last few questions on my 200TDi swap - Defender Source
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  #1  
Old September 13th, 2014, 07:52 AM
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last few questions on my 200TDi swap

Looks like i'm on the last few items to sort out before the truck is ready. Over the past week or so I've attempted to find the correct part numbers needed. I have found some of the numbers but want to make sure they are correct before shelling out $$. Others I have been unable to find a correct number. Hope someone here can help.

The Engine is the Defender 200TDi if for some reason the needed parts are different from a Disco 200TDi.
  • Intercooler/Radiator frame bushings. These are the small bushings that attach to the small nubs on the top & bottom of Rad/IC. I believe 8 are required. I found 572312 but this seems to point towards a 300TDi.
  • Both oil cooler lines.
  • Heater matrix coolant hoses. I believe I need BTR445 & BTR447 for the matrix that has the 90 degree downward bends. Truck is RHD.

Ill probably have a few more items once I get the rest of the truck together later today. Thanks in advance on the help.
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  #2  
Old September 13th, 2014, 07:54 AM
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Robert Davis
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Andy:
The 300TDI radiator frame bushings are the same/interchange with the 200TDI.

Has Dave contacted you regarding engine pickup yet?
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  #3  
Old September 13th, 2014, 07:57 AM
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Quote:
Originally Posted by rdavisinva View Post
Andy:
The 300TDI radiator frame bushings are the same/interchange with the 200TDI.

Has Dave contacted you regarding engine pickup yet?
perfect! We spoke earlier this week for a Monday morning pick up.
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  #4  
Old September 13th, 2014, 08:08 AM
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Quote:
Originally Posted by BostonAndy View Post
perfect! We spoke earlier this week for a Monday morning pick up.
Thanks!
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Uncle "Richard" Douglas has a Land Rover with big wheels that never gets stuck... until he breaks something so it won't go. Uncle Douglas always breaks something. - Anna Crowther at the Conclave 2012 (AKA Carburetor Neck)

"What's with this death wobble, Uncle Douglas, I can't keep it in 1 lane?"
UD: "Just Power through it man!"
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  #5  
Old September 13th, 2014, 12:12 PM
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Also it appears the holes for the hand brake bracket are not on this recon Disco LT230. Any one have advice on what to do?
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  #6  
Old September 13th, 2014, 11:25 PM
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I put a disco t-case in my truck a few months ago. I just drilled and tapped the holes for the parking brake bracket.
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  #7  
Old September 14th, 2014, 12:18 AM
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Yes. You just drill and tap. Make sure you remove the shift interlock solenoid.
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  #8  
Old September 14th, 2014, 08:09 AM
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Thanks for the advice everyone. I bought a tap last night. As for the solenoid, this 1.2 didn't come with one.
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  #9  
Old September 15th, 2014, 09:27 AM
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Looks like I need to track down some new oil cooler lines. Any differences between Disco/Defender 200TDi engines? Anyone know the part numbers by chance?
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  #10  
Old September 15th, 2014, 10:26 AM
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I take the old ones to a hydraulic ship with measurements and have new ones made.
It's not always a lot cheaper, but is a lot quicker.
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Uncle "Richard" Douglas has a Land Rover with big wheels that never gets stuck... until he breaks something so it won't go. Uncle Douglas always breaks something. - Anna Crowther at the Conclave 2012 (AKA Carburetor Neck)

"What's with this death wobble, Uncle Douglas, I can't keep it in 1 lane?"
UD: "Just Power through it man!"
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  #11  
Old September 15th, 2014, 10:44 AM
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I got mine from Trevor at Rovahfarm. I just ordered the ones he has listed there for the 300tdi and they work just fine. They are in the "heating and cooling" section for some reason. They're $25 each.
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  #12  
Old September 15th, 2014, 10:53 AM
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Disco 200Tdi 5speed
Oil Cooler Pipe (Upper) 89-92 NTC4337
Oil Cooler Pipe (Upper) 92-94 ESR1257

Oil Cooler Pipe (Lower) 92-94 ESR1258
Oil Cooler Pipe (Lower) 89-92 NTC4338

I both LR90 & D1 200Tdi's and both look the same (thats if factory fitted)

And yes to BTR445 & BTR447, rovafarm has them in stock
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  #13  
Old September 15th, 2014, 10:56 AM
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Oil cooler lines were changed at some point from using a flare seal to an o-ring seal. So make sure you have the same sealing method at both the radiator and the oil filter adapter.
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  #14  
Old September 15th, 2014, 01:11 PM
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Thanks for all the help guys. Looks like RovahFarm is on holiday this week so Ill take that as a sign I need to take a few days off as well.

I'll take the old lines off and see what style ends it has.
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  #15  
Old September 17th, 2014, 07:38 AM
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Quick update:
Few tasks on hold till some larger wrenches arrive.

I have hit a questionable area with the spill rail line. Seems like the hose was cut and never properly reattached to the injector pump. On closer inspection I found something unexpected. There was a small rubber cap covering the port on the pump and what looks like a plug?. Any thoughts as to what it is?
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  #16  
Old September 17th, 2014, 08:25 AM
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I'm certainly no 200tdi expert, but the spill rail hose attaches to the banjo fitting on the back of the IP. The banjo fitting has two ports; a small nipple for the injector spill hose, and a large (8mm or 5/16) barb for push-on nylon or rubber return to tank. If your picture is what I think it is, it would seem that someone installed a compression fitting on the return barb. Not necessarily a bad thing as you are able to attach a variety of hose connections to that. You just need to pick your poison and go with that.

The rubber cover is correct, that is, it is supposed to be there and look like that.
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  #17  
Old September 17th, 2014, 08:43 AM
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Thanks for the quick reply. I think I now know what the problem is...i assumed. For some reason I had it in my mind there were 3 banjo connections on the back of the IP. Vac/Boost, Injector Spill return, and To tank return. Looks like the spill & return to tank are the same banjo.
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  #18  
Old September 17th, 2014, 08:59 AM
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The rubber cap is for the vent on the underside of the boost diaphragm.
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  #19  
Old September 17th, 2014, 10:45 AM
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your fingernails are dirty

Where are you in Boston, BostonAndy?
I used to live right off Mass Ave in the South End.
I even had a parking space where I could work on my Isuzu Trooper.

.
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  #20  
Old September 19th, 2014, 03:39 PM
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Finally located a 26mm wrench to remove the oil cooler lines. Attached are photos of the ends and the radiator adapters. I've not had much luck searching for differences on the radiator adapter thus unsure what one I have. I'm assuming I'll need ESR1912 and ESR1913?

On another subject, any advice on wiring the B+ terminals up to the starter? This Alternator has 2x B+ blade terminals. Any reason not to connected both terminals to the starter?

Thanks in advance!

@Nomar - I just moved out of Brighton and am out in Waltham.
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