Les Henson Posted October 7, 2008 Share Posted October 7, 2008 The top rad mounts that I bodged-up were a bit awful, but in my defence - time was running out. I had to get it running before she chucked me in Les. Quote Link to comment Share on other sites More sharing options...
monty Posted October 7, 2008 Share Posted October 7, 2008 can you please post up some details of parts/part numbers etc as well...i'm getting very close to making the decision to swap out the 2.5TD in place of a 200tdi....and the more help that I can get the better...particularly in terms of getting all the parts together so i can bring it to someone who knows what to do with them all. Quote Link to comment Share on other sites More sharing options...
disco_al Posted October 7, 2008 Author Share Posted October 7, 2008 the tech archive is a good place to start, read and print Les's excellent guide http://forums.lr4x4.com/index.php?showtopic=2394 next step is to try and source a complete discovery, as thiw makes the job a lot easier. we are using a conversion kit from ebay for the exhaust and intercooler pipes, saves a lot of time and makes everything easier. other than that you will need a new clutch kit, timing belt kit (good idea to do whilst it's out), a good engine crane/tractor/telehandler, good set of sockets, spanners, varying sizes of hammer etc only "special" tools you may need would be a quite large 3 leg puller, large socket set (we used a 3/4" drive set for the crank pulley bolt) and possibly a welder quite an easy job to do really, but it's best if you can talk nicely to someone with a barn or large garage with power and lights Quote Link to comment Share on other sites More sharing options...
disco_al Posted October 13, 2008 Author Share Posted October 13, 2008 It's done!!! Fired up first (ish) turn of the key, after the fuel had primed. Purrs like a kitten, no knocks, rattles or squeeks. No funny coloured smoke out the bak either - result. He is well impressed with the difference, hills that were once 2nd gear it will now cruise up in 4th and still pull. This is a well recommended conversion for the defender, Mr.Henson, hats off to you for an excellent tech archive thread, helped us out many times. Quote Link to comment Share on other sites More sharing options...
monty Posted October 13, 2008 Share Posted October 13, 2008 Ok, getting gathering prices...for the conversion i will need Conversion Kit (intercooler + exhaust) approx £170 off ebay Clutch Kit approx £60 off web Timing Belt Kit approx £39.85 All filters approx £11 So this is working out about £290....is there anything else, no matter how small e.g. rubber seals etc that might be needed other than the engine? Also, what engine ancillaries might I need? Or what must I specify? thanks Quote Link to comment Share on other sites More sharing options...
disco_al Posted October 13, 2008 Author Share Posted October 13, 2008 You need as much as possible really - alternator, PAS pump and pipes (Disco hi pressure pipe will reach, but doesn't sit flush to the cross member. TD oil cooler pipes and adaptors (long enough to reach the rad) Service kit (oil/oil filter/fuel filter), some 8mm fuel hose and jubilee clips, assorted bolts, washers and nuts. New front and rear crank seals (adaptor plate on block needs to come off, along with the flywheel (which are the same 200tdi & n/a) and the front timing cover seal. Defender temp sender, oil pressure switch, (may as well put a new one on). Other than that, just usual consumables, WD40, gaffa tape, selection of hammers, electrical terminals etc... Quote Link to comment Share on other sites More sharing options...
bluespanner Posted October 13, 2008 Share Posted October 13, 2008 Talking about rads. On my hybrid, i think the bodywork is too far back! (rangie chassis, series bodywork, 200tdi & R380) My bottom hose outlet on the 200tdi disco rad iv got exits straight into the PAS box. bummer. What rads have both top and bottom hoses on the intercooler side? Cheers Quote Link to comment Share on other sites More sharing options...
disco_al Posted October 14, 2008 Author Share Posted October 14, 2008 Serck list a two pass rad for the disco 200tdi with bout inlet/outlet on the intercooler side - part number 2142275 Quote Link to comment Share on other sites More sharing options...
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