Pre-tdi conversion - engine jobs

instantsquid · Feb 15, 2010

I've got a Disco 200tdi engine sat on a pallet in my garage, ready to go into my 1988 90 in the next month or so.

What "jobs" on the new engine do you think it's worth doing before it goes in? So far, the list looks like...

-> replace timing belt
-> replace timing belt tensioner
-> replace rear crank oil seal
-> replace clutch (AP Driveline)
-> replace clutch arm with reinforced Steve Parker item (thanks Sean)
-> replace clutch bearing carrier with heavy duty Rakeway item (thanks Sean)
-> clean intercooler with thinners (thanks pos)

Other things (once old engine is out)
-> replace tdi bell housing with 19j one
-> replace tdi oil filter adaptor with the 19j one (thanks Beneagles)

Anything else? Obviously I don't want to strip and rebuild it - but at the same time, is there anything else that I'd be mad not to do at this point?

Thanks in advance,
Ian.

trbod · Feb 15, 2010

i did the belts and clutch on my before crimbo when i did it . not cheap but saves loads of agro if they went wrong in the near furture

Beneagles · Feb 15, 2010

I replaced the sump on mine - but only coz it leaked. Also swapped the oil filter adaptor back to the 19j one so that the oil cooler pipes reached.

instantsquid · Feb 15, 2010

Beneagles said:
Also swapped the oil filter adaptor back to the 19j one so that the oil cooler pipes reached.

Is it a straight swap?

Ian.

Beneagles · Feb 15, 2010

instantsquid said:
Is it a straight swap?

Ian.

Yes.

pos · Feb 15, 2010

There isn't really anything else that you need to do. It might be worth swapping your head gasket because they do tend to go. Mine had already gone when I fitted it (but I hadn't realised) and I then had to whip it off whilst t was fitted to the vehicle. It'll make life easier if you do it whilst it's out.

Also, throughly clean the intercooler through with paint thinners. If it's gunked up with oil, you'll loose a lot of power

-Pos

instantsquid · Feb 15, 2010

I've seen/heard the engine running - all seemed good.

I've added cleaning the intercooler to my list above - I read about cleaning it out once before (think it was one of Buster's posts) but haven't got it on my work list yet.

I take your point about the head gasket, but it's not the end of the world to change with the engine in the car. I'm thinking of jobs that really can only be done with the engine out - i.e. it'd be a pain in the backside to fit the tdi, only to have to take it straight out again.

Ian.

Sean · Feb 15, 2010

reinforced clutch arm
rakeway bearing carrier
130 clutch plate

hughesy · Feb 15, 2010

pos said:
It might be worth swapping your head gasket because they do tend to go. Mine had already gone when I fitted it (but I hadn't realised) -Pos

200tdi's aren't exactly well known for head gasket failure are they. I've had several and never had a head gasket problem.

instantsquid · Feb 15, 2010

Sean said:
reinforced clutch arm
rakeway bearing carrier
130 clutch plate

Thanks Sean. I'd seen mention of the reinforced clutch arm before, so that definitely should be on the list. Hadn't seen the Rakeway stuff before, but did a bit of reading and it sounds like a sensible upgrade while everything is accessible. What's the deal with the 130 clutch plate? I was just going to fit a shiny new AP unit.

Ian.

instantsquid · Feb 15, 2010

As an aside - presumably the Dayco timing belt is up to the job? Or is it a false economy?

Ian.

bobbydog · Feb 16, 2010

ive never heard of 200s being bad for head gaskets that was the rover k series fitted in the gaylander 1. no 200s in my opinion are very cool running engines thats with a rad with no fins on the back and working her in low box 2nd all day do you now the history of the engine i never changed the timing belt on my 200 plus i dont now the engines history . but i like living dangoursly and im sure there non interferance anyway

instantsquid · Feb 16, 2010

I don't know the engine's entire history, no - so have no idea when / if the timing belt has been changed. For the sake of a tenner it seems crazy not to change it while the engine is out of the car.

You're spot-on with the Rover K series though - I had a Lotus Exige from new many years back. That did it's head gasket in under 1,000 miles. You can imagine how pleased I was when that happened...

Ian.

markr · Feb 16, 2010

i`ve just finished the same coversion on my 90 .... i`d fit the conversion exhaust whilst the engine is out ...its a pain afterwards

Pre-tdi conversion - engine jobs

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