200tdi Swap into a 88 UK d-90 - Defender Source
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  #1  
Old May 13th, 2012, 10:30 PM
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200tdi Swap into a 88 UK d-90

Started my 200tdi swap today. I'm doing a time lapse video of the whole install. Heres a few snapshots from the pics today. Basically started from the front and got the radiatior and fan shroud out, and the air filter assembly. Only put in a an hour or so on it this far.

While its out I'll take some time to clean the very greasey engine bay.

Much more to follow... lets just hope this engine works.... if it does I'll have a 2.5TD for sale!
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  #2  
Old May 15th, 2012, 10:42 PM
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So I got the engine out today

All in all pretty damn easy. I can't beleive I didn't run into one bolt that I broke, or was rusted on. I guess the layers of grease kept everything rust free. That being said I got alot of grime to clean out of this engine bay and off the frame!


Things to note - there is one bellhousing nut just below the starter on the upper/middle left hand side, make sure you find it and remove it before you try to take the engine out lol

Tie the hood up before removing the prop

you can get all the bellhousing bolts from either below or in the engine bay. Raise the engine a bit, remove the rubber isolated on the mounts, then drop it back down. This will give you some extra clearance to get at all the bellhousing nuts. They ar 17MM and pretty easy to get at.


I posted this in the tech section but I'll ask here too..... does anyone know if I need a different radiatior frame/housing to house both the radiatior AND intercooler? Also is the fan shroud different?

The rest looks like it will bolt right back up
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  #3  
Old May 16th, 2012, 09:24 AM
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The radiator surround and fan shroud are different, that should've been supplied with your 200tdi.

You'll need to remove your air filter as well, the intercooler hoses will be occupying that space.
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Old May 16th, 2012, 04:46 PM
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if you want you can take a look at my truck, had the same swap done
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  #5  
Old May 19th, 2012, 07:00 AM
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dude, I forgot the weekend is already on us (WTF I just got a good pace going) and I cant get the parts out 'till Monday. Hope that doesn't fawk it up!
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new expansion complete. Not only are we the only Rover shop in Eliot Maine...now we're also the biggest.

"Dedicated to the resurrection of junk through engineering?"
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  #6  
Old May 19th, 2012, 07:45 PM
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Monday is fine. Sent you some coin. Should have this thing running in a week or so.
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  #7  
Old May 20th, 2012, 06:27 AM
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Thanks mate. I was about to take a frame of an old rad when I found a NOS set in the pile all shiney and complete with new rubber grommets and nice new bolts. You win
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new expansion complete. Not only are we the only Rover shop in Eliot Maine...now we're also the biggest.

"Dedicated to the resurrection of junk through engineering?"
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  #8  
Old May 20th, 2012, 09:46 AM
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We got in 90% done! only some small bit remain but it was a very quick and easy install from what I can see.

Matt, Adrian said you might hook him up with a 200tdi radiator frame? Do you have any 300tdi Radiator/intercooler frames? I need one for my convert.
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  #9  
Old May 20th, 2012, 11:43 AM
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Quote:
Originally Posted by junkyddog11 View Post
Thanks mate. I was about to take a frame of an old rad when I found a NOS set in the pile all shiney and complete with new rubber grommets and nice new bolts. You win

Awesome man your the best!

------ Follow up post added May 20th, 2012 11:45 AM ------

Quote:
Originally Posted by junkyddog11 View Post
Thanks mate. I was about to take a frame of an old rad when I found a NOS set in the pile all shiney and complete with new rubber grommets and nice new bolts. You win
Quote:
Originally Posted by ini88 View Post
We got in 90% done! only some small bit remain but it was a very quick and easy install from what I can see.

Matt, Adrian said you might hook him up with a 200tdi radiator frame? Do you have any 300tdi Radiator/intercooler frames? I need one for my convert.

All in all pretty straight forward. all thats left is the radiatio/intercooler and some plumbing. I have to get that fuel line made up which will probably take a couple days for the parts to come in.

Pretty darn close to getting this thing fired up!

Once complete I'll go through what I did in detail with any qwirks that popped up along the way
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  #10  
Old May 20th, 2012, 10:18 PM
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With a turbo that accessible in the engine bay, i would be so tempted to put a bigger one in. :D

Swap is looking good so far, looking forward to the end results.

Did you do anything to the motor before install? I don't know what type of diesel they had where this motor previously ran but i know in my vw tdi that had many miles on it on the pre ultra low sulfur diesel that the intake manifold had a good amount of carbon buildup, and it pulled way harder through gears after i cleaned it. And some bigger injectors and some tuning to the the motor and it could be a quick little car. But I'm sure you know all this stuff.
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Old May 20th, 2012, 11:37 PM
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This was supposedly a fresh rebuild that hadn't been run and sitting since 2009. Not sure if that's 100% accurate but nope didn't really do much. Could care less about max performance. I want reliability, a decent cruising speed, mileage offload and o yea reliabiltiy. I'm gonna bleed the whole fuel system so the little bit of diesel that's in there is of little concern since its so little.
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Old May 21st, 2012, 12:07 AM
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I hear that. Just remember, more power means less effort to get up to speed, which in turn gives better economy and less wear and tear. I'll leave ya alone now lol.
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Old May 21st, 2012, 12:23 AM
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Quote:
Originally Posted by JohnsD90
I hear that. Just remember, more power means less effort to get up to speed, which in turn gives better economy and less wear and tear. I'll leave ya alone now lol.
To a degree A factory 200tdi with my setup should get to and hold 65-70 without much effort. Controlling your right foot has a lot to do with it too lol

No sweat I enjoy the input.
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Old May 21st, 2012, 11:45 AM
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Nice!

There is a SIII 109 SW in town that I see parked in the corner of a local gymnastics place. Everytime I see it I think a galvy frame and a little fix up would be nice. And 2.5 diesel that you just popped out could be a good match for it too...
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  #15  
Old May 21st, 2012, 03:16 PM
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  #16  
Old May 21st, 2012, 07:38 PM
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Originally Posted by airbornrover View Post
Where at ?
The 109? Behind Barnstormers in Rumson. I'm pretty sure the owner of the building owns it - think he said he had it for years and wants to restore it at some point - but it's been sitting there for a while now. Also a 4 door Toyota Land Cruiser - FJ60?
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  #17  
Old May 23rd, 2012, 06:54 AM
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Originally Posted by bossman429 View Post
Awesome man your the best!

------ Follow up post added May 20th, 2012 11:45 AM ------
HAHA that's not often heard around here!

glad to help. Should have said somthn about the fuel lines. I've got all that stuff too!

Have fun with it.
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new expansion complete. Not only are we the only Rover shop in Eliot Maine...now we're also the biggest.

"Dedicated to the resurrection of junk through engineering?"
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  #18  
Old May 24th, 2012, 08:39 PM
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I'm 2 silcone hoses and an air filter canister away from having this swap done... should be here by tomorrow
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  #19  
Old May 25th, 2012, 11:00 AM
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That's great Adrian - can't wait to hear it.

Talked to the owner of the 109 seeing if he wanted your old motor for it but he said he's got too many car things going on as is. The 109 needs a bunch of love - chassis is for shit but I was daydreaming of new chasis, your 2.5 diesel, and a nice big garage and a ton of time.
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  #20  
Old May 25th, 2012, 02:09 PM
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Hahaha. Do it! I'll be glad to help turn some wrenches whenever I can. I'll get to work on a truck that I dont have to pay for. It will be great lol
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