2.5 NA turd to a 200 tdi swap

BenLittle

Well-known member
Callsign: KE7BEN
Great work!

As a follow-on to this - After cutting the trumpets off and welding the pins back - it still sat high. I went ahead and ordered the Defender style mounts and buttoned it all up. Fits perfectly. Thanks.
 

Tbaumer

Technical Excellence Contributor
Didn't have much time this weekend, but got a little done. I didn't pressure wash the engine bay when I still had the running 2.5 NA in - didn't even think about it. It was a mess to work on & chem cleaning with rags would take forever. My drive way is too steep to push, so I picked up a portable winch, secured a solid anchor point & spent a couple hours cleaning (then a couple more cleaning the driveway). Cleaned & POR 15 the cross member. Ordered Bearmach engine & tranny rubber engine mounts.

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Tbaumer

Technical Excellence Contributor
Can't believe it has been almost a month since I started this. Slow process between steps removing, treating & sealing the rust I find EVERYWHERE - And I'm only addressing the rust I won't be able to get to later!

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Tbaumer

Technical Excellence Contributor
Rusted holes in my outrigger. I will do a galvanized chassis down the road, so rust buster & POR15 for now. Missing a corner of metal at the bottom of the bulkhead that holds one of the tunnel adaptor fasteners. These are the reasons weekend engine swaps take months!

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What is this? Nothing was attached to it.

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Tbaumer

Technical Excellence Contributor
Finally out of the crate!
Need to install the transmission brake. I have two to choose from - One from my 110 & one from the other 200 tdi I ordered from the UK. My existing trans brake had oil inside & one return spring disconnected (Explains why the park brake sucked). It also has two drum fixing screws, instead of one like the other, & an oil catcher (?) inside. The other is missing a shoe spacer (I found the spring & nut inside) & has obviously not been used in a long time. I would think they would be interchangeable, but the expander & adjuster assemblies & hand brake cable attachments are very different.
I think I'm going to play it safe & have the drum turned & new shoes on the one that came with, so I'm connecting to what I have.

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Napalm00

Technical Excellence Contributor
If you have the time and coin now would be the time to replace the lt230 layshaft O-ring and all it's external seals.

The layshaft O-ring isn't accessable without removing the unit from the truck .

On the handbrake same deal...I love my xbrake disc brake. One of the first mods I did to my truck about a decade ago. Makes servicing the shafts and the tcase easier and works better with no maintenance.
 

Tbaumer

Technical Excellence Contributor
Cleaned & sealed the brackets, new mounts. Feeling inspired tonight (My wife calls it something else) the 200 tdi is now where it belongs. I know there are things that should be done while it is out & it could be made pretty before install, but this isn't rebuild time yet - It's time to get it back on the road! The full restore comes after I learn more about it. Now if I can just figure out where all these hoses & wires go... :)

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AdamSanta85

Well-known member
If you have the time and coin now would be the time to replace the lt230 layshaft O-ring and all it's external seals.

The layshaft O-ring isn't accessable without removing the unit from the truck .

On the handbrake same deal...I love my xbrake disc brake. One of the first mods I did to my truck about a decade ago. Makes servicing the shafts and the tcase easier and works better with no maintenance.

I wouldn't be surprised if that thing helps performance a little bit too as it is less weight for the drivetrain to spin. I imagine the Xbrake disc is lighter than that heavy drum assembly.
 

Tbaumer

Technical Excellence Contributor
I'm posting pics that will be very obvious to most. Parts weren't just falling into place like I expected, because the 200 tdi came out of a RHD. I pulled up LHD images to copy connections (That's how little I know about engines).
Power steering:

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Heater hoses:

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Looks like I need to get a heater that has straight hose connections.
 

Tbaumer

Technical Excellence Contributor
Found welded studs behind the existing fuel filter - primer, paint & mount.
Once I get everything where it belongs, then new hoses, filters, etc.

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I should've steam cleaned this engine & gear box before installing. It's going to make a mess of things when I clean after.
 

Tbaumer

Technical Excellence Contributor
Staying with the original trans brake for now - Cleaned up & sealed. New expander assembly, shoes, springs & turned drum.

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Tbaumer

Technical Excellence Contributor
Removed Webasto heater. It was disconnected before me & the hoses were dry rotted. It appears to have been factory installed. Which makes for extra wiring in the harness that I don't see in the diagrams.

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