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  #1  
Old May 4th, 2012, 05:22 PM
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200tdi Swap - Step by Step Write up??

I'm going to dig into this next weekend. I'm looking for some step by step write ups on this forum but can't find any.

Its a defender 200tdi motor replacing a 2.5TD, bolting to a lt77

Everything I see says its practically a complete bolt in installation, but I was hoping someone might have or have a link to a step by step write up on this procedure?

Also - Anything I should be doing/checking on this engine before I drop it in. Supposedly its a complete rebuild but it's been sitting on a pallet for years. The flywheel has been resurfaced, it turns over fine. There were a few things loose or disconnected (glow plug wire and starter ground, but other than that I'm not too familiar with these to know what to look for. I just dont want to get it in the truck only to find out an obvious issue was glaring me in the face prior to!

Today my big task was to drill out a broken bolt for a missing lifting eye and fab up a new on - pics attached - starting to get the hang of this welding thing too!
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  #2  
Old May 4th, 2012, 05:40 PM
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Jamie Austin
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pm me your email address, i have the factory 200tdi retrofit instructional manual here.
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Old May 4th, 2012, 05:40 PM
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http://www.glencoyne.co.uk/tdiguide.htm
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Old May 4th, 2012, 06:01 PM
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Thanks!

Now if i only understood half the words in that write up I'd be set!
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Old May 4th, 2012, 08:09 PM
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It is about as easy of a swap as you could hope for. Pretty much just like removing the old motor and putting a new one in.
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Old May 5th, 2012, 09:45 AM
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If you want to go smoothly, take the time to make sure that you have all of the bits there. It should be about an 8 to 12 hour job.
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Old May 5th, 2012, 01:51 PM
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bits as in... radiator, hoses, pipes, etc?

I think i'm all set as the engine has all front accessories. Have all the hoses, radiator and intercooler, exhaust pipes (although from what i read my TD exhaust is an exact match)... etc.

Anything else I should make sure I have?
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Old May 5th, 2012, 03:40 PM
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Are putting in a new clutch or at least new operating arm as they are weak point. You are swapping a diesel for a diesel, as others have said it is about as easy as it gets.
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Old May 5th, 2012, 11:10 PM
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Quote:
Originally Posted by kjva View Post
Are putting in a new clutch or at least new operating arm as they are weak point. You are swapping a diesel for a diesel, as others have said it is about as easy as it gets.

I will inspect them when Ihave it apart. I've heard of people welding a bar across the arm to strengthen it.... is that common?

I think the clutch is relatively new so I'm hoping it doesn't need replacing. If its questionable I'll obviously do it
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  #10  
Old May 6th, 2012, 10:20 AM
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Just replace the throwout bearing, release arm, slipper pads, push rod, slave cylinder and flex hose. The parts are cheap and it is stupid easy to do with the engine out....

Yes, weld a plate on the arm behind the pivot point. They WILL punch through otherwise. Just be careful to keep heat away from the pivot when welding as it is hardened steel.

You can get a throwout bearing with an aluminium housing as well. More dough, but the plastic housings do fail on occasion.
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Old May 6th, 2012, 12:44 PM
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stumbled across this (PDF available)

http://mylandyblog.blogspot.com/
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  #12  
Old May 7th, 2012, 03:52 AM
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So How's the swap going?
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Diesels.....great when they're going and so easy to work on.
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Old May 15th, 2012, 10:36 PM
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SO I got the engine out today, in total I'm about 3-4 hours of work in.

Looking at the TDI vs the 2.5TD alot seems to be dead equal. However, should I be getting a new fan shroud and radiator housing? I dont see how the new small radiatior and intercool fit into the same shround/mount. The fixing instructions I got show a different type.


Exhaust looks like its exactly the same.

I'll be posting pics and a vid in the small projects section btw
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  #14  
Old May 16th, 2012, 09:24 AM
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I went electric, gives alot more room up front
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  #15  
Old May 16th, 2012, 10:26 AM
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200tdi uses a different fan shroud rad and inter cooler.

If you look at my build thread there are some pics of both.
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  #16  
Old May 17th, 2012, 10:46 PM
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Fuel System

OK I'm forseeing an issue when I go to hook the fuel system up.

First picture is of my fuel filter. I dont know what is what?

Second picture is the injector pump on my 2.5TD, there are two connections. One fore and on aft. I'm assuming one was the feed and one was the return?

3rd picture is the injector pump on my 200tdi - there is only 1 Connection I can find (which I'll assume is the feed.) WHat do I do with this return line that has no where to go?


4th and 5th picture - Lift pumps of 2.5TD (dirty one) and 200tdi (clean 1). these are the same, I'll assume I hook them back up the same?

5th and 6th picture. 5th is the #4 injector on my 2.5TD, there is a fuel line fitting there. 6th is the picture of my #4 injector on the 200tdi, just a banjo bolt, no connection. what do I do with this extra line?
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  #17  
Old May 18th, 2012, 09:16 AM
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red bank is a bit far for me but im working in Ridgefield park NJ today. If you want you are welcome to come look at my setup

ill see if i can snap some pics


before i go take a look it looks like you may need to cap a line.

on the 200tdi you can get away with 3 in/out or 4 in /out from your fuel filter depending on how you plumb it

oh an PS check that "filter" it may just be a sedimenter and have no real filter element inside of it. Mine was like this so i replaced it with a real filter
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  #18  
Old May 18th, 2012, 09:43 AM
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200tdi fuel system is very simple. You have a line that runs from the tank to the lift pump. Then from the lift pump to the filter. From the filter to the injection pump. So you will only have two lines to your filter, not three.

On the return, all of the little spill tubes get routed to the injection pump, and then the injection pump will have a larger tube to return to the tank. That red arrow in the 3rd picture is actually pointing to your return line. You can see where the spill tube dumps into it in the same photo. The supply for the injection pump is a banjo fitting at the front.

If it were me, I'd look at the parts manual and just buy the right parts, including the filter housing. It will bolt right up to where the old one was. That way you can keep all your 2.5TD junk together for whoever buys it, and you will have the correct 200tdi parts for your new setup.

------ Follow up post added May 18th, 2012 07:51 AM ------

I should add that the only splice you should have to make is on the return line, using an 8mm (5/16") compression union.
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  #19  
Old May 18th, 2012, 09:58 AM
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Line 1 is from the tank
Line 2 is from the lift pump to the filter (marked also as line 2 on the filter housing)
Line 3 goes to the front large banjo on the injection pump
Line 4 comes from the double sided banjo on the rear on the injection pump to the filter (the other side of the double banjo is hooked up the flexible braided spill line from the injectors)
Line 5 goes back to the tank


I also marked the spill rail direction and where it goes in the other pics


My setup uses one extra line, witch some guys say will cause the truck to not be able to pull fuel if the lift pump goes. but it works flawlessly

Filterhead is a stanadyne FM100 with the 6in long 5micron filter, primer pump on top and clear fuel bowl on bottom
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  #20  
Old May 18th, 2012, 11:11 AM
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As far as I can tell the only difference between what you've done there from the OEM 200tdi arrangement is that you're running the return back up to the filter before sending it back to the tank.

It seems unnecessarily complicated and leaves me wondering what advantage there might be in doing it that way.
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