Engine swaps

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Originally Posted by gromit

My bad, thread had moved on from OP's question. That'll teach me to read through all the posts.......

Colin

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No worries.... I've been caught out like that too! :)

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Originally Posted by debruiser

Sorry... havn't checked this thread for a bit!

As Jerryd stated....

Disco 200tdi motor drops straight in! Use the engine mounts from your 2.25, I've used HD diesel 2.25 engine rubbers on the engine AND gearbox. I did have to remove the battery tray - but then again I've dragged the engine forward 100mm and up 50 or 60mm to fit in the R380/LT230 combo into a shorty and still have a rear prop shaft! Quiet happily his also puts the gear lever in the right location! I moved the battery under the passenger seat, although I have seen photos on the web where they have retained the original battery location (think they just modified the battery tray).

I also took manifolds and turbo from a defender 200tdi and bolted that straight on. It was a bit of a faff fitting my 3" exhaust.... customised the dump pipe, then run the exhaust out into the wheel arch BUT you wouldn't have to do that... I dont have a pipe bender so was just using pieces of bent tube to make the exhaust.

Depending on how original you want it all to look, you could retain the oil bath filter I guess, but I went with a 200tdi air filter jammed in where the cab blower normally goes then stuck a defender snorkel on the side there so I have minimal pipework. As far as the radiator goes, you could run stock location rad OR get a defender rad bracket and have the stock intercooler there too, It'll all start getting nice and cosy in the engine bay at that point if your retaining the series bonnet. But definitely doable - google! I didn't bother with the series bonnet; I used an ex-mil bonnet and a defender grill, I also used a larger IC so placed that in front of the rad jammed as far forward as I could. I'm currently running a separate oil cooler but I'm thinking of using the 300tdi rad oil cooler.... when I get round to getting the right fittings to connect it up. Having the rad forward gives me plenty of room to work on the engine without pulling the rad out! (yes I'm trying to make maintenance easier)

I'm not sure if you'll have room to use the standard cooling fan from the disco - I seem to remember someone saying that it is in a very wrong location.... so thermo's are the way forward, but learn from my mistake and get quality ones, those ebay cheap jobbies are RUBBISH! I have a good one on the IC blowing, and the cheap rubbish pulling behind the rad. The cheap one needs changing out for a quality one.

Originally I had the 200tdi bolted up to a series box, it seems a very common setup over in the UK, but my box ended up being complete rubbish so I decided to upgrade. When the roadworthy man came to look at the car with the series box in it, they thought it was standard turbo diesel, I could have passed it off as a factory engine. THAT is how easy the swap is. if your interested my R380 has the 0.7 5th gear, LT230 has the 1.2 ratio and I'm running 4.7 diffs and 255/85r16s (33's) So 80km/hr is about 1800rpm, 100km/hr is roughly 2200rpm.

When you read all that and think "gee, that all sounds hard" remember that I'm a qualified teacher, I have no mechanical background, just tinkering in the shed. The conversions probably took me 10x longer than someone who knows ANYTHING but I got there in the end.

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Thanks for your info, very useful
Does the 200tdi bolt up straight onto series 2a gearbox , is an adapter needed, what flywheel and clutch combination is used?


cheers


Jason

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Originally Posted by jason young

Thanks for your info, very useful
Does the 200tdi bolt up straight onto series 2a gearbox , is an adapter needed, what flywheel and clutch combination is used?


cheers


Jason

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No worries!

My understanding is that a 2A g/box is the same as a 3... so I'm going to say yes BUT there are 4 extra bolts on the 200tdi that really need to be added (along bottom). No adapters needed.

I was using a series clutch on the 200tdi flywheel. Probably best to use a diesel clutch though....

