200 TDI from a Discovery in Defender using a 19j turbo

I bought the engine from e-bay. Shipment 95£.  It is a 1993 J-reg. discovery engine and it has only don 93.000 miles. With the engine came radiator, intercooler, hoses, air filter, fuel filter and lines, also got the pas-pump and alternator.

Why use the 19j turbo setup?

The Discovery exhaust manifold is in the wrong place. On the Defender engine it sits on top of the intake manifold. But on the Discovery it is poisoned below the intake manifold. This position will get in the way of the left hand inner wing, and on LHD Defenders the turbo is also in the way of the steering link. If the Discovery setup is used I’ll have to make another exhaust front pipe as well plus altering the clutch bracket on the bulkhead. Therefore I wanted to use my old 19J turbo, which is in an excellent condition.

Things you need before the conversion can begin:

Discovery parts:   ·        A 200TDI engine from a Discovery. ·        Radiator and intercooler with frame. ·        Water hoses. ·        Hoses from intercooler ·        Fuel filter assembly. ·        Glow plug relay.

19J TD parts needed:

·        Alternator and - Link-adjustment ERC 6266

·        Pas pump

·        Bracket for pas pump assembly ERC6974

·        Turbo with exhaust elbow

·        Clutch

·        ETC6492 Inlet manifold

·        ETC7633 Exhaust manifold

·        Extra silicone hose from a 19J turbo

·        NRC5435 Engine bracket RH

·        NRC9557 Engine bracket LH

·        Oil filter housing

·        2x NTC3858 Adaptor for radiator / oil cooler

New parts (both Defender and Discovery 1) This is up to you!!!

·       Kenlowe 14in Electric fan.

·       ETC5710 Turbo to exhaust manifold gasket

·       ETC7058 Turbo to elbow gasket

·       ERR2532 Fly wheel housing seal

·       ANR1808 Mounting for engine

·       ERC8849 Camshaft O ring

·        ERR1208 Exhaust manifold

·       ERR2393 Rocker gasket

·       ERR6490 Crankshaft front oil seal

·       ETC5064 Camshaft oil

·       ETC8847 Heater plug

·        FTC2957 Clutch Release Fork

·       NTC4426 Front Pipe

·        ETC8550  Dayco Timing Belt

·        ERR2530  Tensioner

·        ETC8560 Idler

·        ERR1195 Front Cover gasket

·        ERR388 Water Pump Gasket

·        Belt 13x800 (unipart GVB20800)

·        PRC2505 water transmitter

·        ERC8973 Temp adaptor

Things you will need to make up your own special parts:

     ·        2m. of 50mm. steel tube for intercooler.

     ·        A pice of iron bar 20x5x500 mm.

Preparing the Discovery Engine:

	Just taken out of the Disco

Timing belt should be changed, so I wont need to worry about it breaking.
	Cleaned up, ready to fit the new belt and seals. I used a 9,4 mm. drill to lock the fuel injection pump. The crankshaft is locked at the fly wheel plug hole
To fit the engine to the LT77 bell housing, I'm going to cut some new threads in the flywheel housing. The holes are pre drilled, but need further drilling so it would be deep enough to accept the studs. Note. I painted the block in black heat resistant paint

	Whole procedure takes about half an hour.
Pulleys and manifolds
	Servo bracket from the 2,5td must be altered to fit onto the 200tdi discovery engine. First you must fabricate a small V-shaped support-bracket mounted onto the timing case. Second you will have to cut out a lump to mount the alternator in a more forward position to line up the belt pulleys.
Here you see the small bracket mounted between the timing case and the pump bracket.

	Note, that the 2,5td pas pump has been fitted with the pulley from the 200tdi so it would line up to the crank pulley.
	above you see that the crank pulley has been added an extra pulley to drive the pas pump. The new pulley was taken from a 2,25 engine Water pump.
	40 mm. was cut away to move the alternator forward. then turned a new  bush in my lathe. Diameter x length = 20mmx40mm and 16mmx40mm. Inner diameter is 8,5mm.
Heat it up and crimp the new bush in place.

It fits just nice, just as it does on a defender.

Look at the home made bracket from a pise of angle iron.
Belt for pas pump is: 750mm. same width as the alternator belt. The original belt on photo is too wide. so ill need a belt with the same width as the one on the alternator.

	Use the old 200tdi manifold gasket to mark where to cut in the exhaust manifold. then fit the inlet manifold on to the cylinder head. Next step is to must put the exhaust manifold where it should be and mark up on the inlet manifold where it doesn't fit properly. Remove material (only on the inlet manifold).
As you see the manifolds doesn't line up to the studs, so a pice of 5x20x500 mm. steel should be used to hold the whole rig tight on the cylinder head.
Just a test fit.

	the 5x20x500 bar should be drilled using the old gasket as a guide.
	Note the cut in the exhaust manifold

	Cleaned up. ready for the new (Disco) gasket
	Note! Grind the surface flat on the manifold to the same height all three places so that the small angled brackets will fit perfectly.
Also grinded

	Three pices of angled irons drilled and cut to hold the manifold firmly on the cylinder head. Look at the grinded surface behind it.

Ready to go. Only used two days preparing it, thou I'm not fast, just trying to do it properly first time!
Engine going in
The Disco temp-transmitter will read to hot on the old water gauge.   Therefore fit an adaptor to accept the old style transmitter.

	Adaptor and transmitter
Remove the Disco filter housing and fit the TD one. The threads to the cooler pipes isn't the same.

Use a locating peg when fitting the clutch.

	Use the TD fan belt

	Engine mounts is an easy fit.
Old TD alternator used, as well is the old TD harness.

It just fired up first time.

	Old exhaust pipe used as pipe for intercooler
On LHD models its a tight fit. The servo pulley almost touch the steering box.

	Kenlowe fan works fine, but the radiator seems to be large enough not to turn the radiator on at any point. The temp reads a little high due to a higher working temperature then the 2,5NA