Hey guys, new to the forum.
I've had my 98 D1 for a while, and have done quite a bit of modifying.
Having always wanted an expedition rig, I've finally finished the holy grail of North American Disco's.... V8 to 300 Tdi.
I've been encouraged by a few friend to join the forum to share my v8 to diesel conversion experience.
It was quite the learning experience.
Little things like the transmission cooling lines, and fuel filler neck ( hint: air chisel ) will slow you down a bit, but anyone with mechanical knowledge, space, and some time can enjoy double MPG, and finally rid yourself of the Lucas monkey.

I don't pretend to be a mechanic, or " expert", just a guy that has done it.

so, hello and don't be a stranger.

 

Welcome. Please post pix in future or link to same. You will have plenty of interest.

 

Welcome Momo. That is definitely a conversion I'd love to hear about. If I ever got my hands on a 300 TDi, I'd do the same thing.

 

Ok, so it'll take a while to to go through the whole thing.

this is what I started with.


disco clean.jpg

A 98 Disco 1, 4.0 GEMS V8 auto.
the typical full power option NAS Disco.


MODS.

2" Ironman lift kit
full poly bushings
EBC pads and cross drilled rotors
SS extended brake lines
ABS extenders
Magnaflow exhaust
high flow air filter
diff guards
custom snorkel
10K# 2 speed winch
custom winch bumper
custom roof rack
5' high lift
CB radio
steering guard
roll out tool drawer in boot
1500 W power inverter
dual battery set up
a bunch of lights
roof tent
awning
and I'm sure a wack of other stuff that I'm forgetting.

Anyway...
This is why I decided to do the diesel swap.

disco jerry.jpg

Last year, we did a trip to northern Quebec, into James Bay, and onto the Trans-Taiga Trail.
I had to carry 5 jerry cans of extra fuel. That's an extra 100 liters.
We were paying as much as $1.81 / L , up there.
So to fill the truck $181... and another $181 to fill the cans.
I still couldn't get more than 850km with all that fuel.
I don't even want to think about that the total fuel cost for the trip was!

When I got home, I started to look for a diesel conversion.
After looking into International's, Isuzu's and Mercedes, I decided to go with the Rover 300Tdi with matching gear box.
although any of the other engines may be superior, I felt that since the engine is available in the Disco's overseas, it would fit better.

This is a basic list of what I got.
Nothing on this list will transfer from the V8!

300Tdi engine with all ancillaries. ( Alt, AC pump etc.)
Matching Tdi auto transmission.
Tdi transmission crossmember.
rubber engine mounts (2)
rubber transmission mount (1)
rubber transfer case mount and mounting plate to transfer case (1)
Rad support
intercooler and hoses
Rad and hoses
serpentine belt
AC belt
clutch fan

Some stuff had to be fabricated.
the weld on engine perches.
a connector to that goes from the tranny cooling line directly to the cylindrical cooler, vs from the rad.
and a few other minor brackets and mods.

This should give you a scope of what you need to search for in parts if you are to attempt this swap. I was fortunate, as the guy I got the engine from sent me everything I needed in one shot.


I'll get into striping the stuff out in my next post.

Please let me know if there is genuine interest in this post, as it is a lot of work writing it all up.

thanks.

 

I'm hooked. I'd love to do this to my Disco someday.