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 Engine Swap Questions 
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 Post subject: Engine Swap Questions
PostPosted: Wed Feb 15, 2017 4:39 am 
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Hi guys,

I have a 1999 2.0 TD, mechanical injection. I've been stripping it down as I planned to break it, but the love is just too strong and I spent a lot of time and money rebuilding it into a one-off custom car.

Long story short, the gearbox went, as did the power steering pump. Since I've stripped off the gear box, and most of the engine components, I'm very tempted to do an engine swap. The reason being, there's only so much power you can get out of the mechanical injected engine, and the electronic injected engine from the 45 is more tune-able, such as remapping and chip tuning.

Firstly, I know the major differences. Engine loom and ECU will obviously need replacing, but how much do I need to change in order for it to work?

I already have an inter-cooler setup with inlet manifold but I'll probably go FMIC anyway. What about exhaust manifold, alternator, fuel lines, cooling pipes, driveshafts? Is the fuel pump different? I was planning on upgrading the fuel pump anyway but are the stock ones different due to the different power outputs of both engines?

Is it really as simple as Engine, Loom and ECU or is there a lot more to swapping the non-inter-cooled L-series engine with the inter-cooled model?

Thanks

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 Post subject: Re: Engine Swap Questions
PostPosted: Tue Feb 21, 2017 12:07 am 
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I'd probably keep the non intercooled pump engine and fit and intercooler and tweak it upgradiing the gearbox and clutch at the same time. They have been over 150bhp before so comparable to the later and less reliable VP30 pump engines.

There are a fair few differences between the non intercooled engine and the later 25 engine.

The big one is the ECU which is completely different to the non intercooled one.
The crank sensor is completely different too
The flywheel is different
The clutch on the SD is smaller than the later one - fit the bigger clutch if you are thinking of tuning it
The turbo is bigger/better on the later VP30 pumped engines
The head is marginally better machined (but this is trivial)
The gearbox is an uprated spec on the intercooled diesels, but not on the non intercooled ones
Fuel pump is totally different as is the adapter plate it is mounted on

Swapping it is possible but a fair amount of work. It would be easier to mod the engine you have.

The non intercooled engines are tunable, but is is a different (and less refined) way of doing it.
I'd be tempted to fit a big turbo, crank up the fuel and have some fun with the original setup.

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 Post subject: Re: Engine Swap Questions
PostPosted: Tue Feb 21, 2017 1:18 am 
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rover 25's and 45 diesels are being scrapped all the time for no real reason, just by a running spares or repairs can and do the full swap, i am not sure but if your mechanical fuel injection engine has the number 1 injector with the point if injection sensor on it keep them to fit to the later diesel as it will give it a bit off a boost just with that,

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 Post subject: Re: Engine Swap Questions
PostPosted: Tue Mar 07, 2017 10:33 pm 
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Just bought an intercooled 420 Diesel. I'm going to continue to scrap the other car. Spoke to Rover Ron and his Synergy 4 will give me a good 20-25+ on bhp and 20% increase in torque.

I don't think there's much more I can do with the non-intercooled model in terms of power. Are the clutches the same size on both intercooled and non-intercooled models?


Last edited by Jonez on Wed Mar 08, 2017 7:15 am, edited 1 time in total.

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 Post subject: Re: Engine Swap Questions
PostPosted: Tue Mar 07, 2017 10:54 pm 
RT GOD


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Jonez wrote:
Just bought an intercooled 420 Diesel. I'm going to continue to rebuild the other one for the wife. Spoke to Rover Ron and his Synergy 4 will give me a good 20-25+ on bhp and 20% increase in torque.

I don't think there's much more I can do with the non-intercooled model in terms of power. Are the clutches the same size on both intercooled and non-intercooled models?


Non intercooled got the smaller clutch as I said above (215mm vs intercooled which is 228mm).

Non intercooled can give good power (over 150 has been done). The intercooled models with the VP37 are trickier to tune as you can't remap them, but rechipping is possible. Mine does just over 131bhp with no turbo/engine mods.

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 Post subject: Re: Engine Swap Questions
PostPosted: Wed Mar 08, 2017 7:17 am 
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The 215mm clutch will fit though right? Just that I bought a performance clutch upgrade for the non-intercooled model.


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 Post subject: Re: Engine Swap Questions
PostPosted: Wed Mar 08, 2017 11:34 pm 
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Jonez wrote:
The 215mm clutch will fit though right? Just that I bought a performance clutch upgrade for the non-intercooled model.


Not without re-drilling the flywheel to fit as the bolt spacing is different (smaller).

215mm clutch is really going to struggle if you are going to tune it.

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 Post subject: Re: Engine Swap Questions
PostPosted: Thu Mar 09, 2017 12:11 am 
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I guess in that case I have a DriveTorque Stage 1 215mm clutch for sale then.


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 Post subject: Re: Engine Swap Questions
PostPosted: Thu Mar 09, 2017 12:13 am 
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Jonez wrote:
I guess in that case I have a DriveTorque Stage 1 215mm clutch for sale then.


What torque is it rated at? The Standard Di OE clutch is usually good for 250ftlb. (The 215mm OE one tops out at about 200ftlb usually).

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 Post subject: Re: Engine Swap Questions
PostPosted: Thu Mar 09, 2017 12:49 pm 
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http://www.larkspeed.com/index.pl?a=i&p=DT118FR9775


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