Discovery 200tdi into Defender

donb

donb

Well-known member
Finished up the turbo install.

I used a 300tdi manifold gasket which seemed to fit fine. I had to use longer M10 studs though.

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The Alisport turbo kit includes a drain. I have a new 300tdi turbo oil feed on order.

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Few pics of install. I had the 2 exhaust pieces ceramic coated. Overkill and a little expensive. Next time I?ll use the ceramic high heat spray paint I found at Lowe?s the other day.

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I bought some 1/2? stainless bar at the metal yard the other day. Made an EGR plate and will get a bung to weld on for the EGT port.
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RH side engine mount with a Glencoyne bushing:
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donb

donb

Well-known member
Napalm00 said:
Yes.

Install seal into clutch housing . Use red locktite on edge of seal. Cut heads off random m10 bolts and use them as guides to install the clutch housing , main and block gasket square.

Baste block gasket with great stuff as noted in previous post . Use plastic crank tool to protect seal when Installing ( it's an Install sleeve not a shipping thing)

As you tighten down the clutch housing the plastic tool will push through the crank seal and pop out

The reason I mentioned to get the seal from the kit instead is because it's cheaper and comes with the t seals
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Thanks again. This is the best install description I found. I saw some posts saying to install the clutch housing first but I felt it was too hard to know exactly the dept the rear main seal went and would be nearly impossible to get the Loc-Tite on (which can see being an important step).


And mis-information out there about the shipping protector. I can see how it's an install sleeve.


I ordered the parts individually as I didn't see that part on the 200tdi pages. Good information fro people in the future. Great price as part of the kit!
 
1of40

1of40

Well-known member
donb said:
Thanks - I have a 300tdi dipstick assembly on order.



Working with John - maybe meet up today for the cover.


292 sounds interesting but I want diesel and I want to drive this 110 at VOR in a few weeks. I know people shit on the 200tdi but I also feel like a lot of capable people run them and like them. I know it's not without faults but it should be ok. I may rebuild the OM617 and chase down bigger HP with the IP and turbo so that could always end back into the 110. Or a R2.8 once I see one in action in person.
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Don, I've really grown to appreciate the 200 for what it is. Just gets the right mounts to save your dental work. 😂
 
Uncle Douglas

Uncle Douglas

Well-known member
Callsign: delete
My only complaint with the disco 200 is that its the hardest/biggest pita of the rover diesels to do the timing belt on.

A couple of minor tweaks like remove the T fitting off the turbo and run that straight to the ip but pull the wastegate signal from the intake manifold, tune the fueling, and they are great powerplants.
This turbo technics setup should be very cool. Love to hear your driving impressions.
 
donb

donb

Well-known member
Napalm00 said:
Now is the time to drill that manifold for a egt probe !

Also your gonna want to swap the nuts you have holding on the turbo cast elbow for all metal locknut's . The copper coated BMW style are great .

Here is an example https://www.amazon.com/M10-1-25-Cop...+turbo+nut&dpPl=1&dpID=51W9KmBo5zL&ref=plSrch
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I?ve seen your posts on drilling the manifold for an EGT probe but after the money spent I just can?t do it to the new turbo, haha

The probe I have is pretty long so I think at the right angle I?ll just weld an NPT bung into that stainless plate I made.

Thank for the links for the copper locknuts. I?ll add those to the next Amazon order. I will have some exhaust questions down the road.


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donb

donb

Well-known member
1of40 said:
Don, I've really grown to appreciate the 200 for what it is. Just gets the right mounts to save your dental work. [emoji23]
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Thanks Clay - I?ve enjoyed working on this engine so far. Just like you said, from the stuff I?ve read people appreciate them for what they are. And one of the first things I bought were the Glencoyne engine mounts!


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Napalm00

Napalm00

Technical Excellence Contributor
Totally get not wanting to drill the turbo or the new Mani . Just make sure it's deep enough to get a reading !
 
donb

donb

Well-known member
Uncle Douglas said:
My only complaint with the disco 200 is that its the hardest/biggest pita of the rover diesels to do the timing belt on.

A couple of minor tweaks like remove the T fitting off the turbo and run that straight to the ip but pull the wastegate signal from the intake manifold, tune the fueling, and they are great powerplants.
This turbo technics setup should be very cool. Love to hear your driving impressions.
Click to expand...


Looking in the rear view, I should have held out for a Defender 200tdi. But...it?s what I have and I might keep the feelers put for a Defender front plate and cover.

Thanks for the tip on the T fitting. I?ll probably circle back for more info once I get into that part of the install.

Matt from the town next to me got a TT setup on his 300tdi and liked it a lot. It was the catalyst for me to go down this path actually.


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donb

donb

Well-known member
I got the OM617 out of the 110 last Friday. I cleaned the engine compartment a bit and organized some of the items for the 200tdi. Today I found a machine shop that will surface prep the flywheel. I've been emailing Zack at RN back and forth for odds-n-ends.


Tomorrow I would like to get the T-seal and Rear main seal done. I looked for Hylomar 2000 at the local AutoZone stores but nothing. I found an old post ( https://www.defendersource.com/forum/f6/hylomar-2000-alternative-74005.html#post776395 ) and ended up buying a can of Right Stuff and Permatex Ultra Grey for the ladder and oil pan. What do you guys think?


I would love to get the bottom and rear of the engine prepped this week and then installed into the 110 before the weekend. Then do the front end stuff like timing belt and hooking things up next week.
 
donb

donb

Well-known member
Thanks for the tip on just using Right Stuff guys.

I brought the flywheel to a machine shop to get surfaced but he couldn?t get the dowels out. I brought it back home and welded some stuff to them and pulled them out.

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After a quick email, new dowels on way from RN - thanks Zack!


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donb

donb

Well-known member
I had some parts come in so I?m almost done on the 300tdi intake/exhaust/turbo and oil level check side.

The turbo kit comes with a turbo drain setup. Since it?s a 300tdi turbo a new oil feed is needed. Part number is: ERR4894.

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I changed the dipstick tube per tip from Robert Davis (thanks!). I removed some material on the clip and cut the tube where the O ring was. Actually I tried to sand down the ridges and a part of the tube came off. Part number for the dipstick tube is ERR4697. I?m going to weld a piece of the old tube to the end and have to source a copper Follet so the bolt at the block seals up.

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donb

donb

Well-known member
DefendersNW said:
Next time (not that there will be one) drill a 2mm hole on the backside, and tap the dowels through.
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I read posts about drilling the backside but looking at how thick the flywheel is and worried about hitting the correct spot I just fired up the Miller and used some old bolts. Although - I?m almost thinking that the dowels are out to drill them for the next time.


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donb

donb

Well-known member
Sorry about the picture dump but I wanted to document some items that I found during this process.

I was going to lift up the engine and pull the pan tonight. I pulled the transmission plate and test fitted it to the stubby R380 in the 110. I had to pull out 2 of the dowels, tap 4 - M10 hopes for studs and drill out the bottom 4 pass thru holes so I can run Allen head bolts to mount to the engine.

Pics should make my mess of words make sense:

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