defender 200tdi for 2.5td in a 90

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hawkplasterer

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68
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Reading, Berkshire and Creuse, Limousin.
I've just put a 200tdi out of a defender into my 90 in place of the old and very oily 2.5td and was informed it was a straight swap!, all going okish so far but I have 2 questions. I know I should have really got the fuel filter with the engine but didn't, as the engine's out of a defender is there any way I can use the existing fuel filter from the 2.5 TD and adjust the fuel pipes to lift pump and fuel pump and if so how??? and my second question is: the lip of the outerwheel on the crankshaft pulley (that connects to the power steering pulley) has a small section about an inch in length broken away about 7mm in depth (my fault) could I still keep it as it's not as deep as the top of the belt or do I need to change it and could I swap it for the pulley of the TD engine (same diameter). I appologise that the info I've given is vague and descriptions bad but as you may well guess I'm no mechanic. Thanks for taking the time to read and I look forward to any replys. Mark
 
I got a 200TDi stripped upstairs and a 19J in my Landy, i'll check for ya. I wouldn't recommend sticking the damaged pulley back on, but if you do then replace it as soon as you can, a small chip could easily cause an issue and for the sake of something that costs little, it's not worth the hassle.

:EDIT:

Just done some measurements, belt groove is the same as well as the diameter of the pulley front n back, only thing is can see is the part numbers of the belts are different for the PAS, 19J is ETC4272, 200TDi is ETC5815 ( WP/Fan & Alternator are identical for 200Tdi 90> )
 
Thanks for info so far, trying to get a 42mm socket to fit the nut on the pulley on the Td then swap pulleys and hope for the best, have had to swap pas pulley to and should be ok as TD same size as 200tdi (infact I swapped the whole pump the pulley was attached to as I think the shaft the pulley was attached to was slightly bent on the tdi one. I'm going to try to use Td fuel filter assembly with the tdi engine, could anyone tell me on the 200tdi fuel pump and lift pump which pipes go where as I've got 4 pipes, 3 from fuel filter and 1 from fuel tank, I know where they're go on Td and as the lift and fuel pump configuration are different I need to know where they would on the tdi. I've got fitting and pipes for both so I can connect two pipes with jubilees where needed. Thanks again for the advise and look forward to any further replys. Mark
 
So you've got a pipe from the tank going to the lift pump. A pipe going from the lift pump to the fuel filter. A pipe from the fuel filter to the injection pump. And a run-off pipe going back to the tank.

Did you say the TD fuel pump has three pipes? Where did they go on the TD engine?
 
Thanks for latest replys, that pdf file you sent was a massive help Tivster. Do you think then if I pipe it all up correct flow and return etc to the right places I will be able to use the TD fuel filter on the 200tdi engine?, I know most people say it's just easier to use tdi fuel filter but I have'nt got one and really need this up and running today! Is there any other reason it won't work if pipes are going to the right places. Also what size and where could I get the inserts for the narrow fuel pipes if I need to jubilee two together. Thanks in antisipation Mark.
 
Hi Mark,

The way I joined the rigid fuel pipe was to use the flexible hose from a local car shop that is a snug fit over the top of the rigid pipe. I then put a couple of small jubilee clips around the rubber hose.
I was concerned that this might cause the inner, rigid hose to buckle when the jubilee clips were tightened, so I bought some brass tube from a model shop and made little brass inserts for each end of the rigid hose. This helps to prevent the rigid hose from collapsing as the jubilee clips are done up.
As for whether the TD fuel pump will work - there's only one way to find out. You've got nothing to lose by connecting it up the same as it was on the TD engine. I can't see why it shouldn't work.
 
Well all piped up the way the TD was and as far as the fuel side is concerned it's ready to go! Two things stopping me turning her over now, firstly I got the big 41 mm nut of the centre of the TD crankshaft pulley no problem but try as I might I can not get the pulley to come off I've tried tapping, banging, levering and pulling (no proper pulling tool mind) but 2 flipping hours and not a sign of movement and now wondering whether someone's welded the thing on!! You see, as the pulley on the Tdi has a big chip out of the lip I was gonna swap crankshaft pulleys as all measurements are/seem the same as the TD one but as it won't come off I'm stuck, Also tried pulling the front of crankshaft pulley off having undone the 4 nuts holding it to the back part but again wouldn't shift and can't lever too hard in case I damage the grooves. May now have to buy new 200 tdi crankshaft pulley or does anyone think a proper puller would do it? Also one other question the fan cowling on my new 200tdi rad/cooler is cut right down, is this ok as the old cowl on the TD rad went right over the fan but the cowl on the new one would be off set to fan anyway. Thanks again folks Mark
 
You need a good puller or make one up, check my Ongoing Work thread, there's a few ideas in there relating to pullers that people have made, alternatively search for a gear puller ;)
 
hi I have Land rover Free lander MK1 Td4 2003 and I have just removed the crank shaft pulley.

I jacked up the front put it in 5th gear removed the plastic cover etc. I then tried to slacken the bolt with a impact drive to no avail using both types air and electric.
So I got a bar 3/4" drive socket extension bar and T bar and 5 ft of pipe. I got some one inside to hold on the brakes and with one almighty push and pull with the pipe etc it cracked of.
Not and easy job but you must use a 3/4" drive socket set because a 1/2" drive will not move it in fact it will break.
So best of luck to you all who do this job and have many miles of good motoring.

The Bear
 
AlexanderJC said:
hi I have Land rover Free lander MK1 Td4 2003 and I have just removed the crank shaft pulley.

I jacked up the front put it in 5th gear removed the plastic cover etc. I then tried to slacken the bolt with a impact drive to no avail using both types air and electric.
So I got a bar 3/4" drive socket extension bar and T bar and 5 ft of pipe. I got some one inside to hold on the brakes and with one almighty push and pull with the pipe etc it cracked of.
Not and easy job but you must use a 3/4" drive socket set because a 1/2" drive will not move it in fact it will break.
So best of luck to you all who do this job and have many miles of good motoring.

The Bear
Click to expand...

Why would you write this on a 9 year old thread??!
 
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