marieholm Posted December 30, 2012 Share Posted December 30, 2012 Hi guys. I just replaced my old 2.5 NA for a 200tdi defender engine and all is going well except I don't have a clue how to hook op the fuel lines and electrics. Especially the fuel lines seem to be completely different from the old 2.5 NA. Does somebody have a picture or drawing of how it all should run? greetings, Marieholm Quote Link to comment Share on other sites More sharing options...
RustyNissanPrairie Posted December 30, 2012 Share Posted December 30, 2012 everything you need here; http://pdfcast.org/pdf/defender-diesel-turbo-tdi-engine-kit-fitting-instructions-stc939d Quote Link to comment Share on other sites More sharing options...
western Posted December 30, 2012 Share Posted December 30, 2012 everything you need here;http://pdfcast.org/pdf/defender-diesel-turbo-tdi-engine-kit-fitting-instructions-stc939d all that info is Mine, it's been pulled off of here & my photobucket site. Quote Link to comment Share on other sites More sharing options...
Retroanaconda Posted December 31, 2012 Share Posted December 31, 2012 Yep, I followed the official retro-fit instructions when I did a 2.5TD - 200Tdi conversion. Wiring is the same anyway so that just hooks straight up. Glow plugs harness just plugged into a spare plug on the bulkhead, though this may not be present on a 2.5N/A. For the fuel pipes I made up the ends from a set of spare 200Tdi pipes I had around, but if you get the parts as per the instructions above you should be able to make it work. I think I only had to modify one pipe, which was the feed to the injection pump, or the return from it - can't recall which. Quote Link to comment Share on other sites More sharing options...
marieholm Posted January 4, 2013 Author Share Posted January 4, 2013 Thanks for the help. It's all hooked up now except the frontpipe from the exhaust. I can't get it in. It looks like I need to remove the crossmember underneath the gearbox. But this surely can't be the case, right? How do you get the frontpipe in? what am I missing. cheers Quote Link to comment Share on other sites More sharing options...
Diablo Posted January 4, 2013 Share Posted January 4, 2013 If it's like mine is, then I think you will have to remove the x-member Quote Link to comment Share on other sites More sharing options...
marieholm Posted January 4, 2013 Author Share Posted January 4, 2013 it's a 110 if that makes any difference? Quote Link to comment Share on other sites More sharing options...
western Posted January 4, 2013 Share Posted January 4, 2013 IIRC the downpipe goes in from below, get the rear end in place then push it up on to the turbo exhaust elbow. Quote Link to comment Share on other sites More sharing options...
marieholm Posted January 4, 2013 Author Share Posted January 4, 2013 ok, but when I'm under the car there is not enough room to get one end over the crossmember and the other end towards the turbo. Do you jack up the car or use a bridge? Quote Link to comment Share on other sites More sharing options...
western Posted January 4, 2013 Share Posted January 4, 2013 last time the downpipe came off, my 110 was on a raised hydrualic ramp it may be possible to fit the pipe from above, pass it down the side of engine so the rear end is already above the cross member, then loosely connect that to the rest of the system & the should be in the right area to be pushed up with the aid of a trolley jack/block of wood to get it fllt seated on the exhaust elbow. Quote Link to comment Share on other sites More sharing options...
RustyNissanPrairie Posted January 4, 2013 Share Posted January 4, 2013 x-member off. Jack the chassis rails apart with a farm jack or equiv Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted January 5, 2013 Share Posted January 5, 2013 For a defender down pipe it's X member off, I have never managed it otherwise. Mo Quote Link to comment Share on other sites More sharing options...
marieholm Posted January 7, 2013 Author Share Posted January 7, 2013 Thanks guys, I'm afraid I will just have to try to get the x member of. cheers, Quote Link to comment Share on other sites More sharing options...
RustyNissanPrairie Posted January 7, 2013 Share Posted January 7, 2013 easy - undo the bolts, and gentle pry the chassis rails apart with a farm jack/hi lift/bottle jack etc and the cross member falls out. Quote Link to comment Share on other sites More sharing options...
Retroanaconda Posted January 7, 2013 Share Posted January 7, 2013 Then spend the next half a day patching the inevitable rust that's revealed between the crossmember end plates and the chassis rails Quote Link to comment Share on other sites More sharing options...
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