Project Defender 200TDi Engine

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Badger

Badger

Well-Known Member
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Location
Marldon, Devon
I picked up a 200TDi Defender engine today minus a few bits.

The plan is strip it down to a certain extent and rebuild it and getting it ready for a transplant into my 1988 model 90 ( 19J currently ).

I've no experience of this engine ( worked on bikes alot in the past, mainly v twins ) so it's going to be a learning curve and an experience all in one, as such i'll update this thread as i go along.

As customary for Landyzone, a pic is needed to start with, so here's one of it in the back of the landy after picking it up, it's still sat there as i haven't removed it yet ( bit big for me alone to move out ;) )


 
123-eddy09 said:
Looks good. Would offer to give you a lift but I'm in lincolnshire sorry.
Click to expand...

no worries mate, we got it out :D


Using a couple of scaffolding boards and some 8x2 i bridged between the back of the landy & the final place it would sit.

With 2 of us we dragged it across the boards onto the makeshift stand.

I had some used oil which i smeared over the boards to help drag it across.




 
Just done some measurements mate, the block with all on it ( timing cover, starter motor etc ) is 30" long and apprx 24" wide.

Best way i can see it working is place the first engine up against the rear of the cab with the injection pump facing the rear ( so as you look at the back of the pickup, the engine will go left to right )

Then place the 2nd engine the same way pushing them as close as possible, you should be able to move the first engine over the right abit and the 2nd engine to the left so the timing cover miss's the 1st engine's alternator to close the gap abit between them, but you may foul the injector pump on the alternator...

According to my measurements it'll be tight but possible with some jiggling :D

I think the weight is 215kg dry weight, so looking at 450-500kg overall. 1 engine made no difference to the handling on mine or speed etc, in fact i forgot it was there most of the time.

 
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Had a look around the engine the other night, noted a few things missing.

Manifold
Turbo
Alternator

A few pipes are cut off but it wont be too difficult to remedy those.

Checking around, it seems the turbo's from a disco are the same as the Defender for this model engine, so that's helpfull in picking one up, manifold may be abit difficult, but not impossible.
Alternator, not sure if mine on the 19J will fit or do it's job properly ( new one on my 19J anorl ) on the 200, if not i need to track part numbers or find out whether the disco version will fit.
Going to order a new set of rings for the pistons and gaskets ( 3 hole to be safe ) for the head and get to work stripping it down, however i need to concentrate on the MOT looming on her atm, so this will take a back seat for abit, i'll be cleaning the block up abit in my spare time.
 
PaulWilde said:
Just done some measurements mate, the block with all on it ( timing cover, starter motor etc ) is 30" long and apprx 24" wide.

Best way i can see it working is place the first engine up against the rear of the cab with the injection pump facing the rear ( so as you look at the back of the pickup, the engine will go left to right )

Then place the 2nd engine the same way pushing them as close as possible, you should be able to move the first engine over the right abit and the 2nd engine to the left so the timing cover miss's the 1st engine's alternator to close the gap abit between them, but you may foul the injector pump on the alternator...

According to my measurements it'll be tight but possible with some jiggling :D

I think the weight is 215kg dry weight, so looking at 450-500kg overall. 1 engine made no difference to the handling on mine or speed etc, in fact i forgot it was there most of the time.

http://img213.imageshack.us/my.php?image=flatbed.jpg
Click to expand...
Just put a sheet of 18mm constructional plywood down on the floor so you dont damage the tub floor and put dents in it dragging them around.
Strap them down to stop them moving. Weight is not an issue. I've loaded a pallet of bricks into my 90 (one at a time) with no problem. Springs sat down a bit but nowhere near the stops. Dont know what they weighed but definitely more than half a ton.
 
sorry to rain on your parade but the intake and inlet manifold on a defender 200 are like rocking horse poo and not the same as a discovery. turbos are even rarer!!!!!!
 
Tat said:
sorry to rain on your parade but the intake and inlet manifold on a defender 200 are like rocking horse poo and not the same as a discovery. turbos are even rarer!!!!!!
Click to expand...

Indeed the turbos are rare as rocking horse ****, but with a little work it's possible to use a Disco turbo on a Defender manifold, a fair few LHD Landy's have had a mod done to make it work ( still following the details atm, will post up more when i get an idea, but it's possible )

Manifolds for Defender 200TDi : John Craddock LTD - EXHAUST MANIFOLD 90/110 200TDI - ERR678
 
Stripped abit of the engine tonight, got the dreaded crankshaft bolt off but the damper won't come off atm, left it soaking in oil for tonight, don't wanna buy a pulley just to get it off...
 
sypher said:
How goes te pulley removal paul ? have you shouted at it yet
Click to expand...

It's getting silly now, tried a bar ( 1/2 thick steel ) drilled some holes and bolted it to the pully holes with the bar across the main pulley nut ( the big one, not bolted in, couple of mm clearance ) then tightened the bolts up...

Bent the steel.

Tried heat, shock and just about all i can think of from wood chocks against the timing cover and wedging it out, no joy, this is getting silly, my fookin elbow is killing me, left it soaked in oil over night as well...

Just as a note, the main pulley bolt came off with an adjustable spanner :eek: after locking it from the starter gearing
 
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