Pulling 19J and 200TDI going in: Need advise. - Defender Source
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  #1  
Old January 31st, 2016, 11:53 PM
DailyDrivenDefende
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Michael
1989 110, 1985 90 200TDI
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Talking Pulling 19J and 200TDI going in: Need advise.

Hi guys,

I am getting ready to pull my 19J out and install 200TDI (Defender Version).

I would like to pick the brains of the experienced/wise.

Q1: Where do you guys attach the chain on the block to pull/insert the old 19J/200TDI?
Q2: What would you replace since I am going in this deep and with the engine out? I got me new clutch, new radiator and belts.....
Q3: What are things that you do to make things go easy for yourself?

I am thinking about pulling the seat box, fenders and the radiator for restorative purposes while I am at this.

The engine and the rest are coming this Friday. It took a little over 1.5 months to receive the engine from UK.

Here are my Rovers and the gray in the middle is waiting for the transplant.



Thank you!
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  #2  
Old February 1st, 2016, 12:01 AM
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John B.
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There are lifting spot on the head. Read the genuine manual before starting. Also read the factory 200tdi swap kit instructions.

Replace the clutch slave, flex line, fork, release bearing, slipper pads, rear main seal, engine mounts and pilot bearing. Timing belt if unknown.
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  #3  
Old February 1st, 2016, 12:03 AM
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John B.
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Pretty easy job. Normal day with a friend helping. Done one in 5 hours with four people.

The key is having all the proper parts there.
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  #4  
Old February 1st, 2016, 01:30 AM
DailyDrivenDefende
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Michael
1989 110, 1985 90 200TDI
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Quote:
Originally Posted by Red90 View Post
There are lifting spot on the head. Read the genuine manual before starting. Also read the factory 200tdi swap kit instructions.

Replace the clutch slave, flex line, fork, release bearing, slipper pads, rear main seal, engine mounts and pilot bearing. Timing belt if unknown.
Could you point to me to the "Factory 200tdi Swap Kit Instruction"?

Flex line? Slipper pads? I have done other cars but slipper pads, you mean clutch friction element?

Which flex line are you specifically talking about? I should place an order for that.

Thanks!
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  #5  
Old February 2nd, 2016, 01:54 PM
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First thing...is it a Discovery 200tdi or a Defender 200tdi.




.
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200tdi Ex British Army 110 Hardtop 139142kms
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  #6  
Old February 2nd, 2016, 02:00 PM
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http://www.landroverweb.com/Pdf-file...o-Defender.pdf


200TDi into Defender - some useful info - by Glencoyne Engineering


200TDi into Defender - some useful info - by Glencoyne Engineering
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  #7  
Old February 2nd, 2016, 02:01 PM
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John B.
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Quote:
Originally Posted by Ohlins View Post
First thing...is it a Discovery 200tdi or a Defender 200tdi.
First post says it is a Defender...

Quote:
Originally Posted by DailyDrivenDefende View Post
Could you point to me to the "Factory 200tdi Swap Kit Instruction"?

Flex line? Slipper pads? I have done other cars but slipper pads, you mean clutch friction element?

Which flex line are you specifically talking about? I should place an order for that.

Thanks!
Flex line = flexible hose attached to slave cylinder
Slipper pads = pads that contact release bearing housing.

Other things... Gravity bleed the slave while hanging vertically down, before installing to bellhousing. Makes life easy.

Can't seem to find the factory install manual online anymore. Grrrr. Back in the day, LR sold complete kits to install a 200TDI in place of a 2.5TD and they published a nice step by step guide.

You can also get a HD fork and a HD (all metal housing) release bearing. Worth it if you don't want to do them again.
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  #8  
Old February 2nd, 2016, 02:02 PM
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I think that is all Disco 200TDI stuff. Not needed.

The Defender install is a nice simple bolt in with all factory stock parts.
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  #9  
Old February 2nd, 2016, 03:27 PM
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Neil Steinhagen
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Parts to consider having on hand (parts are agnostic to Disco or Defender 200Tdi swap):

Heavy Duty Clutch Release Bearing FTC5200HD
Heavy Duty Clutch Fork FTC2957HD
Release bearing staple FRC3416
Clutch push rod retaining clip FRC3327(I broke 2 of these putting things back together - nothing like being held up by a $0.19 part - order several)
Rear Main Seal (Dowty - Teflon version from Turner Engineering) ERR2532
Rear Main Seal (OEM, cheaper) ERR2532G
Block to flywheel cover gasket ERR1440
Spigot Bearing LFB50050


Watch this video, along with part 2 and 3. It will explain the slipper pads, etc. that you asked about.


