2.5 NA turd to a 200 tdi swap

Tbaumer

Well-known member
Time for a new thread - I can't tell you how exited I am to get started!
A while back I ordered a 200 tdi "kit" & wasn't prepared for how incomplete it was. This was probably my fault, not knowing what to expect or what to ask for. Having never changed out an engine before, I needed a set up that was in good working order & as complete as possible.
Uncle Douglas had one, replaced the timing belt & sent me a crate that made a lot more sense to me, uncut & new hoses, filters, belts, bolted together, with muffler pipe, shroud, fan blade - all the stuff my first order didn't have! AND crated so the engine didn't shift against the trans & radiator! Props to UD for doing the extras.
I'm leaving town for four days. When I get back it's time to get busy!

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Uncle Douglas

Well-known member
water pump,clutch disc, throw out bearing and TOB arm are all new/ 0 miles as well. Lower it in as one assembled lump.

That unbroken fan shroud is unobtainium
 

Tbaumer

Well-known member
There is info on the " enjoy before restore?" Thread that shows how I wound up deciding on the 300 tdi. Julian, at Global Rovers let me switch, after I already paid, to the 200 tdi. To be fair, I probably got exactly what I ordered - it came with the 200 tdi, later suffix trans, new radiator, clutch kit and his mechanic contact gave it a once over. I think someone who is already an experienced mechanic would have been able to do the swap, but it was missing so much & the hoses were cut off, so I couldn't match them or order new without knowing what they were. It seemed like a daunting task to even get started.
I don't want to bash anyone. I didn't reach out to him, I just decided to go with a known runner. I'm going to post & be as informative as much as I can during this adventure.
 

BenLittle

Well-known member
Callsign: KE7BEN
One of the challenges I've had is tracking down the seemingly endless variances in parts, i.e. Discovery vs Defender and year range variances for both.

That glencoyne guide is 'OK' for a high level overview but it misses some details. One example is the radiator/ intercooler frame. It briefly speaks to modifying the Discovery frame, however, fails to mention that the chassis mounts also have to be modified.

If they aren't shortened in height, the radiator frame sits proud of the fenders and the bonnet will not close properly. https://www.youtube.com/watch?v=GUV2qkMtQYQ
 

Uncle Douglas

Well-known member
Meh. Why hack up the chassis when you can just cut the little Disco hats off the bottom of the rad frame and reweld the pins directly to the frame, making it the same height as the Defender frame?

Have had to cut Nigel's cobbles off a couple cross members and welded the proper ones back on before hot dipping. Fortunately they are cheap and available enough that it makes no sense to make them.

https://yrmit.co.uk/product/chassis-radiator-bracket/

Ted you will not have to cut or weld anything to fit what I sent you.
 

Tbaumer

Well-known member
I didn't think I would have to, being a Defender engine.
I'm out of town & not at home this weekend. Totally distracted thinking about getting to this project. In the meantime, since I'm thinking about anyway, I welcome any prep/pull advise.
 

AdamSanta85

Well-known member
I didn't think I would have to, being a Defender engine.
I'm out of town & not at home this weekend. Totally distracted thinking about getting to this project. In the meantime, since I'm thinking about anyway, I welcome any prep/pull advise.
Get a cheap white board to write a TODO/check list, things to buy list etc.

It feels great to start checking completed tasks off and will help you stay on task, organized, and make sure important things don't get overlooked in the heat of the moment.

Organize your tools before you start, that way you don't waste time and patience continually looking for "that" tool.

Consider buying these (if they only had a 13mm......)
https://www.harborfreight.com/11-piece-metric-highly-polished-long-handle-combination-wrench-set-47067.html
 

BenLittle

Well-known member
Callsign: KE7BEN
Meh. Why hack up the chassis when you can just cut the little Disco hats off the bottom of the rad frame and reweld the pins directly to the frame, making it the same height as the Defender frame?
Hmm.. I did that as well. My radiator frame still sits about 1" proud of the fenders. The bonnet rests firmly on the frame.
 

Tbaumer

Well-known member
And it begins. Started removing connections & things in the way. I have a feeling there will be a delay before the 200 tdi goes in, so I can clean things up & rust proof. Progress pics.

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Tbaumer

Well-known member
More pics. The last one is a Webasto rear heater pump, with hoses routed through the front cross member to a heater box behind the middle row seats. Before I got it, the hoses were disconnected where they would have picked up the engine coolant loop, so I don't know if it works. Any reason to keep this with a 200 tdi? If not, I'll yard the hoses now while they are easy to get to.

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Tbaumer

Well-known member
Cross member & rear supports out, so drive train could clear. It took a pretty good tilt & since I tackled this myself, the adjustable engine leveler was a big help.

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chris snell

Administrator
Callsign: NW5W
Staff member
Nice work! I would definitely hang onto the Webasto. These little Tdis don't do much for heating when it gets super cold. I'd love a Webasto for camping.
 

Tbaumer

Well-known member
Not too bad for someone who has never pulled an engine before! Now that that's out of the way :), I think it's time to write a list of things to do while I have access.

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