Topic: 90 - 200tdi conversion (Read 4636 times)

j.stobart · « **on:** November 21, 2007, 22:08:45 »

I am planning to replace my 2.5td 90 with an original 200tdi defender engine this weekend. Can anyone offer any advice as the best way to go about this, i.e is it best to remove front wings and bumper etc, or can it be done without doing this easily enough? I think I am going to replace the timing belt too while the engine is out, and also all the auxilary belts etc. Could anyone suggest any other upgrades I should also carry out at the time before installing my 200tdi. I do plan to fit a side exit exhaust at some point, but this can wait.

I will be lucky enough to have a forklift to lift and lower the engine in place, Would a day be on the ambitious side to expect to have the old lump out and the new lump in and running again assuming that we will be commencing major surgery at around 8.30am?

Any tips or suggestions would be most appreciated.

davidlandy · « **Reply #1 on:** November 21, 2007, 22:14:39 »

as you have a forklift leave the front panels in place - remove the rad

do you have all of the hoses for the PAS and oil cooler , air filter , intercooler pipes etc?

j.stobart · « **Reply #2 on:** November 21, 2007, 22:44:01 »

My 90 already has power steering, so can I just use the pipes etc already in place?

Are there additional pipes from the oil cooler or will the existing pipes be all I need?

Les Henson · « **Reply #3 on:** November 22, 2007, 08:32:03 »

If you are going to fit the 200TDi rad/intercooler then you will have to remove the front panel anyway in order to fit it. The TD rad oil cooler fittings just unscrew, so swap them over with the 200TDi ones. Your oil cooler pipes can then be used. No need to remove the wings (somewhere handy to put tools/coffe/sarnie :)

Thread here on how I did it.

http://forums.lr4x4.com/index.php?showtopic=2394

Les.

Saffy · « **Reply #4 on:** November 22, 2007, 08:37:48 »

Quote from: "j.stobart"

i.e is it best to remove front wings and bumper etc, or can it be done without doing this easily enough?

Could anyone suggest any other upgrades I should also carry out at the time before installing my 200tdi.

Usually the wings stay in place but the front panel is removed for access it is quick to remove even if you *may* not need to by using forklift. It will give you better access to the engine bay for"wiggle" room when mating to gearbox. Unbolting the transmission tunnel give access to all the bellhousing fixings and saves a lot of hassle.

If in doubt of condition then change the clutch and rear oil seal else you will cry. But either case definitely change the clutch fork arm and thrust bearing.

Helped out with my neighbors conversion recently (defender 200tdi into 19j 110) The 200tdi defenders exhaust down pipe was needed as the 2.5td had different stud arrangement. The bonnet stay was needed as the trucks original no longer was usable. The radiator, oil cooler and intercooler from the 200tdi was also fitted. The expansion tank changed over. The partial loom of the glowplug circuit swapped over. PAS system plumbing was the same.

fasthands · « **Reply #5 on:** November 22, 2007, 12:11:51 »

Just fitted a disco engine into mine and that was not too hard, if you have a fork lift to use it will be a doddle, most of the things you need to do are in the previous posts. I have had a side exit exhaust made, full stainless it did cost Â£370 but I think it was worth every penny, I can send you some high res pics of my exhaust if you want, via email if want to pm me your email address. I also put a new water pump on when I changed the timing belt, for what they cost. And change the timing belt tensioner and guide roller too!

8) [/img]

tonycougar · « **Reply #6 on:** November 22, 2007, 22:24:12 »

The only tip I was gonna give ya was the link that Les has already put in for ya.
Have fun, if I was fit I'd love to come and help.

j.stobart · « **Reply #7 on:** November 25, 2007, 21:49:36 »

Well its in, old 19j out and lovely new 200tdi in in around a day and a half, just need some minor points sorting before she can breath a full and fruitfull life again.

The fuel lines from the old 19j engine are different at the fuel pump end for the 200tdi engine ([!Expletive Deleted!] as this was all that stopped it from firing over this afternoon), And I seem to be a hose missing for the airfilter to turbo, and can't figure out which way round the hoses are supposed to go, a picture of the 200tdi defender engine bay would come in useful if anyone has one. Other than that, once its all done, a quick test fire, and then a case of replacing the timing belt, and she's ready to rock and roll. Literally. Can't wait now.

