87 D90 2.5TD to 200TDI Swap... - Defender Source
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  #1  
Old November 21st, 2015, 06:04 PM
LakeLBJ
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87 D90 2.5TD to 200TDI Swap...

Swapping a Defender 200TDI into my 87 90 with a 2.5TD. Just spent an hour on it today, got the hood off and started working on getting the front grill and radiator out. Starting this thread as a build log and for people to chime in with advice as much as possible. Will try to document as much as possible, I'm a novice with this so I'll be asking for help often.
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  #2  
Old November 21st, 2015, 06:26 PM
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I see this swap in my near future. I will keep an eye on your thread. Enjoy, should be fun.
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  #3  
Old November 21st, 2015, 07:02 PM
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1989 110, 1985 90 200TDI
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I will be doing this swap very soon as well. I have been shopping for 200tdi. Where did you source yours?
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  #4  
Old November 22nd, 2015, 07:50 AM
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It's a fun swap. Did it a few years back on my '85 110.
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  #5  
Old November 22nd, 2015, 09:58 AM
DailyDrivenDefende
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1989 110, 1985 90 200TDI
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Quote:
Originally Posted by BostonAndy View Post
It's a fun swap. Did it a few years back on my '85 110.
How do you like your 110 now that you have done it? How long of time commitment is this to do with Defender 200tdi?
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  #6  
Old November 22nd, 2015, 10:09 AM
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Good luck CC, I did mine last summer at Uncle Doug's place. We started on a Friday and had it running Sunday afternoon. Having the skill set and endless knowledge of Doug was an immeasurable help. Do you have power steering? If you don't I would highly suggest doing that while you have it apart as it made all the difference in the world in drivability. Look forward to seeing the progress.
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  #7  
Old November 22nd, 2015, 10:14 AM
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If you did not get a turbo heat shield with the engine, pick one up.
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  #8  
Old November 22nd, 2015, 10:17 AM
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Quote:
Originally Posted by DailyDrivenDefende View Post
How do you like your 110 now that you have done it? How long of time commitment is this to do with Defender 200tdi?
As mentioned above, you can do this swap in a few days with the knowledge and skills. The shop I purchased my engine from 'forgot' a lot of critical parts which added a month or two while I sorted things out.
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  #9  
Old November 22nd, 2015, 10:49 AM
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I am enjoying the repeated confidence booster - "you can do it quick if you have the knowledge and skills" -- ha, I don't have the knowledge and skills for sure!

My goal is to have it done by Christmas, working on it when I can a few hours here and there. I do have power steering.
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  #10  
Old November 22nd, 2015, 10:55 AM
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Quote:
Originally Posted by Red90 View Post
If you did not get a turbo heat shield with the engine, pick one up.
I had been told several times these are nla ? The originals break very easily

------ Follow up post added November 22nd, 2015 10:59 AM ------

Quote:
Originally Posted by Daddymow View Post
Good luck CC, I did mine last summer at Uncle Doug's place. We started on a Friday and had it running Sunday afternoon. Having the skill set and endless knowledge of Doug was an immeasurable help. .
You did it and I helped ?

Time flies, that was memorial day weekend 2014.
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  #11  
Old November 22nd, 2015, 11:01 AM
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You will do just fine and there is a wealth of knowledge and experience on this forum you can draw from so don't hesitate to post questions. It is a pretty straight forward swap with the biggest pain being stubborn bolts etc. That is good that you have P/S already one less thing to deal with.

------ Follow up post added November 22nd, 2015 11:05 AM ------

Quote:
Originally Posted by Uncle Douglas View Post

You did it and I helped ?

Time flies, that was memorial day weekend 2014.
Yes, handing you cold beer was a very important and critical job!
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  #12  
Old November 22nd, 2015, 11:20 AM
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Quote:
Originally Posted by Uncle Douglas View Post
I had been told several times these are nla ? The originals break very easily.
There are (were?) aftermarket ones being made from aluminum that are more robust. The stock ones break at the lower mount. On mine, I rebuilt the lower mount with some steel strapping. I must be ten years on mine with no problems.

With LHD, the accelerator cable is very exposed without a shield.

NTC4833
Hmmmm. You used to be able to get them for $50!!! Now it seems they are $200. Stupid suppliers....
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  #13  
Old November 23rd, 2015, 10:57 PM
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Made some progress this evening. Front panel and radiator out, coolant hoses out. Slow and steady wins the race. Does the 200TDI have a new airbox or does it reuse the existing 2.5 airbox?
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  #14  
Old November 23rd, 2015, 11:32 PM
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I modified but reused my 2.5 air box.
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  #15  
Old November 24th, 2015, 12:31 AM
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Quote:
Originally Posted by Red90 View Post
There are (were?) aftermarket ones being made from aluminum that are more robust. The stock ones break at the lower mount. On mine, I rebuilt the lower mount with some steel strapping. I must be ten years on mine with no problems.

With LHD, the accelerator cable is very exposed without a shield.

NTC4833
Hmmmm. You used to be able to get them for $50!!! Now it seems they are $200. Stupid suppliers....
Theirs one supplier that wants $441.00 for them

Have fun with the conversion, if you have the time take it. Things work out good that way
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  #16  
Old November 24th, 2015, 02:03 AM
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Quote:
Originally Posted by javelinadave View Post
I modified but reused my 2.5 air box.
Ditto to this. The 200tdi has a different one but I modified my original with some
Welded on brackets and made it work

Not a hard swap at all. Just stick to your game plan. Little by little. It can be done in a day or two of you want. But nothing wrong with taking your time, especially the first time.
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  #17  
Old November 24th, 2015, 07:20 AM
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The TDI filter is a fair bit larger. If you can find one it is a better way to go.
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  #18  
Old November 24th, 2015, 07:41 AM
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What about the timing belt on the 200Tdi, has that been changed? If not might as well get R done now.
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  #19  
Old November 24th, 2015, 08:18 AM
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Quote:
Originally Posted by Red90 View Post
The TDI filter is a fair bit larger. If you can find one it is a better way to go.
I'm also an advocate of getting everything from the donor vehicle and staying as factory as possible. It make life in the future a lot better. Only change things when you are doing it better than factory.
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  #20  
Old February 2nd, 2016, 02:04 AM
DailyDrivenDefende
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1989 110, 1985 90 200TDI
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Where is this at now? I am getting mine started this weekend. I would love to pick your brain.
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