Ohlins Posted April 2, 2023 Share Posted April 2, 2023 (edited) 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. Edited April 2, 2023 by Ohlins 1 Quote Link to comment Share on other sites More sharing options...
Ohlins Posted April 2, 2023 Author Share Posted April 2, 2023 (edited) 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...... Edited April 2, 2023 by Ohlins 1 Quote Link to comment Share on other sites More sharing options...
Ohlins Posted April 2, 2023 Author Share Posted April 2, 2023 (edited) 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 Edited April 2, 2023 by Ohlins Quote Link to comment Share on other sites More sharing options...
Ohlins Posted April 2, 2023 Author Share Posted April 2, 2023 First start up...... 1 Quote Link to comment Share on other sites More sharing options...
Ohlins Posted April 2, 2023 Author Share Posted April 2, 2023 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. 1 Quote Link to comment Share on other sites More sharing options...
uninformed Posted April 4, 2023 Share Posted April 4, 2023 Great work 👍 1 Quote Link to comment Share on other sites More sharing options...
monkie Posted April 4, 2023 Share Posted April 4, 2023 This is really interesting and no doubt will be helpful to those wanting to do similar. Admins, one for the tech archive? 1 Quote Link to comment Share on other sites More sharing options...
reb78 Posted April 4, 2023 Share Posted April 4, 2023 Nice thread. Thanks for posting. 1 Quote Link to comment Share on other sites More sharing options...
miketomcat Posted April 4, 2023 Share Posted April 4, 2023 This is very interesting but much as I prefer the 200tdi (I have two of them) I can't help thinking for all the work involved in this conversion it makes more sense to just fit a 300tdi and r380. Especially if you go for factory position and parts. Mike Quote Link to comment Share on other sites More sharing options...
Ohlins Posted April 4, 2023 Author Share Posted April 4, 2023 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. 2 Quote Link to comment Share on other sites More sharing options...
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