideas would be really great, parts i have to play with are 19j complete, 300 tdi rad, and a whole 200tdi disco engine,

so how should i play it ? which parts shal i use ?

mine has sh*t hot breaks btw

Mechanic to fit 200tdi into a Series 3 near Worcester

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