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Defendermatt



Member Since: 15 Sep 2016
Location: Derbyshire
Posts: 230

United Kingdom 1989 Defender 90 Other SW Bonatti Grey

Yes its a VNT from the CRturbo guys in Portugal!

The machine is still not done, but its heart surgery is complete and she ticks over well.

I can post an engine spec list if anyone's interested?

Post #662247 6th Nov 2017 5:43pm
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 161

United Kingdom 1990 Defender 110 200 Tdi HT Bronze Green

Interested! 2001 Defender 90 TD5 'Dotty' NOW DECEASED
1990 Defender 110 200TDI Camper
Home built 13hp Off Road Go-Kart - 40mph tops + no suspension...FUN!

Post #662262 6th Nov 2017 7:03pm
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Defendermatt



Member Since: 15 Sep 2016
Location: Derbyshire
Posts: 230

United Kingdom 1989 Defender 90 Other SW Bonatti Grey

You may wish to grab a coffee for this….. Whistle

So the block (which is a 200tdi) was bored +40 thou oversize and decked flat
All new cam, crank etc. bearings fitted
New pistons, rods and crank were fitted after being balanced with the flywheel and clutch cover (some guts is 300tdi)
The pistons were ceramic coated on the crown, and Teflon on the skirts
A new 300tdi head was sourced, with new valves etc. then was ported
Head is fitted using ARP studs
Modified injectors
Internally modified fuel pump
VNT turbo from the guys in Portugal
Custom 2.75” downpipe which mates to an Alive TD5 sports system (2.5”)
Currently using a BAS TD5 intercooler with custom SS pipes

A bit of a Frankenstein, but ticks over sweet as a nut Thumbs Up

Post #662604 8th Nov 2017 11:54am
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 161

United Kingdom 1990 Defender 110 200 Tdi HT Bronze Green

Thanks for the update, this looks like a great project (hopefully you can get some dyno figures...).

What 300tdi parts did you use other than the head gasket?

Thanks! 2001 Defender 90 TD5 'Dotty' NOW DECEASED
1990 Defender 110 200TDI Camper
Home built 13hp Off Road Go-Kart - 40mph tops + no suspension...FUN!

Post #662622 8th Nov 2017 1:41pm
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Defendermatt



Member Since: 15 Sep 2016
Location: Derbyshire
Posts: 230

United Kingdom 1989 Defender 90 Other SW Bonatti Grey

Hopefully will get it on the dyno when complete

Pretty much a 200 bottom end and 300 top end with 300 rods and pistons.

Post #662628 8th Nov 2017 2:13pm
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 1673

2004 Defender 110 Td5 DCPU Epsom Green

Exciting stuff!!!

Post #662633 8th Nov 2017 2:39pm
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Pickles



Member Since: 26 May 2013
Location: Melbourne
Posts: 3572

Australia 2013 Defender 90 Puma 2.2 CSW Keswick Green

Hazza wrote:
Thanks for the update, this looks like a great project (hopefully you can get some dyno figures...).

What 300tdi parts did you use other than the head gasket?

Thanks!

Yep, Dyno figures would be very interesting, incl torque.
Pickles.

Post #662756 8th Nov 2017 10:32pm
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Boost



Member Since: 17 Oct 2014
Location: Gloucestershire
Posts: 198

United Kingdom 1986 Defender 90 200 Tdi SW Arles Blue

Defendermatt wrote:
You may wish to grab a coffee for this….. Whistle

So the block (which is a 200tdi) was bored +40 thou oversize and decked flat
All new cam, crank etc. bearings fitted
New pistons, rods and crank were fitted after being balanced with the flywheel and clutch cover (some guts is 300tdi)
The pistons were ceramic coated on the crown, and Teflon on the skirts
A new 300tdi head was sourced, with new valves etc. then was ported
Head is fitted using ARP studs
Modified injectors
Internally modified fuel pump
VNT turbo from the guys in Portugal
Custom 2.75” downpipe which mates to an Alive TD5 sports system (2.5”)
Currently using a BAS TD5 intercooler with custom SS pipes

A bit of a Frankenstein, but ticks over sweet as a nut Thumbs Up




Bow down Bow down Bow down

Did the ARP studs fit alright in the end?

This must be one of the most refined tdi's in existence now! Hopefully Thumbs Up 200Tdi Big turbo party wagon - Club86 on YouTube

Post #666523 23rd Nov 2017 10:01pm
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Defendermatt



Member Since: 15 Sep 2016
Location: Derbyshire
Posts: 230

United Kingdom 1989 Defender 90 Other SW Bonatti Grey

Yes. Got them all sorted and clamped down real nice Thumbs Up

Post #666749 24th Nov 2017 9:50pm
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Dorothythedefender



Member Since: 29 Jun 2020
Location: scotland
Posts: 1

United Kingdom 1985 Defender 90 200 Tdi HT Belize Green
Re: 200Tdi Race engine - Weak points and limitations

Boost wrote:
Hi

I'm looking at increasing the power significantly on my Discovery 200tdi engine. This is for fun.

So far I've got a bunch of parts together, besides the usual FIP tweaks with EGT and boost gauges.

-Big universal full-width intercooler
-Garrett turbo from a 4.4 Perkins engine - 3" downpipe and straight through exhaust
-Water/methanol injection setup
-Dry nitrous kit

Things I'm looking into:

-ARP Head studs
-Cometic/ upgraded head gasket
-Porting/polishing
-Performance coatings - internal engine components/ ceramic coated exhaust manifold

I'd like to give the engine a full rebuild including balancing at some point in the future but for now just looking at something in the 150-200hp range that'll hold together if treated with some respect.

Would anyone know what the main weaknesses are in the 200tdi if it's given some abuse with this setup? I know the heads can crack, but no ones snapped a con rod or anything silly have they?


At the moment with the fuel pump settings changed and the stock turbo wastegate set to 16psi, the 90 can chirp its tyres pulling away in 2nd (235 tyres, LT77, 1.6 Transfer ratio)


Supposing one can get a reliable 200hp and 300 lb ft. of torque from this engine, what's going to break first? Will the drivetrain handle it or would a sintered/paddle clutch have to be used with limited slip diffs?


I'd appreciate any advice or previous experience Thumbs Up


Really like this thread and all the info. I have followed the Blue 90 progress on Club 86 and wanted to do a similar thing with my 200tdi 90. I've got a Defender engine so turbo is up to and wanted to implement the same Perkins turbo swap you have coupled with a manual boost controller.

Couple of questions about the downpipe and how you made that. Did you purchase a universal 3inch flange and, bolt that up and then weld the pipe to that?

Post #840678 30th Jun 2020 12:54pm
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