rjblank

not entirely... the intercooler will not fit. all else will. You would have to modify an intercooler to fit sideways and the inlet/outlets moved on the intercooler. as it is now, it's a tight fit

The new mounts work great at limiting the vibrations and were well worth the effort. I'll be working with Glencone Engineering http://www.glencoyne.co.uk/ to come up with a bolt-in version of the chassis side of the engine mounts. It will still require removal of the series mounts from the chassis. More to follow soon.

Black Wolf, what kind of flares do you have there?

Here are the exhaust pics. I exited the turbo over the chassis rail, through the bulkhead support, under the outrigger in front of the rear wheel (to Grandmother's house we go). It's 2 1/4 ID pipewith a vibration dampening flexi joint. I have to go shoot some more pics of the finished install and post them. I was too tired last night to photograph it.

My old series 3 had a smokey 2.25 diesel and a top speed of 53 miles an hour (downhill) I just completed (yesterday) a 200TDI conversion (yes, another one) but this Disco engine install is slightly different, hence this post. I owe a huge Thank You to my friend Richard, at Glencoyne Engineering, and his assistant, Adam, for their help. Without them, this effort would not have been possible. Glencoyne's experience in 200DI conversions was invaluable. "Ok, so what's so different?" you ask... I used the Disco engine mounts, a series radiator, 300TDI intercooler and seperate oil cooler. Other than that, nothing really... My series radiator is in excellent shape and I didn't want to lose it. Besides, it's bigger and theoretically, would cool better (especially with the large cooling fan). Along the way, I rebuilt the series gearbox, replacing two slightly worn gears and an Ashcroft's high range transfer box. The only thing I would have done different is the chasis side of the engine mounts... I used old Disco mounts that were lying around, and cut them for what I needed. In retrospect, It would have been easier to use square tubing fron the chassis rail for mounting the disco mounts (like I wanted to from the beginning, but got in a hurry and used what I had around). I know the old mounts would "work" , but the engine vibration transfer to the chassis is too much. With the Discxo mounts, it is so much smoother... now to get my shifter handle to stop vibrating... I'll have the exhaust pics uploaded soon...

Nice job. I need one... I guess I'll have to do mine on my own though...

I love it... I have been thinking about doing the same thing. This is an awesome job.

I can let you know how well the Disco mounts work limiting the vibes in about 10 days, when mine is running. I'll send pics. IT looks like a pretty straight forward operation... and after removing the factory series mounts, I think the Disco mounts will be easier to install. I've been studing how to do the conversion for about 6 months. Just now getting to turning a wrench to it. I was going to use RR 3.54 gears, but decided to do a high range txfer box instead. Bought a small oil cooler to install where the horn used to reside, and the intercooler will fit on the other side of the rad support, just in front of the radiator. How did you sort out the exhaust? Steve Parker pipe? I am looking to come outside the frame, below the passenger floor with the exhaust.

Richard, at Glencoyne, is the one who did the conversion you speak of. He has done quite a few of the 200DI conversions. I've seen four or five of them now. They actually work out quite well. He had an 88 he drove for quite a while and only parted with it for a bigger 109 vehicle. The only "downside" is the increased noise and occasionally one will need the fuel delivery optimized. The lack of performance would not be noticed when it had the turbo, since the turbo made up for it. Richard can provide all the details. He says that it has all the power of a 2.25 petrol, but with better mileage. I have a series 3 that I am converting to a 200. I am taking a slightly different approach to the install. Instead of using the factory series engine mounts, I am using the Disco mounts. The 200's on series engine mounts create too much vibration at idle for my liking... I'll have the pics posted soon. At this point, I have an empty engine bay and a mountless frame. Next weekend will see the engine installed and working on the electrics and exhaust.

If you have access to a welder, you can fab up some good dual function bumpers... I have seen many trail vehicles using tube bumpers as air storage tanks especially in vehicles with limited carry space. (like the Land Rover) If you are looking at CO2 for an alternative to a pump, you can also use Nitrogen in the same fashion.