Also watch this video about the rear main seal.
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  #10  
Old February 2nd, 2016, 03:46 PM
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Quote:
Originally Posted by Red90 View Post

Can't seem to find the factory install manual online anymore. Grrrr. Back in the day, LR sold complete kits to install a 200TDI in place of a 2.5TD and they published a nice step by step guide..
I used the kit LR sold. Have the booklet. I can scan and send if you can't find this online.
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  #11  
Old February 2nd, 2016, 03:51 PM
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John B.
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Just found it. Hidden in a strange place....
Attached Files
File Type: pdf 200Tdi info.pdf (1.05 MB, 46 views)
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  #12  
Old February 2nd, 2016, 03:53 PM
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Quote:
Originally Posted by xplorUtah View Post
I used the kit LR sold. Have the booklet. I can scan and send if you can't find this online.
Have a look. The scan I uploaded is not the best and I'm not sure if it is complete. If you have something better, might as well scan it.
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  #13  
Old February 2nd, 2016, 04:27 PM
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Michael Sword
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I'll go out on a limb here as we just did the same job to my 89 110 last month. Only thing I'll add, which I didn't know initially, is that it was recommended to upgrade to a stronger transmission. I was running the LT77 mated to LT230, everything pointed to this being fine. My buddy is running a 200tdi with the same setup in his 91 with a 200tdi, but what I didn't know then is there are different LT77's the later ones are stronger. Sure someone will chime in with the correct suffix.

So mate of mine, Jonesy, has a 200tdi in his and we pulled his tranny out and the LT230 was destroyed, replaced both IIRC. He drove it the next weekend to Uwharrie and it stranded him on the way home. He had a new R380 shipped from Ashcroft and installed. So I asked the question of the guys who rebuilt my 200TDi and they agreed I would need an R380 sooner or later. For me, I didn't want to have to pull the engine again any time soon. If you can find one of the stronger boxes in good shape that would be a good way to go also. Just something to think about.
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  #14  
Old February 2nd, 2016, 04:34 PM
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Quote:
Originally Posted by wanabewheelin View Post
I'll go out on a limb here as we just did the same job to my 89 110 last month. Only thing I'll add, which I didn't know initially, is that it was recommended to upgrade to a stronger transmission. I was running the LT77 mated to LT230, everything pointed to this being fine. My buddy is running a 200tdi with the same setup in his 91 with a 200tdi, but what I didn't know then is there are different LT77's the later ones are stronger. Sure someone will chime in with the correct suffix.
The "best" route is to get the box that came with the engine. Both for strength and better gearing. The "H" suffix box that came with the 200TDI was the strongest. It also has a higher 5th gear ratio, which make highway use better.

The earlier boxes "F" and "G" or basically the same strength, but have the lower 5th. Before "F", the layshaft bearings were quite small and eventually fail.

From Ashcroft:
Quote:
The 'D' and 'E' are very similar the only difference being the reverse gear was a little fatter in the E,
When they went from 'E' to 'F' larger layshaft bearings were used.
The 'G' was further improved by all the gear teeth including the pinion getting approx 20% thicker. Also a much wider pump was used to increase the lubrication and cope with the fact that some of the LT77's were now being supplied oil cooled, ie V8 NAS 90, 3.9 RR Classic and the 3.5 EFI Discos.
The 'H' (termed the LT 77S) was the same as the 'G' in terms of strength but used a different synchro set up called the'Double Synchro', In reality it didn't work much better.
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  #15  
Old February 2nd, 2016, 04:58 PM
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I recommend you run the engine before the install. You may not have any recourse given you bought it overseas but it still seems worth the effort. I really wish I had done so as it would have revealed a good number of inconsistencies with the seller's claims.
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  #16  
Old February 2nd, 2016, 05:41 PM
DailyDrivenDefende
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Michael
1989 110, 1985 90 200TDI
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You guys are awesome. Please keep them coming. I will keep updating this thread as I make progress.
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  #17  
Old February 2nd, 2016, 07:33 PM
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Quote:
Originally Posted by Red90 View Post
Have a look. The scan I uploaded is not the best and I'm not sure if it is complete. If you have something better, might as well scan it.
that is the book I have. Frankly I found the parts list in i the most help.
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  #18  
Old February 2nd, 2016, 07:49 PM
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Do you have the sandwich fuel filter? Should replace that too with a spin-on.
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  #19  
Old February 2nd, 2016, 08:05 PM
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Michael
1989 110, 1985 90 200TDI
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I looked through the manual as well. I found the exploded parts diagram to be extremely helpful. Where can I find more of those?

Thanks Neil, John, Michael, Andrew, 1of40 and Adam!!
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  #20  
Old February 2nd, 2016, 08:18 PM
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John B.
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The factory part catalogue has all the parts diagrams. Just google. Lots of places to download.
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