300TDi Installation QRD

I'm weighing a couple of options with regard to building out my LHD 1996 D90:


Considerations:
- The overhaul is likely the cheapest, though filled with pitfalls due to the unfamiliarity of the T16 here in USA
- I understand that the 300TDi does not require an ECU; I really like this if this can be confirmed
- I am not certain if the TDi will match up to the R380J 66A (long stick) gearbox; I believe it will match up - if it does the gearbox will also get an overhaul + Roamerdrive
- I suspect the swap will be faster and simplified but then I'll have a T16 and tons of parts and specialty tools without a good home; ebay?
- The overhaul would keep it original and it would involve a complete tear down (new pistons, reconditioned head, injectors, and any part that can and should be replaced)
- Swap would have potentially fewer problems and the problems that would occur would be easier to address
- 300TDi parts and support are more common
- I considered a GM350 and other engine swaps but I really don't want to diverge that much

Any and all comments and suggestions welcome. What are some pitfalls that I should avoid? I've got a competent mechanic and machine shop (admittedly the machine shop has never delt with T16).

I would like to hear about some experience others have had.

Thank you from the Pacific Northwest

Here are some pictures for your viewing pleasure.

A rare 90 with the MPi engine in.

I have a Tdi. But I wouldn’t swap one in myself. Nice engines in the day, but very loud and unrefined. And if I’m understanding you correctly you are in the USA. Petrol power with your much cheaper fuel prices has to be the way to go.

I do get the Mpi is probably more revs and lacks the low and mid range punch of a diesel. An interesting conversion would be to turbocharge it. Rover used a Turbo version of that engine in a number of different cars. 200hp and a big fat flat torque curve. Suspect it would really suit a 90.

The other obvious option would be. Rover V8. 4.0 or 4.6 should be pretty easy to find in the USA. Will be much nicer to drive than a Tdi.

Did I mention Tdi’s are unrefined?

If you wanted to go diesel. A Td5 or BMW M57 would be my choice.

Tdi needs one wire to run, no ecu on pre 96 tdis, later ones can be converted by just changing the injection pump.
200 very crude, 300 less crude but still crude! both under powered, 25/30 bhp down on the mpi.
Both will be unbelievably noisy compared to the mpi.

As above plus the oil leaks from the T series HG are very common, from memory 1 corner almost always leaks and doesnt have any effect on running other than making a bit of a mess

Mine don’t leak. It does need to be wound up to keep going though.

The only reason they didn’t fit the turbo versions was cos it would out do the 3.5 v8.

It’s yours, your Choice and we (mostly) don’t understand your regs.

But if you are gonna take it out, save the bits Europe has a market for them. But don’t go diesel

V8 conversion would be easier.

J

300bhp/ton said:

I do get the Mpi is probably more revs and lacks the low and mid range punch of a diesel. An interesting conversion would be to turbocharge it. Rover used a Turbo version of that engine in a number of different cars. 200hp and a big fat flat torque curve. Suspect it would really suit a 90.

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The turbo was considered. However, a new ecu would be required to do this plus a whole bunch of other engine modifications. The short of it is that it is cheaper to source a T16 turbo and ECU and overhaul that.

300bhp/ton said:

The other obvious option would be. Rover V8. 4.0 or 4.6 should be pretty easy to find in the USA. Will be much nicer to drive than a Tdi.

Click to expand...

This swap has similar problems as other engines (ECU, gearbox match up, ancillary components).

If it came down to an engine other than the 300TDi; then I would go with GM350.

Kev12 said:

As above plus the oil leaks from the T series HG are very common, from memory 1 corner almost always leaks and doesnt have any effect on running other than making a bit of a mess

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I have a H and the oil leak comes out on top of the head. You can see in the picture what I mean - yes the spark plug holder is broken and I've already got a new one at the ready. I've been good at soaking up the excess oil. I was thinking that a new head gasket (Klinger), camshaft gaskets(?) among other things, would fix this problem.

The overhaul is planned for this coming fall. I'll post updates and photos as the process moves along.

SpagettiDefender said:

The turbo was considered. However, a new ecu would be required to do this plus a whole bunch of other engine modifications. The short of it is that it is cheaper to source a T16 turbo and ECU and overhaul that.



This swap has similar problems as other engines (ECU, gearbox match up, ancillary components).

If it came down to an engine other than the 300TDi; then I would go with GM350.

Click to expand...

Really don’t think a Rover V8 would be all that hard to swap in. 350 would be way more work.

You could buy a Discovery 1 or 2 as a donor. Not all that many bits are needed tbh. And all should be quite attainable, even in the USA.

Tdi is ok. But I honestly think you’d be disappointed in how they run. You can tweak them, but this will make them run hotter. In the U.K. we get away with this. But I think it would be more of an issue with higher altitudes and long climbs or extreme temps.

I’m not trying to knock the Tdi’s. I’ve owned several and have a fairly juiced up 200Tdi in my 88 pickup. I just feel there are better options if you are spending the money. And I assume a 2.8 Crate engine will cost you quite a bit.

The reason I went Tdi was mostly that I had loads of choice 2nd hand and fairly local and it only cost me £300 for the complete engine.