decided it was time to remove the (aftermarket) clock as it was draining the battery:mad:

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also fit the Lucas turbo / boost gauge I've had stashed for such an occasion:p

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also decided to replace the horribly crimped terminals on the illumination bulbholder with nicer items..

now need to fit the 200tdi so the gauge can do something:oops:

Rich.
 
been driving the Ninety around & comuting so ~55 miles a day without issue....

so I've parked it up and will give it a good going-over as something is about to fail catastrophically :confused:

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in other news, bought a Garret GT2062V turbo

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(ebay, from a 2004 Audi A4 Avant TDI Sport MK2 with the 2.5L BDG code 161BHP V6 diesel engine) as...

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I've memories of reading their compatablity with the 200tdi manifold bolt-pattern.

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can confirm it will bolt to a Disco 200tdi exhaust manifold so hopefully will fit the Defender 'top-mount' turbo manifold:confused:

these have a vacuum actuator operate vnt ring so either I need to sort some electronics to controll this or find a suitable pressure operated actuator to replace it.:eek:

^^ this is irrelavent as I've not fitted the tdi engine in the Ninety so another 'one-day' project (was cheap:p)

more ideas & fiddlin to follow....

Rich.
 
Brought tears to my eyes - I had a disco exactly the same as J609MUT. I eternally regret having sold it. Now I have 93 200TDI 2 door and a 95 300 TDI five door that I am working on. I'll post my project in a day or so.
 
minor update...

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new tyres & 'old' D1 wheels for the ninety

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full set (4) of 205/80/16 COOPER A/T3 SPORT 2, seriously smaller diameter and circumference to the previous 7.50x16 so maybe helpfull to the 2.5d pOwErHaUs:D

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also, visited Farmfoods and captured 4 x 10Litre tubs of veg oil (2 x 10 Litre tubs for £25 so £1.25 / Litre:cool:) - obviousaly I'm NOT intending to use this as fuel;)

honest:p

Rich.
 
minor update...


lOcjJyO.jpg

also, visited Farmfoods and captured 4 x 10Litre tubs of veg oil (2 x 10 Litre tubs for £25 so £1.25 / Litre:cool:) - obviousaly I'm NOT intending to use this as fuel;)

honest:p

Rich.


But if you were, say, to be intending on using this as fuel - and of course you are not - how would you do it? Just spit balling, as the yanks would say...
 
But if you were, say, to be intending on using this as fuel - and of course you are not - how would you do it? Just spit balling, as the yanks would say...

erm, open fuel tank cap, open veg-oil can, pour veg oil into fuel tank & drive:D

although I wouldn't use veg oil in anything newer than a 300tdi as they (newer) don't like it;)

allegedly of course:p

Rich.
 
erm, open fuel tank cap, open veg-oil can, pour veg oil into fuel tank & drive:D

although I wouldn't use veg oil in anything newer than a 300tdi as they (newer) don't like it;)

allegedly of course:p

Rich.
Ahhhh! that obvious? With diesel getting going up from stupid to stupid prices, might be the way to go!
 
okey, I'm fitting a 200tdi in the Offender (Ninety) starting tomorrow hopefuly and there was one item I've been searching for - the Defender 200tdi rad / fan shroud:confused:

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couldn't find one in Newbury or locally - found this one on ebay and it was delivered today:cool:

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it had a section cut off & re-fixed - easily tidied if needed but I'll look at that another time:p

anyway, 2.5d out tomorrow & hopefully the 200tdi in place:)

Rich.
 
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more Diesel, Tesco £1.20 / L....

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started dismantling the 2.5d before the 200tdi goes in (hopefully tomorrow?)

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had a fight with the floorpans, 20 different fasteners and most rusted solid:confused:

more fun to follow:eek:

Rich.
 
okey, a few photo's:oops:

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the 200tdi, out of the garage (it's still full!) and readied for action;)

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new oilpressure switch fitted.

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the turbo side showing a mostly complete heatshield - first one I've ever seen & I'd thought they were something of legendo_O

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jetwashed inside the bellhousing (& everything else:p) then new clutchfork / release bearing and liberal coating of cv grease where needed:)

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image showing the fuel pipework.
will be changing to the newer (simpler) fuel filter setup...
the feed from tank / sedimenter to the engines lift-pump is common between the 2.5d and 200tdi engines so will stay, the return is a different matter....

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so bought the 'proper' 200tdi (maybe 300tdi also?) return pipe @ great expense - from LR direct.

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]
BUT.....

there was a problem.......

