Last night I did some measuring and checking of parts for the final assembly of the 200.
There are 2 mounting lugs on either side of the rad/intercooler frame that have to be cut off. When I mounted the rad/intercooler into the supports on the front I found that indeed the rad/intercooler are about 3cm too high for the TD radiator holder brackets to fit over the 200Tdi rad.
So the mounts will have to be cut down and welded.
With the rad in place I took some measurements and checked that I had all the pipework needed to complete this.
Water pipes:- About 40-42mm internal diameter- The Tdi ones aren't long enough but the TD ones are, so don't need to buy any more.
Internal heater hoses:- The TD ones aren't long enough but the ones out of the Disco are.
Oil cooler pipes:- About 30cm too short, so I have taken them to Pirtek to have them extended (about £60) by 30cm.
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Fuel Pipes:- Using the Tdi filter then pipes are too short to mount the filter onto the bulkhead where the TD one went. Got some 8mm ID fuel hose from a motor factor for £5. There are 2 pipes to the filter that need extending so I will just cut the pipes and slip on the new hose so that the filter can be mounted in the same place as the TD one. Then there are the fuel tank and spill return pipes to connect up. As these aren't hight pressure then I will just join the pipes up using the same fuel hose.
Turbo-intercooler pipework:- After a lot of measuring and playing with all the pipes I have I know I haven't got anything that will work, especially the turbo output pipe that is very close to the innter wing. I am going to splash out on some bling
Air intake is the last thing to look at. I have the flexy hose from both the TD and Tdi so I think I shold be ok for that. It's just deciding where to mount the air filter.
Here are some photos of the lower turbo output that needs a very tight curve hose.
Input to the intercooler
Intercooler output to the engine
Lower water hose that isn't quite long enough.
Internal water heater hoses
How soon do you think the rad will last with fins like this????