A wealth of info can be found here: "200Di" diesel conversion for Series Land Rovers - by Glencoyne 4x4 (Thetford)

and here: http://www.expeditionlandrover.info/...conversion.htm

not trying to fob you off! Just sharing resources, this is how I plucked up the courage to do the conversion myself! :D


EDIT: Just remembered. depending on what accessories you are running on the 200tdi, you may have to buy/make a new alternator mount, I used the series mount and added a block under it to stand it off so that the fanbelt could run the water pump and the alternator. You can buy the standoff bits from glencoyne if you're not up to the challenge. I think it depends on if you want to retain the series alternator or move up to the 200tdi unit. I'm using a 200tdi alternator. Have a read of the glencoyne site, he covers everything.

In addition to tapping the the holes on the 200tdi flywheel housing, so that it can be bolted to the series box; it is also necessary to mark and drill for a dowel to locate the gearbox in the correct position.

When I did mine the holes on the Disco flywheel housing had to be drilled to increase them by 1mm from memory,

Cheers Charlie

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Originally Posted by chazza

In addition to tapping the the holes on the 200tdi flywheel housing, so that it can be bolted to the series box; it is also necessary to mark and drill for a dowel to locate the gearbox in the correct position.

When I did mine the holes on the Disco flywheel housing had to be drilled to increase them by 1mm from memory,

Cheers Charlie

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You've done one as well chazza? NICE! Did you retain the turbo? Does it go pretty well for you? I've converted to and R380/LT230 combo so I have little fear of killing gearboxes... It goes pretty good... if only I had power steering and disc brakes!

^^ Do you have any pics of the installation to share ??

I've got a 200tdi motor sitting in the garage waiting to go in, I've already prepped the Series Gearbox ready. I just need a kick up the bum to start the conversion :D

I think the wiring side of it is putting me off :confused:

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Originally Posted by jerryd

^^ Do you have any pics of the installation to share ??

I've got a 200tdi motor sitting in the garage waiting to go in, I've already prepped the Series Gearbox ready. I just need a kick up the bum to start the conversion :D

I think the wiring side of it is putting me off :confused:

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what wiring? if you're coming from a 2.25D its one wire for the fuel cut solenoid.

If you've got a either of the petrols all the wiring is in place you just need to move it around a little and depending on if you have the push button start series (yes all you new luxobarge owners the shed class did it back in the 50's and 60's) one wire for the startermotor.

The draw from the TDI starter isnt massively more than petrol starter so you dont need to upgrade the wiring just to get you started but its worth doing for longevity reasons.

Total wiring requirement for a tdi is

2 wires for the alternator unless you want a tacho then its 3 and the wiring from any of the series engines is in the right spots already for any of the alternator equipped engines
1 for the fuel cut solenoid
1 for the Low oil pressure (and the one from the series is already in the right spot
2 wires for the startermotor, 1 the main feed and 1 for the signal wire.

Photos... gee... there is my build thread:

http://www.aulro.com/afvb/members-ri...ies-3-swb.html

or for a sample....

here is 200tdi a bolted to a series box with a sals diff:

https://www.aulro.com/afvb/images/im...016/06/354.jpg

https://www.aulro.com/afvb/images/im...016/06/355.jpg

https://www.aulro.com/afvb/images/im...016/06/356.jpg

Here is a 200tdi, R380/LT230 jammed into an 88" with a sals diff.

https://www.aulro.com/afvb/images/im...016/06/357.jpg

https://www.aulro.com/afvb/images/im...016/06/358.jpg

https://www.aulro.com/afvb/images/im...016/06/359.jpg

https://www.aulro.com/afvb/images/im...016/06/360.jpg

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Originally Posted by debruiser

You've done one as well chazza? NICE! Did you retain the turbo? Does it go pretty well for you?

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Well the problem is I have been diverted onto a kitchen renovation and the S3 project is gathering dust.

Yes it has a turbo and the intercooler is set up on an angle above the steering relay; that way the panels don't need changing and the radiator can sit on top of the front cross-member.

I just have to plumb the oil cooler pipes to the heat-exchanger; do some wiring; finish the PCV plumbing and it should be ready to start.

The rest of the car needs work though and it is unlicenced,

Cheers Charlie