2.5 petrol, 2.5 diesel how much difference? fitting 200tdi?

[spy]

Hi all,

Just wondering how much difference there was between a 2.5 petrol and a 2.5 diesel 110?  I dont mean engine but are gearbox, etc the same?  What about exhaust setup?  

How much more work is there in fittin a disco 200tdi engine into a 2.5petrol 110 than the 2.5 diesel?   Any real difference?  

Cheers,

Mike

[90sam]

the gearboxes, are the same and i doubt it will be that much harder. heres a link i found helpful!
http://www.llawnroc.f2s.com/200tdi_conversion.htm

[sas pinkie]

As far as I recall, the 2.5 petrol hasnt got a fuel return, which will be needed by the diesel. The fuel lines will run in a different route. So as long as you get some deisel fuel lines with the engine then not much more work to put it in.....

The rest will go in the same, regardless of petrol or diesel..... (you will also need a wire loom with the relay in for the glow plugs as you havnt got the glow plug switch posistion on your ignition switch....)

Another thing to check... On most deisel cars, they tend to have heavier duty springs on the front as the engines tend to be heavier, dont know if this is the case with defenders, of course, if you have already upgraded the springs it wont be a problem.

[muck_truck]

The transfer box may also be different.  if its a 2.5na the transfer box will be a 1.6 (not sure in the pertol though)

it would still work with a 200Tdi but motorway speeds will be slower compared to a 1.4 transfer box that would be on a Tdi.

[sas pinkie]

I personally would source a military spec gearbox (lower first and second ratios) and then attaching a disco transfer box.

[90sam]

So i've just put a 200tdi in mine out of a defender, and it shouts and screams at about 65mph would my transfer box be a 1.6 Do defenders with a tdi in have 1.4 and would this make it better for cruising. How hard is it to put a disco one in?

[sas pinkie]

Piece of wee wee if you have a defender gear box, bit harder if you have 1110 or 90 on, as some of the linkage needs sublte mods. Not beyond your average hobbie mechanic tho, and could be done over a weekend with ease.

[90sam]

I've got a 90 gearbox but i thought the defender was the same lt77? How do i know whehter my transfer box is 1.6? and can i get a 1.4 off a defender would that fit straight swap!

[ChrisV8]

:lol: Should have a little sticker on the back of the transfer with the ratio. Otherwise look at the serial number then have a look on Ashcrofts site they have all the relevant details of ratios to serial numbers and where to look.

Likely a petrol 110 will have a suffix 22D box which is a 1.41 but may have 20D which is 1.667.

Disco one is 28D but an mpi has a 22D, a neighbour now knows that having put an mpi transfer onto his tdi, revs it's doo daas off at 70 mph now !!

[extreme90]

sam it was only the 110's the had the 1.6
yours will be 1.410
if you want to better motorway speed you need to fit a disco transfer box but then your max tyre size will be 31 inch
anything more your going to start dropping down gears going up hills
dan

[90sam]

ohh thats alrite then i'll leave it as it is. i've got 7.50s on but it'll be fine for me, just wondered if i had to replace my transfer box to go with the engine! Time to sound proof then tweak it me thinks!

[stefan]

As far as I recall, the 2.5 petrol hasnt got a fuel return, which will be needed by the diesel. The fuel lines will run in a different route. So as long as you get some deisel fuel lines with the engine then not much more work to put it in.....

The rest will go in the same, regardless of petrol or diesel..... (you will also need a wire loom with the relay in for the glow plugs as you havnt got the glow plug switch posistion on your ignition switch....)

Another thing to check... On most deisel cars, they tend to have heavier duty springs on the front as the engines tend to be heavier, dont know if this is the case with defenders, of course, if you have already upgraded the springs it wont be a problem.

The 2.5 petrol does have a fuel return, my website as listed in the first reply has most of the details you'll need when changing from a 2.5 petrol to a Disco 200 Tdi.

Stef

[fasthands]

I converted 110 2.5 petrol defender to a 200tdi using a disco engine. It was quite easy really the wiring is very easily adaptable I just wired a glow system seperate  . the exhaust is a little tricky but if you go to the breakers and get a exhaust down pipe from a mondeo it is a large bore pipe with a tight bend, so cut the flange off the mondeo pipe and weld the tdi one to it, or use the petrol flange with a little addaption to the holes. checking the position once the engine has been fitted, this gives a good smooth exhaust exit with plenty of clearance of the passenger footwell. It worked superb on mine! I then routed the pipe from the turbo compressor outlet through the inner wing round the strut and back through the inner wing to the intercooler using a 90 degree steel pipe about 2" in dia.and some rubber hose suitable for use with turbos. This was better and easier than trying to get a real tight bend pipe in between the turbo and inner wing you will see what I mean when you come to fit it! also check the studs on the rear of the engine as they are in a different place, and there are two dowels to remove before you can fit the g/box. and the engine mounts and brackets from a petrol engine fit on no problem! hope this helps! :)

[spy]

Sorry to reincarnate such an old thread but the time has finally come to make a start on this!  Does anyone know stefan who did the excellent guie that was linked to at the begining of this thread? 

The link no longer works and I cant find the printout I did of it all that time ago.  It really was detailed and would save me some nitemares if I could get another copy....


Thanks,

Mike