Engineering a 200Tdi into a series 3

Thanks guys,

I'll continue with the search for a flywheel to suit the Isuzu C240 motor, see what the best price is for the 200Tdi and speak to Talk Torque then make a decision.


Colin

G'day Colin,
i am in the process of converting a S3 109" to a 200tdi; initially I was going to install it and try for licencing but instead I read the WA Transport website and decided to use common sense, for as they point out if a modified car is involved with a fatality the driver is seriously in the poo and in any accident the insurance people don't want to know.

So my recommendations are:
1. Look at the VicRoads website, or ring them and ask to speak to an engineer.
2. Have a look at these links http://www.infrastructure.gov.au/roa...jan2011_v3.pdf
Vehicle Standards Bulletin 14 (VSB 14)
http://www.infrastructure.gov.au/roa...Jan2011_v2.pdf
Vehicle Standards Bulletin 14 (VSB 14)
These are the National Standards, which Victoria may, or may not follow - WA does.
4. Once you have received a letter of approval-in-principle from VicRoads you can proceed, safe in the knowledge that it will get licenced, as long as your work is sound and safe and the engineer is happy.
5. Select an engineer - VicRoads might have a list of approved engineers - WA does.
6. Liaise with she/he before proceeding.

With regard to the 200tdi engine; Nitemare pointed out to me that 300tdi parts will fit; such as the exhaust manifold.

Isuzurover discovered that a 300tdi can be made to fit the Rover gearbox.

Wagoo told me how he converted his S2A box to an unbreakable New Process truck box, which solves the gearbox strength issue.

I plan to use a Roverdrive overdrive initially and do Wagoo's conversion when the Rover box karks it,

Cheers Charlie

Thanks Charlie,

I'm probably going to get the little Isuzu working first as it's been registered with this fitted. Power output is similar to the 2.25 diesel.
200Tdi is likely to come later.

I've found that if the weight of the car doesn't increase by more than 10% and the power doesn't increase by more than 10% you don't have to upgrade the brakes. The current owner has used LWB brakes anyway.
I realise an engine change has to be done and signed off correctly otherwise you effectively don't have any insurance cover

Because this is 'just another toy' as the wife put it, I don't intend to throw too much money at it initially but who knows....


Colin

I've been offered a 200Tdi and LT77 gearbox c/w intercooler, air filter etc.
Obviously a stronger box than the Series but how easy to fit ? I also understand that you need the Stage 1 front axle, is this just to get a proper CV joint because it's permanent 4WD ? A Salisbury rear axle might be an option as well.

Hopefully I collect the vehicle this weekend or next. Once the Isuzu is running and connected back up to the gearbox I'll have to make a decision regarding the motor.


Colin

i hope the lt77 you've been offered is a defender/90 one as the disco one will put your gearstick in the middle of the centre seat due to the length of the bellhousing

a stage1 axle would be nice as that will allow you to retain the permanent 4x4 but on saying that i know someone that still has a normal Series front axle with an lt77 and hasn't broken anything,remember the problem is reduced being as there's a centre diff with the lt77 (the axle uj's might still "knock/kick" on full lock though, i don't know)

a defender lt77 and lt230 is about 4" longer than a Series box which really requires you move your engine forwards about 2" and have custom length propshafts, you can swap the lt230 for a Series transfer box with an adaptor, you still have to move the engine but you can then retain the original props and selectable 2x4/4x4

it's worth you looking at Ashcroft Transmissions website for more detailed instructions on what can be achieved with the LT77 and 200tdi, lt230 can be modified for selectable 4x4/2x4, Ashcrofts also supply the lt77/Series transfer adaptor

NiteMare,

The engine/gearbox is from a Defender but not sure if I want to take on an engine transplant.
I might stick with the Isuzu or even look for a 2.25 petrol.

Decisions, decisions.....

Colin

200tdi's are reasonably easy to get hold of if you want one, so I'd say stick with what you were planning - get the Isuzu working and see what its like...
By the time you drop in a 200tdi, LT77 change diffs etc you've almost built a County :angel:

Steve

Dont forget its a much easier conversion if you fit the 200 as a di..no turbo,

You do need an old 2.25d exh manifold...but the std exh sys will connect...downward facing pipe,

Thats what I fitted to my S3 SWB..loads of power very good mpg engine bay very simple.

Nick.