Went out for a longer test drive Sunday morning to make sure nothing fell off, smacked into somthing else or otherwise could destroy the hard work.
Wow, lots more power. On the sttp hill where my TD could barely get make it to the top at 30mph in 2nd the 200 keeps pulling up the hill at 50!
Top test speed 70mph without trying. Cruising without effort at 60 and even able to OVERTAKE!!
It's like driving, dare I say it, a modern car!!
Absolutely worth removing a working TD for a 200TDi.

Just got the last bits to do like ensure the viscious fan doesn't chop the lower water pipe up and hit the PAS unit casing and cover any pipes and hoses to stop chafing.

It's back on the road!




you'll be looking for excuses to drive it now , i know i did .

just a quick point with the fan tho , i took mine off and replaced it with an electric one and it never comes on ....but , you may get a high reading on your gauge , this is down to it not being matched to your engine ..

you'll be looking for pump tweek info next , but thats for another day ...

RICK...
 
The temp sender is the one off the 2.5TD so it's the correct one for my guage, but obviously the Disco 200 runs at a different temp to my old TD.

I will do the timing on the injection pump and will have to try the cheap Hiclones I got in the intercooler pipes at some point as an experiment.

What else can I play with to make the engine more fun to drive with??? :D

Bigger intercoolers and lots of ££££ don't count. :)
 
The temp sender is the one off the 2.5TD so it's the correct one for my guage, but obviously the Disco 200 runs at a different temp to my old TD.

I will do the timing on the injection pump and will have to try the cheap Hiclones I got in the intercooler pipes at some point as an experiment.

What else can I play with to make the engine more fun to drive with??? :D

Bigger intercoolers and lots of ££££ don't count. :)


theys loads you can do to power it up , but , it may be a good idea to make sure its ok first ....
the pump tweek will cost you nothin , but i'd wait fer a while first just to make sure ....
 
No worries, going to leave it as standard until it breaks:D
I'm more than happy with the power increase already and there is plenty more to do like fix the doris' bike, fix my bikes, fix the house.......
 
fix the house.......


arrrh the old house or landrover choice , i had the same choice a while ago and guess what won .... it wer me landrover ..... i musta bin stoopid ...

i went from this ....

100_0219.jpg




to this .....


000_0408.jpg



and all the points in between , and it ended up splittin me and my mrs up cos i would'nt finish the house .... still not all bad , i speak to her every day now which i did'nt before :rolleyes: and she still does my laundry.... she only lives up the road which is handy .... she's a good women but she dont get landrovers ....... silly cow ..:rolleyes:
 
No worries, going to leave it as standard until it breaks:D
I'm more than happy with the power increase already and there is plenty more to do like fix the doris' bike, fix my bikes, fix the house.......


Oi Farty breath, less of the Doris poor 400 has been waiting a long while, you've only left it this long cos with this bump I can't ride it now anyway, hence more Landy time!! Grrr! House, ahh the bl**dy thing can wait, bikes and cars always come first, shame kids get in the way! :D Oh and may I add everyone except me has been for a test ride in the Landy, sob! :(

MBx
 
Oi Farty breath, less of the Doris poor 400 has been waiting a long while, you've only left it this long cos with this bump I can't ride it now anyway, hence more Landy time!! Grrr! House, ahh the bl**dy thing can wait, bikes and cars always come first, shame kids get in the way! :D Oh and may I add everyone except me has been for a test ride in the Landy, sob! :(

MBx

houses and kids always get in the way ..... its a fact ....:rolleyes:
 
Your 400vv is next on the list of things to be fixed. I'll take you out in the Bus as soon as I'm happy it's less likely to implode :D


And the house..... let's get someone else in to fix that.
 
And the house..... let's get someone else in to fix that.

Good plan although it can be expensive.

So BBB is fit for a littel shake down time this weekend then?
So we can see what falls off?

BTW
I think i found out what that grunching noise was, Water in the swivels and rusty uj's. :eek:
So i could do with filling them up this Friday.
 
MMmmmmmmmmmm, brought the 110 into work today..........

















I CAN OVERTAKE TRUCKS! :)















I CAN OVERTAKE BMW X5's! :) :)












I can stay in the outside lane of the motorway at 70+ without being towed !!!!! :D :D :D

The 200Tdi is fantastic. Best £500 I have ever spent on a vehicle :D :D

And I can now hear the stereo properly rather that using it to try and drown out the TD :rolleyes:
 
This is the list of jobs and the order I did them in with parts prices.
Hope this helps anyone who thinks this is a large job. It is but by breaking it down into little sections it makes it easier to cope :D

Step order - 2 May 2008 with parts required.
Complete driveable Discovery 1 with 200Tdi £315 on ebay.
Solve water leak from rad top hose. Radweld in rad and tank- Water leak stopped
New radiator cap. 99p from Challenger 4x4
Remove Rad/intercooler. Disco/Done
Replace cam belt, gaskets and oil seals. 200 tdiCam belt kit/Done (£60 From Paddocks)
Remove exhaust. Done
Keep power steering bottle and pipes on engine. Yes, done
Remove anything in engines way. Yes, done
Remove all cables and pipes and label them all. Done 2 elec cables with connectors. Fuel filter and fuel return pipe
Remove floorpan and tunnel to get at clutch bellhousing bolts. No need
Remove bellhousing bolts. Done
Remove glow plug system. 1 cable removed.
Remove bonnet.
Remove 200tdi engine. Engine crane, removed (£200 for crane and load leveller brand new. Ebay)

