Series 2 to 200Tdi Conversion

border · Monday at 18:51

Starting new thread on this.
Some will know I am doing a 200tdi conversion to Series 2. Just finished rebuilding the engine which was stressful enough but basically I have hit a brick wall. Think the rest is going to be much more harder. I knew this was not going to be easy but been reading info on Glencoyne , he mentions it will be easier with no Turbo, but after reading on it seems very complicated. Now would rather do it With Turbo on but dont mind if I have to do it without.
Starting to Panic Now,

I am at the stage now where engine and box is back in to rolling chassis, got most of the body parts, Bulkhead, wings rear tub bonnet front grill etc. But thats it.
Do Not have
Exhaust ,
Radiator.
Intercooler
Hoses,

There's loads more bits I need.
Any Info or pics of how others have done it will be greatly appreciated. Thanks.

lynall · Monday at 19:09

Have you drilled the flywheel housing for the bottom 2 or 4 bolts?

Exhaust I made my own, but think Steve parker used to do a kit.

Rad I used the original s2 one, mine is the early narrow type and keeps it cool just fine.
I did fit the intercooler as using the narrow rad means it was pretty easy, just a couple of bent up brackets to secure the cooler. but many do not fit the cooler at all.

Series top hose fits so long as you use s2 engine top stat hose fitting.
Bottom hose is much more challenging.

Throttle was just a lashed up cable job from the bulkhead cross shaft.

I used original oil bath air filter.

I did all mine on the driveway at home, so basic tools etc.

Steve on your engine thread has done a much neater job than me, he will be the one to ask.

lynall · Monday at 19:13

I got most of my info from Glen Anderson who had posted on terri ann land rover page, which is a goldmine of info.

Here is link to Glens conversion, Iirc his is a 109 which is why he used the defender manifolds.

Converting a Series Land Rover to 200 Tdi diesel

steve2286w · Monday at 19:19

Haha was watching to see if anyone comes back with the 200tdi in a series 2 , I did the 200di in a series 3 which was simpler as you can use the S3 exhaust manifold and exhaust , radiator , keep the oil bath filter and a battery under bonnet if you wish , didn’t use intercooler , but your bulkhead does not. Look too different to the s3 but not sure with the turbo .. are they clocked round a bit to get a better pipe route
Steve Parker gone bust now

border · Monday at 19:40

Thanks Everyone, seems there is quite a few different ways to do this, cant weld so making my own exhaust is out of the question. I have heard some use the Disco Rad and some use 2.25d exhaust manifold. Got my bloody head spinning now.
Is it a good Idea to loosely fit bulkhead and front radiator grill first to give me some Idea of what will go where ? would love pics if anyone has any.
this is bulkhead I have,

steve2286w · Monday at 20:11

This was my write up

Refurbed 200di into Series 3 with fairey capstan winch

After 5 years of the 200tdi engine sitting in the garage I finally got round to stripping it down checking for wear and putting new bearings in. this is described on another thread here https://www.landyzone.co.uk/land-rover/200-tdi-engine-checking-refurb.346897/ Must haves on this project for...

www.landyzone.co.uk

Probs a few more peeps on the members projects thread with better exp of fitting it with turbo
Agree fit your body parts loosely and see where the 200tdi may cause probs

300bhp/ton · Monday at 23:54

border said:
Starting new thread on this.
Some will know I am doing a 200tdi conversion to Series 2. Just finished rebuilding the engine which was stressful enough but basically I have hit a brick wall. Think the rest is going to be much more harder. I knew this was not going to be easy but been reading info on Glencoyne , he mentions it will be easier with no Turbo, but after reading on it seems very complicated. Now would rather do it With Turbo on but dont mind if I have to do it without.
Starting to Panic Now, I am at the stage now where engine and box is back in to rolling chassis, got most of the body parts, Bulkhead, wings rear tub bonnet front grill etc. But thats it.
Do Not have
Exhaust ,
Radiator.
Intercooler
Hoses,

There's loads more bits I need.
Any Info or pics of how others have done it will be greatly appreciated. Thanks.

Completely pointless running with no turbo, you might as well just have a normal 2.25 petrol or diesel in there. The entire point of fitting a more modern turbo powered engine is for the fat turbo torque curve and extra power. --- all IMO of course. But why go to all the effort and cost of an engine conversion to end up with something less refined and slower than a completely standard 2.25p petrol!

