1989 110 19J to Defender 200TDI Swap and ETC. - Defender Source
Defender Source  

Go Back   Defender Source > Build-up's, Projects & Registry Profiles > Truck Build-up's & Restores

Join the Defender Source Community Today
Reply
 
Thread Tools
  #1  
Old March 26th, 2016, 12:07 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
1989 110 19J to Defender 200TDI Swap and ETC.

Hi guys,

I have been asking sporadic questions all over the forum and I figure I would get organized a bit so that what I go through would help other people as well.

This is how I bought it back in November 2015, IIRC.
Attached Thumbnails
Click image for larger version

Name:	IMG_0033.PNG
Views:	77
Size:	589.5 KB
ID:	145931   Click image for larger version

Name:	IMG_0034.jpg
Views:	104
Size:	119.5 KB
ID:	145932  

Click image for larger version

Name:	IMG_20150926_102524.jpg
Views:	80
Size:	138.4 KB
ID:	145933   Click image for larger version

Name:	IMG_20150926_102539.jpg
Views:	103
Size:	101.8 KB
ID:	145934  

Click image for larger version

Name:	IMG_20151011_132043.jpg
Views:	78
Size:	132.6 KB
ID:	145935  
Reply With Quote
Sponsored Links
Advertisement
 
  #2  
Old March 26th, 2016, 12:15 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
So far I ordered and received Defender 200TDI from UK.

Mounted on the engine stand and ready for clean up.
Attached Thumbnails
Click image for larger version

Name:	IMG_20160205_191637.jpg
Views:	74
Size:	81.1 KB
ID:	145936   Click image for larger version

Name:	20160206_131629.jpg
Views:	105
Size:	141.0 KB
ID:	145937  

Click image for larger version

Name:	20160206_134649.jpg
Views:	76
Size:	146.7 KB
ID:	145938   Click image for larger version

Name:	20160207_130357.jpg
Views:	106
Size:	158.6 KB
ID:	145939  

Reply With Quote
Sponsored Links
Advertisement
 
  #3  
Old March 26th, 2016, 12:17 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
I have taken the front wings and grill out.

It was fun removing the hood by myself.
Attached Thumbnails
Click image for larger version

Name:	20160213_161451.jpg
Views:	98
Size:	148.0 KB
ID:	145940   Click image for larger version

Name:	20160220_005606.jpg
Views:	103
Size:	180.2 KB
ID:	145941  

Reply With Quote
  #4  
Old March 26th, 2016, 12:20 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
I have been cleaning the engine and getting ready for fresh coat of paint on the block.

After removing all the dirt/oil/grease/grime, I noticed the block is gold(?).

I have ordered POR15 for the coloring. I have heard this thing is basically only paint that you cannot undo.

I am planning on doing the bulkhead with POR15 as well.
Attached Thumbnails
Click image for larger version

Name:	IMG_20160313_164242.jpg
Views:	96
Size:	117.7 KB
ID:	145942   Click image for larger version

Name:	IMG_20160317_214406.jpg
Views:	83
Size:	113.8 KB
ID:	145943  

Reply With Quote
  #5  
Old March 26th, 2016, 12:26 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
I have been tinkering with turbo and rusted hardware.

So far, I got both downpipe and the manifold separated from the turbo.

I thought about rebuilding the turbo but after spending weeks of soaking and heating the hardware, I still could not undo the 4 bolts on CHRA. Decided to go with VNT. Which makes me wonder if I should do a top end rebuild.....

I picked up Harbor Freight Diesel Compression Tester to check the compression before deciding if I should do the top end rebuild or not.
20 Piece Diesel Engine Compression Tester

I will be doing the compression test tomorrow.

Just to give a little history of the engine. I bought the engine off of a guy name Mark Prinold. He has been selling 200TDI engine kits through ebay and I could not find any negative feedback. He has been pretty good with communication but I haven't reported any problems yet so I don't know if he would change his demeanor when I sing a different tune.

In the kit, I supposedly have been given all the components (some new and majority of them are old) I need to bolt the engine in.

While it is mostly complete with fan shroud and belts, hoses.... I am also suffering from what you all are dealing with, the ship fitter's disease.

So as I am tearing down stuff, I am ordering parts.
Attached Thumbnails
Click image for larger version

Name:	IMG_20160319_201100.jpg
Views:	96
Size:	114.7 KB
ID:	145944   Click image for larger version

Name:	IMG_20160316_220248.jpg
Views:	95
Size:	130.3 KB
ID:	145945  

Reply With Quote
  #6  
Old March 26th, 2016, 01:00 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
Q: How do you guys clean your dirty small parts and bolts?
Reply With Quote
  #7  
Old March 27th, 2016, 02:15 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
I have been using tumbler with walnut media to get the grease and caked dirt off of the hardware. It has been doing a descent job but not great. Got me a part washer and will be giving that a try.