Thanks for all the information guys.

tonycougar · « **Reply #8 on:** November 25, 2007, 23:27:01 »

If you go back to LR4x4 as posted by Les above, and look for 200tdi timing belt change there are several good photos of a 200tdi engine bay there. That same thread would be useful for your impending timing belt change. Like I have said to you before Les is a godsend and his how to do its in the tecnical archives have helped me imensely on many a job now.
If I've not said it before Les......THANKS

Les Henson · « **Reply #9 on:** November 26, 2007, 03:45:40 »

Aww shucks - thanks Tony :D

Les.

j.stobart · « **Reply #10 on:** December 01, 2007, 22:29:43 »

All plumbed up, and sounds mint, started first turn of key!! at very least I was expecting some teething problems but no, she just roared into life, to say I am chuffed would be an understatment.

First attempt at changing an engine, and after just three days graft and lots of swearing, its done, dunno what I was frettin about, was a walk in the park really!!!

Just looking for where I can get a side exit exhaust now and get that really nice noise everyone but me seems to have. Has anyone got any suggestions for a local (west Yorkshire) supplier?

Bush Tucker Man · « **Reply #11 on:** December 02, 2007, 20:45:52 »

Quote from: "j.stobart"

I am planning to replace my 2.5td 90 with an original 200tdi defender engine

Mick ('Muck') Moses has an article in the January issue of 'LRW' on this very exchange.

Pity you're not up Barnsdale Road, as he's not far from Peckfield Bar, & might be happy to offer words of advice??

By The Way;
I can't say I've seen your 90 around Castleford & I pass through there (& Glasshoughton) a lot whilst out on the bike.

Without being too specificas to a street-name, where may I see it 'hanging around'??

biggerlandy · « **Reply #12 on:** December 02, 2007, 21:48:36 »

gwyn lewis do a cool side exit kit

land-def-90 · « **Reply #13 on:** December 03, 2007, 20:31:29 »

hi a mate of mine had a custom made stainles steel exhaust made for his impretsa, sounds lovely and was very reasonable, i think they were based in colne but not sure, worth giving them a call 01282414413

j.stobart · « **Reply #14 on:** December 04, 2007, 09:41:21 »

Pity you're not up Barnsdale Road, as he's not far from Peckfield Bar, & might be happy to offer words of advice??

By The Way;
I can't say I've seen your 90 around Castleford & I pass through there (& Glasshoughton) a lot whilst out on the bike.

Without being too specificas to a street-name, where may I see it 'hanging around'??[/quote]

Funnily enough, I'm not far from Barnsdale Road, and I think I came across Muck the last time the lane flooded as he was draggin some poor stricken astra driver through the murky waters lol.

You'll find me mostly floatin round Allerton Bywater, but most of my mud munching is done at Frickley. What do you drive?

Bush Tucker Man · « **Reply #15 on:** December 04, 2007, 22:50:01 »

Quote from: "j.stobart"

Funnily enough, I'm not far from Barnsdale Road, and I think I came across Muck the last time the lane flooded as he was draggin some poor stricken astra driver through the murky waters lol.

You'll find me mostly floatin round Allerton Bywater, but most of my mud munching is done at Frickley. What do you drive?

So you know Mick then???

What do I drive?? Well it says in the 'signature' block below, but 'click on the pic'

j.stobart · « **Reply #16 on:** December 05, 2007, 16:59:57 »

Sorry, a bit dim when it comes to these forums!!!

Nice motor you got there.

I don't know Mick, but know of him via the "yroc" website and I think he was also at Langley Farm in September.

I take it from the web shots album you do quite a bit of laning then, is there a few of you go when you go, if so can anyone tag along? Don't get to do as much laning as I aren't really confident on the rights of way issues, I do use track explorer and wayfinder, and have a couple of maps, but its much more fun when there a few of you go.

j.stobart · « **Reply #17 on:** December 09, 2007, 22:38:53 »

Well its all done, and I now have an huge :D on my face. I was expecting a good increase in performance, but it has far surpassed my expectations, goes like stink, took it for a blast today and it flew round to 80 in next to no time (landy time anyway) with more to go, but daren't take it much more than that as didn't fancy being overtaken by my wheels etc as they flew off lol.

got a slight niggle though, the heater plug light is staying on though only dim, even when keys are out of ignition. It glows bright like it should to heat the plugs, but stays on dim when it should be out. Anyone any suggestions?

davidlandy · « **Reply #18 on:** December 09, 2007, 22:50:04 »

did you retain the old TD glowplug wiring or did you wire it all up with the relay?

j.stobart · « **Reply #19 on:** December 09, 2007, 23:41:05 »

didn't use the relay as the 90 didn't have it on either

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AuthorTopic: 90 - 200tdi conversion (Read 4636 times)