Ohlins

Indeed....I had the donor engine on the floor.....the LT77 is a reconditioned one and the cost was just rings, shells etc. There's only 180,000kms on the 200tdi engine. I thought I'd give it a whirl. This way I can at least buy a new head if it zaps because the 200tdi head is hens teeth. I'll sell my 200tdi which will cover the parts prices.

Difference in con rods..the 200tdi will not fit into the 300tdi pistons......the 300tdi have a chamfer at the small end and their pistons have same to receive it.

First start up......

Head mounted with T piece for water hose...... Plumbing connector from water pump to head.......I filed it to make it rough and mounted dry before tightening...I will look for a longer connector Injection pipes.....one bridle connector will fit back on

Engine hoofed out....... Sump removed to find the previous owners lift pump arm in there. Just light debris on the oil strainer.....non metallic..old silicon Cylinders honed as best I can..... Pistons and rings etc installed after cleaning the pistons up Gasket...... Sump put back on and sealed......

I have a 1986 ex army 110 with a Discovery 200tdi engine fitted, along with 300tdi manifolds, turbo and down pipe. As per normal the 200tdi head finally zapped due to a crack in in the bridge across the valves. Unusually this happened only about 10kms from home and not in Outer Mongolia. I made a U turn and limped home whereupon I later put my reserve 200tdi head on, kept for just this very same scenario. I kept my 300tdi engine from my old Discovery which was scrapped and which had 600,000kms on it and I would use this for donor parts and with a new head with only 200,000kms on it After constant 5000kms oil changes this engine still shows the factory honing in the cylinders, the big end shells are smooth with no grooves and the crankshaft journals are like new. Should I not just drop in the 300tdi? No.....not for me....the engine mounts for the 200tdi are a straight fit, as is the bell housing, (albeit with my Steve Parker bottom countersunk bolt kit) main vehicle feed wiring plug is the same and the 200tdi does not have the serpentine belt set up along with the belt tensioner, P gasket scenario and pulley bearing in the front cover. I don't mind the traditional fan belt set up along with the PAS steering belt. I'll lift the engine out because it's goofy to try and do it from below due to the allow 'ladder'. I will need for my fit in no particular order...... 1. New Victor Reinz MLS 3 hole head gasket 2. New valve stem oil seals for the take off head. 3. Grinding paste etc to lap the valves and spruce up. 4. The 200tdi head bolts 5. 300tdi fuel injection hard feed pipes from the fuel injection pump to injectors. Take off the connection bridles to allow the pipes to be bent to offer up to the injectors. 6. New rocker cover gasket 7. To keep it correct 4x300tdi pistons (it works with 200tdi pistons also ,so a drop on head will actually work) along with new rings 8. Bore honing drill tool to spruce up the cylinders. 9. Copper T pipe and hose to adapt and feed to the heater hose. 10. Copper reducer connector to adapt from the 200tdi larger diameter water pump hose to the smaller 300tdi hose, a hose also that you must find that has a suitable bend to get to the head. 11. Plug hose at the thermostat housing that would originally go to the plastic 300tdi coolant reservoir. I have a metal one. 12. 300tdi injectors and new copper sealing washers.....200 fuel banjo connectors will work as far as I know..I used my 300tdi ones with new copper sealing washers 13. The 300tdi water temperature sensor will not work with my older gauge when connected. The needle will go to the red.I will order an aftermarket 14. 300tdi con rods. 15 300tdi small end bushings 16. Big end shell bearings are the same for the 200 and 300 17. 8x con rod nuts 18. 1x Oil pump gasket 19. 1x tube of Instant gasket 20. 1x clutch thrust bearing and spigot bearing if need be..mine was dry due to water off roading 21. Service kit and new oil. 21. New thermostat. 22. Exhaust manifold gasket I lifted the engine out and set to take it apart.

Running OK, so far, after 400kms that is

Hi I'm just about to work on a photo 'How to' this afternoon.

I have just done this..all going well to date.

Thanks...I may consider this for next summer for my V8 ex army Defender 110. .

Necessity is the Mother of invention. Well done. .

First start up just to see that it works......we'll find a water hose routing solution next.....we're thinking it should not be up to full power when we test drive due to the different pistons, injectors and fuel pump calibration but we'll see and report back. We should give it a whirl this weekend.

Yip......I too have that set up on my 200tdi Disco engine in my Defender, with a 200tdi head, that is. Really hard to find a 200tdi head here in France at present and Frederick needs the Disco for the Rallye des Cimes and others here as he's clerk of the course. All the best .

My friends 200tdi cylinder cracked in the usual place between the valves. He couldn't find an other cylinder head and as I have parts here we decided to give it a whirl to show others our findings when we put on a 300tdi cylinder head without changing out pistons. We couldn't find anyone else on the internet who had chronicled it. If it all goes horribly wrong we don't care......it's only a 30 yr old engine on a 30 yr old Land Rover. I'll list what parts are required at the end along with some mention as we go along... 200tdi cylinder head that was leaking water. I had a 300tdi head kicking about so as you can see the distance between the valves is further apart than on the 200tdi. We set about cleaning the dusty head that's been in the workshop with copious amounts of brake cleaner..... We will need the rocker assembly too..... We cleaned off the block as best we could in readiness for the head to be fitted, scraping off any left over gasket material........ We put on a new cylinder head gasket and mount the head.......we torque down first to 40Nm then continue two tightening sequences at sequence at 60 degrees.....each flat on a bolt is about 60 degrees hence the marker pen marks. 300tdi pistons have a different combustion chamber to the 200tdi pisttons......so there should not be a perfect burn pattern going on. We'll see what it drives like later. 300tdi pistons...... 200tdi pistons....... You'll need the 300tdi rocker assembly and injectors.....glow plugs are the same as are the pushrods.....the 200tdi valve stem caps will work if you haven't lost any down into the pushrod holes. The first goofy thing you'll find is the hard fuel lines from the injection pump need to be 300tdi....17mm same size to tighten as with the 200tdi, but the thread is different.... You'll also need to take off the connectors that keep the fuel pipes together and parallel. You'll be pulling and bending same to make them fit. Once we set the valve clearances and put on the rocker cover the next goofy thing we found was that the water heater tube was fouling the connection of the water temperature sender which meant the tube would not pass......after tightening the sender gingerly the tube was able to pass.....so no need for a 300tdi inlet manifold. You'll also need the 300tdi rocker cover breather canister and the thermostat housing.....after that it's ready to go apart from rummaging about for some water hoses to connect the water pump and heater.