Variable Nozzle Turbo showed up today from Allisport. Of course, there is something missing from the shipment. I cannot find any gaskets in the box..

To receive the turbo, it took a full week from the time of order to receiving it.

Downpipe is cast. I thought it was going to be flange welded to a mendrel bent pipe.

Let's see how responsive Allisport UK is.
Attached Thumbnails
Click image for larger version

Name:	IMG_20160326_230744.jpg
Views:	97
Size:	74.1 KB
ID:	146072  
Reply With Quote
  #8  
Old March 27th, 2016, 02:21 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
Removed the fan clutch, used bicycle tool. Has 4 sizes built in and it only cost $15 shipped.

Fan clutch (32mm) is reverse threaded on 200tdi. Bosch 8 cyl was not. Thought that was interesting.
Attached Thumbnails
Click image for larger version

Name:	IMG_20160326_162609.jpg
Views:	101
Size:	114.5 KB
ID:	146073  
Reply With Quote
  #9  
Old March 27th, 2016, 10:53 PM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
Bulkhead was picked up. I am debating if I should sand blast this and POR it or just paint over the existing paint. It almost has no rust.
Attached Thumbnails
Click image for larger version

Name:	IMG_20160327_190745.jpg
Views:	64
Size:	109.4 KB
ID:	146144  
Reply With Quote
  #10  
Old March 27th, 2016, 10:56 PM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
Took the head off of the block...

Not looking good.

Any recommendations????
Attached Thumbnails
Click image for larger version

Name:	IMG_20160327_185607.jpg
Views:	741
Size:	152.0 KB
ID:	146145   Click image for larger version

Name:	IMG_20160327_190002.jpg
Views:	71
Size:	187.0 KB
ID:	146146  

Reply With Quote
  #11  
Old March 27th, 2016, 10:58 PM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
Cross hatch patterns for resident experts' review..
Attached Thumbnails
Click image for larger version

Name:	IMG_20160327_185011.jpg
Views:	92
Size:	146.3 KB
ID:	146147   Click image for larger version

Name:	IMG_20160327_185034.jpg
Views:	80
Size:	113.4 KB
ID:	146148  

Click image for larger version

Name:	IMG_20160327_185130.jpg
Views:	55
Size:	143.2 KB
ID:	146149   Click image for larger version

Name:	IMG_20160327_185136.jpg
Views:	71
Size:	152.7 KB
ID:	146150  

Reply With Quote
  #12  
Old March 27th, 2016, 11:30 PM
o2batsea's Avatar
o2batsea
Status: Offline
Bill Adams
66 109 sw 94 lwb
Member
 
Join Date: Jul 2009
Location: kensington md
Posts: 6,129
Registry
Bucket of diesel and a couple different kinds of brushes. Was it low on compression?
__________________
Bill Adams

1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"

All my troubles are Rover
Reply With Quote
  #13  
Old March 27th, 2016, 11:47 PM
Red90's Avatar
Red90
Status: Offline
John B.
1991 Defender 90, 200TDI
Site Team
 
Join Date: Sep 2003
Location: Calgary
Posts: 8,063
Registry
Quote:
Originally Posted by DailyDrivenDefende View Post
Took the head off of the block... Not looking good. Any recommendations????
What do you think looks bad?
__________________
Pissing people off on the "net" since 1983.

Land Rover. Turning owners into mechanics since 1948.
Reply With Quote
  #14  
Old March 28th, 2016, 12:00 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
Quote:
Originally Posted by Red90 View Post
What do you think looks bad?


If you look at the right side, you can see where the exhaust has been leaking.

Or is this something you saw already and don't consider being not a big problem?

I'd rather have the latter.

I am ready to have the head rebuilt. My concern is the deck on the block.


BTW, how does the cross hatching look to you?
Reply With Quote
  #15  
Old March 28th, 2016, 12:11 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350


What do you think of his technique in cleaning the top deck?