:mad::mad::mad:

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different threads...
guessing imperial on the '86 Ninety & metric for the Bosch pump 200tdi:confused:

so, I've refitted the origonal return pipework onto the tank (untill I get a suitable stub or metric 'nut / olive' to remedy) and bodgedcut the pump end and TEMPORARLY joined onto the pump with rubber fuel hose / pipe clamps:oops:

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looks like this:oops:

Annoyed as I tried to do this properly but failed due to a thread missmatch that I couldnt combat with the contents of my workshop:mad::mad::mad:

anyway....

more to follow....

Rich.
 
more that follows:cool:

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nearly in the bay.

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getting closer....

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oooooh!

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it's in, straight on the gearbox / input shaft & a little jiggling for the (new Genuine LR) mount rubbers to fit the chassis:)

about this time was dinnertime so bonnet on & a cuppa.....

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then the saga of powersteering....

everyone says that a disco pas box fits...

it does BUT nobody mentions that the non-pas box has (4 off) imperial bolts & nuts securing ot to the chassis whereas the pas box uses METRIC bolts screwed into the casing:rolleyes:
need to find bolts now (M12 x 90mm long I thinko_O)

also, disco & Ninety / defender steering arms are interchangable:cool:

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pas pipework fitment fun - I'm playing with the pipe routing to get a neat fittment across the crossmember....

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and failing:oops:

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more tangles! the air / oil cooler was a temporary fittment to run the engine on the floor - 1/2"bspp threads on the engine pipework.

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fitted a new / aftermarket 200tdi type throttlecable & spent ages trying to route it neeatly:rolleyes:

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theres more fun lurking on this side:eek:

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starting to look more complete...

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started playing with the intercooler & rad hoses....
I'd bought new 200tdi rad hoses (& they SHOULD fito_O) and managed to buy a new / genuine LR top intercooler metal pipe (huge cost from LR Direct:(:(:() but need to make the lower pipe...

subject of rad-pack, need to fit one:D:D:D

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BUT theres another issue...

I bought a 200tdi Disco radpack (£30 in newbury) as they're cheaper & easier to find than the Defender 200tdi type....

but they need altering:rolleyes:

Call for the Anglegrinder:D

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side mounts trimmed & removed then it fits in the hole:)

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but now it's too tall:rolleyes:
I'm going to remove the channel-shaped risers & hopefully it'll be correct - I've seen some people alter the chassis's mounts to lower but I'm going to fettle the rad frame.

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bought a 200tdi Defender turbo - airfilter hose....
I'm intending to use a spare 200tdi Disco airfilter case in the 'standard Defender position so this should join the 2 - need to sort mounts for it I suppose:(

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curiosity had a poke at me, would the bonnet close???
yes but it rests on the turbo heatshield:mad::rolleyes::mad::rolleyes:

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another view...

the Ninety has the strengthening ribs fitted to allow carrying a spare wheel on the bonnet - I was sorta expecting these to clash....

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thats my progress so far, I have found the front axles number - will check the heratige cirtificate but dont expect it to match on this squaddy-charriot (TUL,FFW):D:D:D

more tomorrow after I've visited Foundary4x4 to hopefully get some bits....

Rich.
 
Looking good! Great write-up too!:cool:
But one of the Land Rover curses. A mix of metric and imperial threads… :mad::rolleyes:o_O
 
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test-fitting rad-shroud / top hose & intercooler pipe to gauge the possibility of D1 200tdi airfilter fitment.
pair of D1 @00tdi 3 door (non-sunroof) in background for effect :cool:

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another view - looks promising:)

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drivers side looks sorta empty @ front:confused:

more to follow....



like trying to fit the downpipe now the engine is in:eek:

Rich.
 
more wombling around today:oops:

went for a roadtrip in the t4 van heap to Foundary4x4 - my Local parts supplier (~50 miles away) hunting for goodies...

they dont do counter-service but 'collection' or postage, somewhat different to my last (pre-covid) visit:(

they were helpfull & sorted a few bits so not a wasted journey:cool:

way home the long / slow way over the mountains so probably 100 miles return:eek:

then to Halfords to sort a replacement 17mm ratchet-spanner and bought a few other spanners like 33mm open-ended (£9.99?) and a 33mm socket - both to tighten the pas steeringbox drop-arm nut:cool:

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played with the pas pipework and routed them accross the crossmember as best I could see, probably completely wrong but hey-ho:(

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the steeringbox end, 2 hoses & 1 metal hard-pipe.

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pump end...

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this is an important photo as it shows (sorta) the area that the lower intercooler pipe needs to rum, I've spread the pipes to give more clearance - but it might not be needed?

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the routing across the erm, crossmember:confused:
theres 2 plain holes in the crossmember's vertical face and I'll fit rivnuts to secure the pipes...

more faffin tomorrow...

Rich.
 

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