200 TDI into a Series IIA

[baja gs]

Why a 200di minus turbo? I have done some reading on this matter and have come up with this. To begin with I am not a professional mech. That said, I saw a British site that sold the 200DI. Their claim was that without the turbo, mating the engine was much easier, that the standard radiator could be used. Also no intercooler. The non turbo is less worry on the trans and drive train, and fitting under the bonnet. The 200 TDI was made to withstand the added pressure caused by the turbo, so without the turbo, should last a long, long time. Now with this set up, it wont be a big jump in power, as far as a big noticeable increase in speed off starts and such, but will pull a mountain pass at 60-65 instead of 45. I dont know that this is all true, thats why Im asking. If this is the case, maybe some one could jump in with some good advice.

[TeriAnn]

There was a long thread about the 200di conversion on the Series II club forum a year or two ago. The proponents of a non-turbo conversion were saying that the non turbo 2.5L 200di provided about the same power as a stock 2.5L petrol engine. Which is about 13HP plus some additional torque better than the 2.25L engine Americans are used to. That would make it less powerful the the stock US version of the LR six cylinder petrol engine.

If the advocates are right don't expect to climb hills faster than a LR with the six cylinder engine but you get a HUGE increase in fuel mileage and an engine that will outlast the petrol versions.

It is a conversion for a massive increase in fuel economy and not so much for speed according to the advocates on the SII club forum.

[Lalo88DK]

Why a 200di minus turbo? .

The stock series drivetrain won't cope well with the extra power of a 200TDI, I know a few that have regretted fitting a 200 TDI in a Series.

I would not fit a 200TDI in a Series Land-Rover.
200Di is a much better solution, and a 200DI will last nearly for ever, but will also be a bit more noisy without the turbo.

[REDrum]

The stock series drivetrain won't cope well with the extra power of a 200TDI, I know a few that have regretted fitting a 200 TDI in a Series.

Interesting.
Which series?
What was the "won't cope" and "regret"?
What parts did the increased/HP/Tq cause to fail?
What did TDi swapped owners do to prevent failure a second time? (assuming they did not remove turbo or whole tdi..)

Thnx

[TeriAnn]

Interesting.
Which series?
What was the "won't cope" and "regret"?
What parts did the increased/HP/Tq cause to fail?
What did TDi swapped owners do to prevent failure a second time? (assuming they did not remove turbo or whole tdi..)

Probably pretty much all Series except stage I and 101's.

Won't cope means gearboxes tend to break as well as those wimpy 10 spline rear axles.

First you want a 24 spline rear axle conversion. You can get by with the stock gearbox if you are not into popping the clutch. Only problem is that the aftermarket gearbox replacement parts tend to be less than original quality. Some people with 109s install a LT77S five speed gearbox.

Some people have been known to use the stronger LT95 four speed gearbox. Others just try to be easy on the clutch with a stock box. If you do an LT95 you will probably want to swap in a Disco front axle assembly.

You just can not swap out one part of a drive train without thinking about how the new part will affect every other part. Well you can but eventually something in the rest of the drive train may well cause you to think beyond that one component you replaced.

[REDrum]

Won't cope means gearboxes tend to break

Thanks, I'm looking for data on what specific gears and/or in/out shafts break? Upgrading axle shafts is a no brainer.

You just can not swap out one part of a drive train without thinking about how the new part will affect every other part. Well you can but eventually something in the rest of the drive train may well cause you to think beyond that one component you replaced.

Agreed, having been in motorsports and rally for 25 years I know all about it....

[VermontOverland]

Matt Browne at Overland Engineering in Maine is the guru on tdi's in series trucks. He's working on my Series III tdi as I write this (installing power steering). I run a stock gearbox, a RN high ratio tcase and a 24 spline GBR rear end and the main wear point I've had is the rear driveshaft ujoint, which is a good, relatively inexpensive "fuse" for all the added power and torque.

I absolutely LOVE the tdi in the series. Incredible additional power in all conditions, but it really shines on those long highway trips. Just rips along growling away.

[REDrum]

So we have one more thing in common Peter, dark green diesel series III.

He's working on my Series III tdi as I write this (installing power steering)

I didn't know that was your's, I touched it on Tuesday.... I'm working w/ Matt on sourcing and prepping a 200tdi for "Ticostan" Your rig set up is my goal, just with less stickers

Damn this is a small community.

[Skookumchuck]

My engine shiped out to me today. I am hoping to have it late next week and get started with the conversion. It is coming with a 300 TDI exhaust manifold which I hope will cure the steering box issue. I will be taking lots of pics as we start and get this done. Will post as we get things done.

[TeriAnn]

It is coming with a 300 TDI exhaust manifold which I hope will cure the steering box issue.

Isn't there a power steering pump mounting bracket available for the tdis?

If yes it should be easy enough to put in a RR P38 power steering box & eliminate the stock steering box.

But there is a negative side. I discovered that the manual steering was an important part of my daily upper body workout. Now days I keep a pair of dumbbells sitting next to my chair in the living room to use whilst watching TV in the evening.

[Skookumchuck]

what is the cost of a p38 steerig box? The guy I bought my Rover off of has one for sale. Lugging a chainsaw around will work at keeping my beer belly to a six pack or a 24 if they are a good sale price....just finished eating a rack of smoked ribs getting ready to watch the game .

[TeriAnn]

what is the cost of a p38 steerig box?

It really depends. A lot of P38 RRs have been going to the wrecking yards. Depends upon what the wrecking yard asking price is. I would guess well under $100.

[Skookumchuck]

thanks the guy up here wants $700 for a brand new in the box one.

[CMorris]

I have a spare P38 set up that I would love to get out of the shop for $100.........problem is shipping, the thing weighs a ton!

[o2batsea]

Matt Browne at Overland Engineering in Maine is the guru on tdi's in series trucks. He's working on my Series III tdi as I write this (installing power steering). I run a stock gearbox, a RN high ratio tcase and a 24 spline GBR rear end and the main wear point I've had is the rear driveshaft ujoint, which is a good, relatively inexpensive "fuse" for all the added power and torque.

I absolutely LOVE the tdi in the series. Incredible additional power in all conditions, but it really shines on those long highway trips. Just rips along growling away.

Um, he's over on GnR trying to get some answers for you just now. I replied to his post, but he may end up having to order up a bracket for ya.

As I stated earlier, the 200tdi is not a "drop in", it's major reconstruction.