------ Follow up post added March 27th, 2016 09:17 PM ------

Quote:
Originally Posted by o2batsea View Post
Bucket of diesel and a couple different kinds of brushes. Was it low on compression?
Yes, the last cylinder towards the rear of the vehicle had no compression.
Reply With Quote
  #16  
Old March 28th, 2016, 12:18 AM
Red90's Avatar
Red90
Status: Offline
John B.
1991 Defender 90, 200TDI
Site Team
 
Join Date: Sep 2003
Location: Calgary
Posts: 8,063
Registry
Quote:
Originally Posted by DailyDrivenDefende View Post
If you look at the right side, you can see where the exhaust has been leaking. Or is this something you saw already and don't consider being not a big problem? I'd rather have the latter. I am ready to have the head rebuilt. My concern is the deck on the block. BTW, how does the cross hatching look to you?
Not sure what you are seeing. The pictures are not clear enough to see anything. Is the exhaust valve broken?

Cross hatching looks fine. Basically like new. Just clean with a scotchbrite pad and some solvent.
__________________
Pissing people off on the "net" since 1983.

Land Rover. Turning owners into mechanics since 1948.
Reply With Quote
  #17  
Old March 28th, 2016, 12:44 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
I am glad that cross hatching checks out.

I made some highlights on the photo. Look at the carbon buildup on the deck and on the head on the corresponding side.



BTW, which brand of head gasket do you recommend, John?
Attached Images
 
Reply With Quote
  #18  
Old March 28th, 2016, 12:54 AM
Red90's Avatar
Red90
Status: Offline
John B.
1991 Defender 90, 200TDI
Site Team
 
Join Date: Sep 2003
Location: Calgary
Posts: 8,063
Registry
Just looks like gasket material to me. If they leak, it is normally into the tappet.

Elring head gasket. http://turnerengineering.co.uk/acata...t-TDI-294.html
__________________
Pissing people off on the "net" since 1983.

Land Rover. Turning owners into mechanics since 1948.
Reply With Quote
  #19  
Old March 28th, 2016, 01:05 AM
DailyDrivenDefende
Status: Offline
Michael
1989 110, 1985 90 200TDI
Member
 
Join Date: Oct 2015
Location: Washington State
Posts: 350
Quote:
Originally Posted by Red90 View Post
Just looks like gasket material to me. If they leak, it is normally into the tappet.
I want to take your word for it but when I did the compression test, that cylinder did not build any pressure that I can read. That got me undoing the head this evening.

LOL. I have to say I always look for your response in all my posts, John.

Having said that.

Can any machine shop that rebuild head work on any head like redoing valve guide and seals and such? Should I be looking for someone who works on rovers instead?

Do I need to index the push rods before taking them out? Or should I just drop off the entire head with them?
Reply With Quote
  #20  
Old March 28th, 2016, 07:46 AM
speedpin's Avatar
speedpin
Status: Offline
Adam
1986 110
Member
 
Join Date: May 2010
Location: Fredericksburg, VA
Posts: 1,739
Registry
Michael,
The swap is coming along, good job! the head should clean up as long as there are no cracks between the valves (bad) and between the injector and glow tips (not as bad). The head gasket was probably failed at the spot highlighted on the head, where the carbon build up was. You can always go with a turner gas flowed head for more performance and piece of mind about 1400$ I think but its bolt on. I had to do some homework and help my machine shop with the specs on the valve play etc. Not a lot of shops deal with tdi rover heads. maybe a local guy will chime in with a shop close to you. but get pressure tested, new valve seals, valve job, and skim to ensure its flat for new elring gasket.


Also! on the defender tdi you can not remove or install the thermostat housing if the head is attached to the block. The bolts hit the timing cover. Make sure you have a good gasket on the housing prior to putting the head on the block. maybe use some shorter bolts so you can remove it if needed without pulling entire head just to replace gasket. can be a pain!
Adam
__________________
~ Semper Fidelis ~
Reply With Quote
Sponsored Links
Advertisement
 
Reply

Lower Navigation
Go Back   Defender Source > Build-up's, Projects & Registry Profiles > Truck Build-up's & Restores

Tags
110, 200tdi, defender, tdi

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Disco 200tdi transplant for RHD defender engine/trans/etc Macker For Sale - Parts 40 April 25th, 2016 09:46 PM
Pulling 19J and 200TDI going in: Need advise. DailyDrivenDefende Defender Technical Discussions 55 February 15th, 2016 02:50 PM
1989 LHD Defender 110 200tdi from Lithuania Michail For Sale - Vehicles 11 January 10th, 2016 02:06 PM
1989 110 19J 2.5 TD trouble starting Elbee Defender Technical Discussions 43 April 13th, 2015 03:26 PM


All times are GMT -5. The time now is 11:25 PM.


Copyright