Converting 2.5NA Diesel 110 to 200tdi?

[Douglas S.]

I've recently been researching the purchase of an Ex-MOD 110. However, I'm not sure that the naturally aspirated diesel would be adequate for my needs and there appear to be a number of these trucks that have been converted to the 200tdi units. How difficult of a swap is this to complete? I'm hoping for a "bolt-in" type of conversion (I know that nothing like this is really bolt-in).

Any input is appreciated.

 

[David Harris]

I've recently been researching the purchase of an Ex-MOD 110. However, I'm not sure that the naturally aspirated diesel would be adequate for my needs and there appear to be a number of these trucks that have been converted to the 200tdi units. How difficult of a swap is this to complete? I'm hoping for a "bolt-in" type of conversion (I know that nothing like this is really bolt-in).

Any input is appreciated.

I don't have all the details on hand at the moment, but I think it is pretty simple, if I recall. Most will probably tell you to go to 300 Tdi, though.

 

[Nonimouse]

If you work hard and have a second set of hands it's a day, if you take your time it's two days

It's about as simple as it gets

When I have five minutes I can go through the whole thing if you want

By the way the 2.5NA LT77 will most likely be the early one with the lower first gear. It's noisier and not quite as strong as the later ones but it makes a hell of a difference off tarmac

 

[Red90]

If you get a 200TDI from a Defender with all of the parts needed from the donor truck, it is completely bolt in.

When I did mine by myself in my garage, it was around 12 hours of work. With a friend, it can easily be done in a day.

I would also suggest bringing the gearbox and transfer case from the donor vehicle as the gearing is better and they are stronger.

Other options like a Disco 200TDI or 300TDI require modifications. Nothing too complex but the work is doubled.

 

[Douglas S.]

Great info. It completely blew my mind when I found out I could get a Defender for less than $10k, and here I was looking at Toyotas.

I know they aren't the most comfortable vehicles in existence, but coming from a Jeep with no roof, carpet, or doors I think just about anything would be an improvement.

I'll likely revive this thread in a few months if I find something that suits my needs.

 

[Maryland 110]

We did a 2.5 petrol to 200 Tdi in a day. The 1.6 tcase that you most likely have will need to be swapped out, so as John suggested above try to get the trans and tcase from the donor truck.

 

[Nonimouse]

Doug

What the other two poster forgot to add is that prior to 'swapping out' your old trans have a good long think about what you are going to do to the truck.

The later LT77's are a little bit stronger and a little bit quieter - but only if they haven't got twice the miles on of the original...

As I mentioned the early NAD Mil vehicles have a slightly lower first gear so do make a better box for a 110 loaded or towing, especially if you run 255/85's or bigger.

The 1.44 T box on your potential donor motor may be at the end of it's natural life - a 200Tdi lives a lot longer than any 'box or T box. The 1.66 T box is the best T box for bigger tyres if you do mostly road/easy off road miles. It's also a good sell for those wanting to get autoboxes working properly on big tyres...

Keep an open mind on all the info you get, sift through it. For example the 200Tdi Disco lump is actually a very easy fit and is the best of the 200Tdi's (which is a slightly better engine than the 300Tdi). Okay it's not as easy a fit as the Defender 200Tdi but it's still achivable in a weekend with a couple of sets of hands extra. If you pre-empt the minor issues and 'build' your motor prior to fitting it's even easier.

Whatever you do, have fun

 

[Maryland 110]

We took a disco 200 and upon learning it wouldn't work with lhd steering (3yrs ago before I had done many of these)switched the manifolds with 300 tdi parts. The truck was running 255.85.16's and had a top speed of about 50 mph in 5th gear with the 1.6. This was with an early suffix lt77 that I'm told has a slightly lower 5th gear. So we converted to a 1.2 tcase and now gearing is ideal to run 70 on the highway and no trouble in first away from a light. This in a 110 pickup.

 

[Nonimouse]

As it should be

 

[Red90]

The later LT77's are a little bit stronger and a little bit quieter - but only if they haven't got twice the miles on of the original...

As I mentioned the early NAD Mil vehicles have a slightly lower first gear so do make a better box for a 110 loaded or towing, especially if you run 255/85's or bigger.

In my experience (we have a lot of 2.5NA to 200TDI conversions here), the later LT77S (suffix H) is MUCH stronger than what is in the ex-MOD trucks (suffix B and C). First check what suffix box you have.

The 200TDI boxes also have a higher 5th gear than the early boxes making highway use much better.

1.6 boxes are too low for road use. For a 110 with a 200TDI, a 1.4 is a much better choice with the proper 200TDI gearbox. If you kept the ex-MOD box, then I would suggest 1.2, but like I say, make sure it is a "G" suffix first. And, this is with larger tires as well....

 

[JSQ]

What's your budget?
That's the real question here.

 

[Nonimouse]

In my experience (we have a lot of 2.5NA to 200TDI conversions here), the later LT77S (suffix H) is MUCH stronger than what is in the ex-MOD trucks (suffix B and C). First check what suffix box you have.

The 200TDI boxes also have a higher 5th gear than the early boxes making highway use much better.

1.6 boxes are too low for road use. For a 110 with a 200TDI, a 1.4 is a much better choice with the proper 200TDI gearbox. If you kept the ex-MOD box, then I would suggest 1.2, but like I say, make sure it is a "G" suffix first. And, this is with larger tires as well....

You know, sometimes I just want to get into a 'discussion', you know, one of those "actually I think you will find...." However I'm going through a 'Life is just too short phase' right now. So can we save it for later?

 

[Douglas S.]

What's your budget?
That's the real question here.

I'm hoping to spend less than 15K (cost of vehicle only, I'd spend extra later for an engine conversion, upgrades, etc.).

Keep in mind that I can also import up to the year 1995, so there are likely other engine choices available to me.

 

[TeriAnn]

Keep in mind that I can also import up to the year 1995, so there are likely other engine choices available to me.

The newest vehicle legal to import and license must be at least 15 years old in Canada, at least 25 years old in the US and no newer than 1974 in the Republic of California.

 

[Douglas S.]

The newest vehicle legal to import and license must be at least 15 years old in Canada, at least 25 years old in the US and no newer than 1974 in the Republic of California.

I'm in Canada, so '95 is the newest I can go.