200TDi with 300 Exhaust - Defender Source
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  #1  
Old April 26th, 2016, 01:29 PM
CircuitTested
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200TDi with 300 Exhaust

Long, long story but I ended up with a 200TDi block and a 300 turbo/exhaust manifold that I wanted to swap into my 86 petrol 90. Figured it couldn't be that bad. I was very wrong. Anyway, here are a few pictures of our custom exhaust route. Thought it might save some poor soul some trouble down the road. The second bend was made to leave enough clearance to bleed the clutch without taking the entire downpipe out.










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  #2  
Old April 26th, 2016, 01:53 PM
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Thanks for posting. I'm headed down this lane soon I hope in a RHD 110. Did you run into trouble with the dipstick being in the way?
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Old April 26th, 2016, 01:55 PM
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If I recall correctly the dipstick was ok but a tight fit, just needed bend it a bit and it cleared. Let me know if you run into any trouble...the hoses were a bit nightmare too so just order 2x whatever you think you'll need so you can make some custom bends.
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  #4  
Old April 26th, 2016, 01:59 PM
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Who did your exhaust work?
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  #5  
Old April 26th, 2016, 02:01 PM
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Hoses or pipes?
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  #6  
Old April 26th, 2016, 03:24 PM
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Quote:
Originally Posted by Naplm00 View Post
Who did your exhaust work?
Done in house at our shop. Located in Fairfield County, CT

------ Follow up post added April 26th, 2016 03:25 PM ------

Quote:
Originally Posted by 1of40 View Post
Hoses or pipes?
I was referring to all of the intake and coolant hoses but order some 45 degree exhaust pipe bends ahead of time from summit or something...you'll need them.
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Old April 26th, 2016, 03:35 PM
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I got to ask why did you not just buy a down pipe? They come with a nice flexible section that stops some of the droning. But nice work anyways.
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  #8  
Old April 26th, 2016, 03:37 PM
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Originally Posted by roverman2010 View Post
I got to ask why did you not just buy a down pipe? They come with a nice flexible section that stops some of the droning. But nice work anyways.
I assume because he is using a 300TDI turbo with a short bellhousing gearbox.
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  #9  
Old April 26th, 2016, 03:45 PM
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I do not see that would matter? Has he moved the engine? You would only use a stumpy when fitting a R380 in so the gear levers come back to the opening in the tunnel.
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Edward Teach is the Blackbeard, and is a member of the Birmabright Brotherhood.

Still looking for that place where I can carry a paddle and get asked what's that.

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  #10  
Old April 26th, 2016, 03:49 PM
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Quote:
Originally Posted by roverman2010 View Post
I do not see that would matter? Has he moved the engine? You would only use a stumpy when fitting a R380 in so the gear levers come back to the opening in the tunnel.
It is a 200TDi, with 200TDI mount locations and a 300TDI turbo. The standard 300TDI exhaust goes straight into the motor mounts and then the cross member hump is in the wrong place.

On a "proper" 200TDI, the exhaust comes down behind the mounts next to the bulkhead and the turbo is placed for that reason.
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Old April 26th, 2016, 03:52 PM
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I bought a full 300 exhaust kit from downpipe to tail pipe from Safari HP but, that downpipe will need to be chopped up to snake by the engine mount. That's the part I'm not looking forward to.
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Old April 26th, 2016, 03:53 PM
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Yup...
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Old April 26th, 2016, 04:06 PM
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Anon, how many shop hours is fair for all the downpipe drama (assume I'm having a standard DP cut and welded to snake by the motor mount)?
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  #14  
Old April 26th, 2016, 04:13 PM
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It took my guy about 6 hours to fab and weld everything but it might take an exhaust shop a little less. Problem is everything is just so tight, we had to bang divots in the top pipe that connects to the turbo to fit a socket around the bolts...figured that out once everything was done so that added a bit of time.

Also, not sure what truck you are installing it into but the 300 exhaust was a huge disaster. Didn't fit anywhere, ended up getting a 200 (with the muffler horizontal in the back) and it fit right into place on the old 2.5L petrol exhaust mounting locations.
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Old April 26th, 2016, 04:16 PM
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Quote:
Originally Posted by CircuitTested View Post
Also, not sure what truck you are installing it into but the 300 exhaust was a huge disaster. Didn't fit anywhere, ended up getting a 200 (with the muffler horizontal in the back) and it fit right into place on the old 2.5L petrol exhaust mounting locations.
I fitted a later (rear tank style) 300TDI rear exhaust to my (originally) 2.5NA 90. You need to add two hangers, but it was quite straightforward.

http://www.red90.ca/photos/land-rove...ybrid-exhaust/
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  #16  
Old April 26th, 2016, 04:23 PM
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ok my bad I was thinking the 200 disco exhaust manifold/turbo was the same as the 300 Tdi set up.
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Edward Teach is the Blackbeard, and is a member of the Birmabright Brotherhood.

Still looking for that place where I can carry a paddle and get asked what's that.

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57 LR 88" SXF 858
85 LR90
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  #17  
Old April 26th, 2016, 04:31 PM
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I've got a 2.5NAD 110 now sporting a 200 Disco using a 300 turbo/exhaust. Advice from folks here was the 300 exhaust was the closest match. We shall see. Seems nothing has been as easy as posts suggest but, I've been told it would be different if I knew what I was doing.
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  #18  
Old April 26th, 2016, 04:35 PM
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so you would use this?
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Edward Teach is the Blackbeard, and is a member of the Birmabright Brotherhood.

Still looking for that place where I can carry a paddle and get asked what's that.

JnK Services
FC101 GS FFR
57 LR 88" SXF 858
85 LR90
95 D1 Tdi
05 D3 HSE
97 XK8 BRG FHC For Sale
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  #19  
Old April 26th, 2016, 04:38 PM
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Jon, does that work on RHD and LHD trucks by chance?
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  #20  
Old April 26th, 2016, 04:44 PM
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Quote:
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Jon, does that work on RHD and LHD trucks by chance?
Pretty sure non of these types of installs (short bellhousing Disco 200TDI or 300TDI) work with LHD.
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