300bhp/ton · Tuesday at 00:05

BTW - the Tdi will run fine without an intercooler, so long as you aren't juicing up the Tdi. But it would be better with one. Lots of options for an intercooler, although factory Tdi ones would likely be the most challenging to fit.

Throttle, you'll want a Defender throttle pedal (Pre TD5) and Tdi throttle cable, its then fairly easy to rig up. You'll need to clock the turbo to get the pipes in the right place and exhaust manifold will be the hardest bit. Steve Parkers used to sell one, but they are no longer, so you may need to find someone to help you here.

Rad wise, Tdi's often run cool, but when working they will get hot. So make sure it is suitable.

lynall · Tuesday at 00:31

Throttle, defender cable cut down and home made bracket, been on there for the best part of 15 years now.

lynall · Tuesday at 00:32

Series stat top onto tdi stat housing.

border · Tuesday at 12:05

Thanks Everyone Did not plan this bloody conversion, I bought it with 200tdi already fitted which was started about 12 years ago then left, did not look in to the ins and outs until after I payed for it, so got to be done now one way or another.
Gonna get bulkhead on this week to decide which way to go.
keep the pics coming they say everything.

steve2286w · Tuesday at 14:41

Similar to mine kept the cross shafts and original cable with a home made turned ally thing , keeping the hand throttle too

300bhp/ton · Tuesday at 15:31

300bhp/ton said:
Throttle, you'll want a Defender throttle pedal (Pre TD5) and Tdi throttle cable, its then fairly easy to rig up. You'll need to clock the turbo to get the pipes in the right place and exhaust manifold will be the hardest bit. Steve Parkers used to sell one, but they are no longer, so you may need to find someone to help you here.

Just to add to this, you don't actually need a Defender throttle pedal. Although this is what I have on my current setup. On my past Tdi Series I used the stock Series pedal and attached a stock Tdi throttle cable to the rod mechanism by the passenger footwell end. You'll need to fab up a bracket to hold that end of the Tdi cable though. Sorry, can't find a picture of what I had.

border · Tuesday at 18:12

300bhp/ton said:
Just to add to this, you don't actually need a Defender throttle pedal. Although this is what I have on my current setup. On my past Tdi Series I used the stock Series pedal and attached a stock Tdi throttle cable to the rod mechanism by the passenger footwell end. You'll need to fab up a bracket to hold that end of the Tdi cable though. Sorry, can't find a picture of what I had.

A mate has a spare Defender pedal for me to try, also I'm getting a second hand Disco Radiator to mock up and see whats what, might need the Series Rad yet as both can be used from what I've heard

lynall · Tuesday at 19:26

steve2286w said:
Similar to mine kept the cross shafts and original cable with a home made turned ally thing , keeping the hand throttle too View attachment 344838 View attachment 344839 View attachment 344838 View attachment 344839

Gotta have hand throttle for the pto winch :banana:

Wildefalcon · Tuesday at 22:03

I kept the series link rods. Well I welded two together.

Just visible here, re routed to avoid a repositioned air filter.

border · Tuesday at 23:02

Any Exhaust pics of how thy are routed

border · Thursday at 22:04

Got the bulkhead painted in a fashion, first time spray painting its not to bad but it will do me. will get it fitted then see if I can get ideas of where I have to run things, had 2 bolts lined up what I thought were for bulkhead but to wide to go through the holes, they look about maybe m12, any one know the right size and length theres a local place to me should have some in . save me ordering some and having to wait until next week .

border · 2025-07-12T18:45:20+0100

Got things in to place now to see which way to go. Turns out someone is taking over Steve parkers gear and is going to be still produced. Now if I fit one of these to my exhaust manifold from Turbo Will the rest of the standard series exhaust parts fit on to it ? https://www.ebay.co.uk/itm/22664344...VQ9K9R&hash=item34c5009593:g:ttMAAOSwmeNn0eJO

lynall · 2025-07-12T19:38:30+0100

I think std series exhaust might be to small a diameter?

Nice pipe, but 234 quid kin hell!

I made my own.

I had to go up because of pto shaft, early diesel also took their exhaust out the nearside inner wing.

Series 2 to 200Tdi Conversion

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