Vehicle & Technical > Defender

2.5 petrol, 2.5 diesel how much difference? fitting 200tdi?

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90sam:
ohh thats alrite then i'll leave it as it is. i've got 7.50s on but it'll be fine for me, just wondered if i had to replace my transfer box to go with the engine! Time to sound proof then tweak it me thinks!

stefan:

--- Quote from: "sas pinkie" ---As far as I recall, the 2.5 petrol hasnt got a fuel return, which will be needed by the diesel. The fuel lines will run in a different route. So as long as you get some deisel fuel lines with the engine then not much more work to put it in.....

The rest will go in the same, regardless of petrol or diesel..... (you will also need a wire loom with the relay in for the glow plugs as you havnt got the glow plug switch posistion on your ignition switch....)

Another thing to check... On most deisel cars, they tend to have heavier duty springs on the front as the engines tend to be heavier, dont know if this is the case with defenders, of course, if you have already upgraded the springs it wont be a problem.
--- End quote ---


The 2.5 petrol does have a fuel return, my website as listed in the first reply has most of the details you'll need when changing from a 2.5 petrol to a Disco 200 Tdi.

Stef

fasthands:
I converted 110 2.5 petrol defender to a 200tdi using a disco engine. It was quite easy really the wiring is very easily adaptable I just wired a glow system seperate  . the exhaust is a little tricky but if you go to the breakers and get a exhaust down pipe from a mondeo it is a large bore pipe with a tight bend, so cut the flange off the mondeo pipe and weld the tdi one to it, or use the petrol flange with a little addaption to the holes. checking the position once the engine has been fitted, this gives a good smooth exhaust exit with plenty of clearance of the passenger footwell. It worked superb on mine! I then routed the pipe from the turbo compressor outlet through the inner wing round the strut and back through the inner wing to the intercooler using a 90 degree steel pipe about 2" in dia.and some rubber hose suitable for use with turbos. This was better and easier than trying to get a real tight bend pipe in between the turbo and inner wing you will see what I mean when you come to fit it! also check the studs on the rear of the engine as they are in a different place, and there are two dowels to remove before you can fit the g/box. and the engine mounts and brackets from a petrol engine fit on no problem! hope this helps! :)

spy:
Sorry to reincarnate such an old thread but the time has finally come to make a start on this!  Does anyone know stefan who did the excellent guie that was linked to at the begining of this thread? 

The link no longer works and I cant find the printout I did of it all that time ago.  It really was detailed and would save me some nitemares if I could get another copy....


Thanks,

Mike

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