To the OP, not sure about the difficulties of a -A to -D swap but my experience with the -D has been great, but it is my only O-200
flight experience. Although, I would think
if your -A case is salvagable, it would probably be more cost effective to stick w/ overhauling the -A and adding new lightweight accessories.
contactflying wrote:Yes lots of paperwork and expense if available. All that to go with a lighter built engine that is unproven. New engines have glitches that are worked out over time, if the airframe types they are attached to stay around long enough. If Cessna's LSA stays around in large enough numbers, the engine will be tweaked and proven. With the new recreational rules won't they just stay with 152 and 172. The D engine could become an expensive to maintain orphan.
I would hardly say the -D is unproven, it's essentially the same as an -A that comes stock with lighter accessories. I
believe there are slight changes on the case and cylinder fins, but the big savings come from a new style oil sump, slick mags, and lightweight starter/alternator. The -D is just tweaked and improved from the old O-200s that have been around for so long... And the 162 isn't really (or ever was) around in large numbers, especially w/ Cessna scrapping a bunch of the unsold airframes. The 162s are a good source for these engines (we got ours from a 162) but these engines are also being used on other aircraft.