90 200d to td5 conversion .......

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Defenderbob

Member
Posts
16
Location
Notfolk
so I'm after a some advise here please, I have a 1985 defender 90 truck cab. It's in the workshop now being stripped, ready for rebuild / resto
In all fairness it really ain't in bad nick.
I would like to modernise the old girl up and fit a td5 engine and box. .....
So my question is. Is this possible, is there anything different on the chassis or bulk head I need to be aware off.?
Thanks Bob
 
The transmission tunnel is different for sure. Though the bulkhead should be the same as people have put TD5 bulkheads into 200tdis before, so should work the other way round.
 
With enough work, anything is possible, but there'll be quite a few modifications to get the TD5 in and running. The fuel delivery is a little peculiar as the engine needs its fuel delivered at 60 psi so there are two fuel circuits, a low pressure one and a high pressure one. So you'd want to transplant the TD5 fuel pump, filter set up and fuel lines. You'll want the ECU and wiring looms from a TD5 as well, both the 'red plug' loom and the 'black plug' loom, as the instruments are all TD5-specific. As you'd need to strip all this off a scrap TD5, maybe it would be easier to buy the said scrap TD5, fix it and then drive around in that, rather than transfer all the components across!
 
Sooooooooooo the old 200 is a bit sentimental it's only been mine a week but have been in the family since nearly new. The old girl has been stood up for 12 years, I don't mind a challenge and have a bit of spare time, I just want to get It right first time as not to have to cut drill weld the galv chassis once it's been done etc. I have a few contacts in the insurance world etc so could maybe get my hands on a completely smashed td5 and transplant the lot.
Apart from the the straight forward (ish) swapping of engine box loom dash clocks fuel (that does seem like some list) is there any thing you would know of that need cutting, welding, brackets etc for it all to go onto original chassis. Don't mind spend a few quid on it to make it smart, usable and last lots more years. All help here is so gratefully received and taken on board.
 
td5 sits in the same position as 300 tdi apart from engine and box ,seat box floor plates ,props etc are the same as 300 tdi,currently your transmission in a 200 tdi sits 50mm ish further back , i would fit the td5 as a td5 or 300 tdi would be that way all parts can be std off the shelf parts ie exhaust ,hoses and wiring etc,apart from welding engine mounts the rest should bolt up
 
jamesmartin said:
td5 sits in the same position as 300 tdi apart from engine and box ,seat box floor plates ,props etc are the same as 300 tdi,currently your transmission in a 200 tdi sits 50mm ish further back , i would fit the td5 as a td5 or 300 tdi would be that way all parts can be std off the shelf parts ie exhaust ,hoses and wiring etc,apart from welding engine mounts the rest should bolt up
Click to expand...

Nice one my bulk head needs replacing any how so once it's all stripped if I go td5 route I can then hopefully drop engine an box in sort out the mounts check bulk head fits ...... Restrip and go for galv chassis.... Then let the build begin.?...
 
Marmaduke said:
I would have thought that it'd be easier and cheaper to sell your 200 as they fetch decent money and buy a TD5 for less than it would cost to do an engine transplant
Click to expand...

I do agree really it just the truck means a lot to the grand parents they have had it an awful long time. I would love to just keep it, do it right up, properly and keep it in the family for many years to come
 
Defenderbob said:
Sooooooooooo the old 200 is a bit sentimental it's only been mine a week but have been in the family since nearly new. The old girl has been stood up for 12 years, I don't mind a challenge and have a bit of spare time, I just want to get It right first time as not to have to cut drill weld the galv chassis once it's been done etc. I have a few contacts in the insurance world etc so could maybe get my hands on a completely smashed td5 and transplant the lot.
Apart from the the straight forward (ish) swapping of engine box loom dash clocks fuel (that does seem like some list) is there any thing you would know of that need cutting, welding, brackets etc for it all to go onto original chassis. Don't mind spend a few quid on it to make it smart, usable and last lots more years. All help here is so gratefully received and taken on board.
Click to expand...


My mate said exactly the same when I told him to break it with rotten chassis, he rebuilt it and modded everything whilst he was at it , in the end there was nothing apart from the wiring loom left of the original car, so much for sentimental!
 
Ah well, in this case the wiring looms are among the things you would want to change too, so they've got all the right plugs and fittings for the TD5, its instruments and paraphernalia.
 
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