My 200TDi Engine Swap - Defender Source
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  #1  
Old November 11th, 2013, 07:03 PM
javelinadave
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My 200TDi Engine Swap

I'm going to try to keep this as up to date as possible. I ordered a 200TDi motor from David at Urban Land Cruisers in late September. The motor arrived at his shop Nov 1st. I received videos today with compression checks for each cylinder and a video of the motor running on their test frame.

Cylinder 1:



Cylinder 2:



Cylinder 3:



Cylinder 4:



Engine Run:



I must say that the engine looks spotless and I am looking forward to the install.
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  #2  
Old November 11th, 2013, 07:05 PM
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How much did the engine cost and how much to have it installed?
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  #3  
Old November 11th, 2013, 07:12 PM
javelinadave
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Quote:
Originally Posted by couga861900 View Post
How much did the engine cost and how much to have it installed?
You need to talk to David about the engine cost. I added some items not usually include so I'm not sure what the basic engine cost is.
I'm installing it with a few friends so the install will costs several pizzas and a few gallons of beer and Gatorade.
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  #4  
Old November 11th, 2013, 07:15 PM
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I should still be heading out in january, will this be in by then? Good luck with the swap!
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  #5  
Old November 11th, 2013, 10:25 PM
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I should still be heading out in january, will this be in by then? Good luck with the swap!
I'll be bummed if it isn't done before Dec 1st.
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  #6  
Old November 12th, 2013, 12:54 PM
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Gotta give Urban Land Cruisers props for making those videos. They sure give you some confidence in what you're getting!

I did this swap in my 110. It's super easy and you'll be done in a weekend provided you have all the bits.

A word of caution though about the early LT77. I put my 200tdi in front of the military LT77 that came in my truck, and used a 1.2 ratio Dicovery transfer box. It was a great combination until the LT77 failed.

Are you swapping the entire drivetrain or just the engine?

Oh and you'll be amazed at how sporty it will be with the 200tdi (by comparison of course).
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  #7  
Old November 12th, 2013, 12:57 PM
javelinadave
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Just the engine. Leaving the stock LT77 and x-fer case.
David is providing all the bits required for the swap.
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  #8  
Old November 12th, 2013, 01:14 PM
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When are you doing the transplant? May be in your neck of the woods...
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  #9  
Old November 12th, 2013, 01:30 PM
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Hope you have better luck with your transmission than I did!

Although it had been recently rebuilt, my exmod LT77 lasted only about 7 months behind the 200tdi. The LT77 was significantly changed in the 200tdi models to deal with the increased torque.

Since you have the lower first, second and fifth gears in your LT77, you could handle the 1.2 ratio transfer case, and it would quiet things down significantly. Maybe increase your fuel economy as well.

I'll be impressed as hell if you don't find some bits that you need that weren't included. It won't be anything major, but there are a few little bits and bobs that you wouldn't think about until you're actually screwing it together. At least that's how it always goes in my world!
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  #10  
Old November 12th, 2013, 01:30 PM
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When are you doing the transplant? May be in your neck of the woods...
If I get the motor by then I'm planning on Saturday Nov 23rd. PM me your phone number and I'll keep you posted.
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  #11  
Old November 12th, 2013, 02:22 PM
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As far as the LT77 goes, check the serial number. If the suffix is less than "G", the layshaft gears are small and will fail eventually. It is nothing to panic about, but something to plan long term to get a later model LT77 or a stubby R380.

The other thing to keep in mind is 5th is lower in the pre-200TDI LT77 boxes, so you end up being undergeared for highway speeds.

I assume you are doing everything with respect to the clutch throwout system while the engine is out? All of those parts have a limited lifespan.
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  #12  
Old November 12th, 2013, 03:37 PM
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Wow, that's impressive. I'd certainly have confidence buying an engine after being able to see the compression test results and it running! My hat goes off to Dave at Urban. Looking forward to seeing the install too.
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  #13  
Old November 13th, 2013, 07:02 PM
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David sent me a video of the full, up to temp engine run today. I have to say that the level of service up to this point has been WAY beyond anything I expected.



The motor ships out tomorrow for FAR less than I guessed.
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  #14  
Old March 10th, 2014, 09:28 PM
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So, what happen next?
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  #15  
Old March 10th, 2014, 09:45 PM
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Yes, I way dropped the ball on this thread.
Engine was installed with basic hand tools in a weekend.
The rear main seal developed a leak that David took care of.
So far, everything is running well.
Sorry for the lack of pictures or detail. If anybody is doing a 200Tdi swap feel free to PM me any questions.
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  #16  
Old March 10th, 2014, 09:45 PM
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+1 for David and his crew. Bought my 110 Ex-MoD and 200TDi through him. I'll be doing the same swap come May/June.
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  #17  
Old March 10th, 2014, 11:01 PM
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Today we took out my 2.5td and tomorrow we'll be inserting the 200tdi engine. The engine came with the 2.5td tranny. I didn't get the chance to change my clutch. My truck was down so long that I don't care at this point. If it goes, I'll just replace it. I have a clutch kit on its way. I just wanted to know what challenges to expect with this transplant.
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  #18  
Old March 11th, 2014, 08:10 AM
javelinadave
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Other than lowering the radiator mounts on the chassis everything bolts right up without any modification. The radiator mount on my truck needed to be cut, shortened about an inch if I recall correctly and welded back into place.
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  #19  
Old March 11th, 2014, 08:29 AM
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No modification necessary to the rad or frame when I installed the 200tdi into my 1984 90 that started life as a 2.5NA

I purchased an entire motor and setup out of a 1993 200tdi defender

Just about the most simple install one could hope for
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  #20  
Old March 11th, 2014, 08:49 AM
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I planned on using the radiator from the 2.5td. Am I suppose to change the radiator?
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