The more l thought about it...the more l realized working at work, on the defender, was not something enjoyable enough. Plus, at the end of each day...l'd have to bring it in, then get it out afterwards. So, Friday, ran down to work, removed rack and light bar, and drug it home. Went out last night and started preparing it for engine removal, removed floor panels inside and bell-housing nuts, then this morning she came out at about 10:30.

Floor panels removed, three differnt style fastener heads, phillips, straight slot and 10mm cap screws. I'm like...really?



Engine out.




Emptiness.




Engine just cleared the grill and bumper. Thought l might have to let some air out of the tires...but she made it out and over.

Still waiting on the new engine's arrival, hopefully Tuesday.

 

Have you had a delivery yet?

 

Yes, showed up at work on Monday, 30th, needed to be delivered at a shop with hi-lo. Disassembled the package, powerwashed everything and loaded her up. Put it in the garage at home yesterday morning. Waiting for parts now, new clutch, rear seal, etc. Need to get after the wiring harness, too, before it goes in...someone along the line added a security system that needs to go. And inside the dash is a "wire butt connector" nightmare.

 

@The Deputy I feel your pain the trailer wiring on mine is a nightmare, the PO used a good solid yellow cable, but the routing front to rear is nuts

 

Yeah, was helping a friend out once that had lost power to his trailer brakes, after installing controller/wiring himself. He was just one of those guys, last minute type...phone call went like..."hey, we're leaving for texas in the morning and l just installed a brake controller...worked fine for a bit...started up and went around the block...and now it's not working". Me, l'm like...you're leaving in the freaking morning and you decide to wire your controller the evening before???. Anyway. After a bit of inspection...found where he had zip-tied the wire to the exhaust pipe.

 

Mine was done with romex and wire nuts running on the bottom of a frame rail....

 

200tdi waiting patiently for the parts to arrive.



Spent some time removing the aftermarket security system. What a joke, my 11 year old grandson could have by-passed the system in a blink of an eye. Removing dash cluster was just necassary for removing stupid idiot light to signify the system was armed.




Swapping out one wire, covered with electrical tape by-passed the entire system...lol. (this is their connection, not mine)




Anyhow, hopefully the new lunk of pure unadulterated power will be sitting in here soon.



Did some cleaning after this picture, bell housing is clean and ready for upgraded throwout bearing lever. Other parts are to arrive Tuesday, so over Christmas break l'll hopefully hear this thing run...again.

 

gee what could go wrong with that

 

Pleasant 38° F this morning, so l turned on the heater for a bit in the garage, got it up to 50°F...and moved forward with engine swap. Assembled the new clutch/pressure plate/throw out bearing. Doubled checked everything in the engine bay...and dropped her in. 200tdi is pretty much a direct fit, granted, oil cooler lines are different. The one line on the new engine was bent during shipping...so, thought l'd just use my old ones. Wrong, fittings different. I'll be able to straighten the line tomorrow at work, torches are a beautiful thing...lol. Need to change return line to tank fitting for fuel...and then rewire glowplug system, 2.5td doesn't use timer, 200tdi does. All minor stuff, in the grand scheme of thing.

7:30 am...



10:30am...






Need to drill a couple holes for filter housing, different location and change oil/filter and mock up some temporary heater hoses...forgot to order new ones (different sytle). Primed the fuel all the way through the injection pump, so maybe sometime before Christmas...still make some noise.

 

Nicely done!