200TDi outside vehicle.
Replace clutch and output oil seal. Done clutch plates and cover and output seal (£80 Paddocks).
Cleaned inside housing no oil leaks.
Mount exhaust downpipe - Used all studs, replaced 1 nut. Exhaust downpipe - £80 on ebay
Undo engine mounts. Use a long breaker bar and 19mm socket. New rubbers £6

110 2.5TD
Remove anything in engines way. Front slam panel and top rad mounts removed.
Remove front bumper
Remove radiator
Remove exhaust from lower joint Done
Undo engine mount lower bolts Done
Undo bellhousing bolts. Lift and remove engine rubber mounts. Drop onto chassis and undo all the bellhousing studs and starter motor wiring.
Remove all cables and pipes, leave loom in the bay Done
Remove fuel filter and pipes strap to engine Done
Remove PAS pump pipes from box leave on engine Done
Remove bonnet.
Remove TD engine. When out remove the engine mounts.

110 with no engine
Remove exhaust front section so it can modified to fit later.
Check gearbox rubber mounts OK.
Jetwash engine bay, check for welding and waxoil.
Clean bellhousing and check clutch fork for wear. Welded strengthening plate across back. All coeated in grease and grime and rust free.
Change Clutch slave cylinder . Lubed up ball joints with copper slip (£10)
Bleed clutch
Change gearbox oil for Difflock stuff. New Difflock gearbox oil. Looks like ATF- £45 for 3 litres

200TDi and 2.5TD out of vehicles.
Seal exhaust upper mounting and wrap with heat tape.Seal exhaust joint with firepaste and wrapped with heat wrap £12
Check engine studs for ones to be removed. 2 removed as they do not line up with gearbox bellhousing.
Check out for hole for dowel in gearbox bellhousing.No hole so dowel removed.
Flush out cabin heater. Done and clear
Tidy up engine bay wiring and axle breather pipes. Done
Transfer engine mounts to 200tdi using rear block mounts under alternator. Tighten nuts on mounts to block but do not fit rubbers. Done
Replace fan and PAS belts with new. New PAS and fan belt (£10 Paddocks)
Change clutch release bearing. Placed new one in

200TDi fitting.
Lift engine into bay and adjust for fit. Lower until starter motor wires can be connected.
Earth lead to chassis.
Lower engine and adjust until studs line up and push engine in.All studs done up. Need 3 lowest bolts tapping
Do up bellhousing studs.
Glow plug system leave as was, remember to only hold for 5 seconds.
Fuel stop solenoid.
Throttle linkage. Attached and adjusted.
Lift engine and gearbox until you can put in the engine mount rubbers. Lower engine onto rubbers and tighten.Done.
Remove 2 small lugs either side of the radiator frame
Cut down Radiator/intercooler lower mounts by 3cm - Welding
Weld 2 pins to top of rad for mounts. Done and painted with hammerite
Remove Tdi oil cooler pipes and get extended by 30cm Pirtek 30cm longer for £60
Fit oil cooler pipes into filter.Done
Check new rad/intercooler fits.
Flush out radiator and intercooler
Turbo heat shield.
Internal heater pipes- steel pipe feeds rear, pipe nipple feeds front. Used old ones out of Disco.
Swap Temperature sensor on front of engine and wire up.
Change alternator wiring. 2 thick brown cables to large stud.
Oil pressure sensor .
Mount Tdi PAS pump pipes. Fill with PAS fluid.
Replace water expansion tank from disco.
Mount exhaust front section. Will need adjusting to fit 110. 6cm cut out.
Mount disco fuel filter and pipes and heater system. Need 8mm and 10mm id fuel hose. £2 per metre from Camberley Auto Factors.
Connect up intercooler pipes. In at bottom out of top. Darton fabrications £120
Radiator hoses made up from all the bits. TD ones are long enough. Added section to expansion tank pipe
Mount rad/intercooler and upper bracket from disco or BBB
Fill up with water and anti freeze and radweld into rad. Anti freeze £5
Mount air filter and pipes- Mounted on RHS above alternator using Disco filter and holders.
Mount viscous fan.
Check water, oil, PAS levels .
Prime fuel system with hand pump.
Remove fuel solenoid wire and run on starter to prime fuel and oil sysytem.
Start and run
Move steering from lock to lock and top up PAS bottle
Replace bonnet
Replace bumper
 
You make it sound so easy :rolleyes:
The only things I would add are:-
1. Lower the engine and gb to remove top Bell housing studs (Right B*** if you don't).
2. Have a couple of mates to help when mating the new engine to Gearbox.
 
You make it sound so easy :rolleyes:
The only things I would add are:-
1. Lower the engine and gb to remove top Bell housing studs (Right B*** if you don't).

Why not use the TD flywheel housing - it bolts straight on and there's no need to remove studs. Only drawback is needing to remove the flywheel.
 

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