Not quite 4-5 hours as one correspondent has done but my son and I managed to change the 2.5TD for a 200Tdi in the Defender over 2 days. This also included two trips back to the source of the 200Tdi to get bits that I had missed!
One trick that I have learnt is that to get at all the bell housing bolts (and there are 11 of them!) the easiest way is to remove the floor pan and tunnel which give 100% easy access.
Of interest;
- The exhaust downpipe from the Tdi did not mate up to the existing Defender system, but the 2.5TD downpipe fitted the Tdi manifold.
- The fitting on the fuel return from the injector on the Tdi is male (as is the one on the pipe from the Defender tank) - that was one trip back!
- The bonnet stay on the 1990 Defender ("knee" type) cannot be used with the 200Tdi as the lower pivot is on the 2.5TD radiator mounting bracket which is removed for the Tdi - that was the second trip back
- New holes had to be drilled for the radiator header tank, the air filter and the radiator mounting brackets (one existing hole, one new)
Everything else was a direct fit.
Altogether, not a bad learning experience.
I now have 2.5TD engine parts to sell:
Head Injector pump Exhaust manifold and turbo Inlet manifold Power steering pump
Complete Allisport Intercooler and all pipework for the 2.5TD in a 110 (or a 90 I assume?)
Cheers
Peter