Disco 300tdi swap into a 90TD

Keep going mate, it's looking good.

Great thread, really enjoyed reading it end to end! Fingers crossed the rest goes smoothly.

Cheers for the encouragement, I couldn't find any write-ups for a 300tdi upgrade that covered things that could go wrong , lucky me I thought I'd had have it done days ago but still plodding on....

With a bit of tweaking the disco power steering pipes will mate up but I'll have to alter the pipes that go to the reservoir but that's easily done by using the 19j pipes which is a proper result, the reservoir ends up on the right hand side (from the front) so it needs to be placed out of the way of the top intercooler pipe





The new fan belt was i cheeky one to get on but managed to lever it on with a screwdriver



Then came the rad, the saying goes 'measure twice cut once' for me it seems the wrong way around, cut the rad mounts where 'I thought' was the right height welded them up put the rad in place took it out again , re-cut the mounts re-welded the mounts the put the rad in again and finally it went in.



Then came the rain...... So not a happy camper as the tratter is to heavy to push under cover so I got soaked and my phone went flat

Chopped up the 19j oiler cooler pipes to lengthen the tdi pipes and they fit well, the bottom rad hose fits fine but I had to lengthen the top hose with a piece from the 19j.

Connecting the exhaust my body was underneath and so out of the rain but my legs were open to the elements and the bolts took an age to get tight.

I've got a 12" flexalite electric fan with a through the core rad mounting kit which I'll be controlling via a switch on the dash so that's still to be wired up.

Put coolant in taking out the plugs so hopefully no air locks, soaking wet, cold and ragged off I called it a night...

Got home tonight after work and decided to have a mess for half a hour, after having the battery on charge I connected it up, filled the fuel filter with fresh clean fuel, gave it 10 seconds of glow plugs cos it's really cold outside and it fired straight up, bit lumpy for a few seconds but then it settled down. IT'S ALIVE.......

Still got to bleed the brakes and clutch, change the wires to fit the alternator, put the brackets on the top of the rad, sort the intercooler pipes, sort an air filter and put the tranny tunnel and floors back in the sort the fan..

It seems to have been a long time coming and I'll get some more pics up of what I've done but I'm on a 6 day shift pattern so another week is going to pass before it's finished but I don't care now, it's all chips and gravy:5bparty:

Brilliant

getting there!! keep going

Slowly but surely. Getting it started is a big step in the right direction

Trying to do a little job every night, sorted the intercooler pipes last night and plan on sorting the alternator wiring tonight. Still impressed with how much easier 300tdi engines start compared to 19j ones, they seem a lot quieter to

The fan belt is easy to change, you just need a socket and T bar on the bolt of tension wheel [the one with the holes] and leaver back against spring to release belt.cheers John.

Right, six days at work are over so its time to get on with the tratter, I have been doing the odd job in the evening when I've got home from work. No mean feat when you've been up since half three every morning but just want it done

One night I put the wiring and relay in for the electric fan, another I put the floors back in, then another I sorted the intercooler pipes. Little jobs but good to get them out of the way.

So today, always fun working outside



With the wing off I needed to sort this, not exactly engine swap but it had to be done...



Fortunately henry fits right in the front jacking point



The disco chassis comes to the rescue and it's double thickness to



I had plenty of practice template making when repairing the rear chassis so it's no longer daunting chopping the rails to bits



Finally getting my eye in when it comes to welding



Paint and dinitrol and it's job done and time for dinner then my £25 bumper back on



Finally back to the swap, I had to move the brake equalisation jobber because it fould the RH engine mount so template and angle grinder to the rescue



Wing back on, front grill in place so I could do my last bit of welding which was the little jobbers on top of the rad surround so I could use the brackets off the tratter



And then my phone went flat

One last pic at the end of the day and it finally looks like a tratter again



Still haven't bled the brakes or clutch and the fuel pump has started to drip, all jobs for tomorrow as well as sorting the air box. On the plus side I had it running for about 40 mins just to get some warmth in it, no leaks or over heating problems and a nice warm cab

Short term solution to a long term problem..



Don't know how successful it will be but at least I've driven it out on the road and it's plenty faster than a 19j

nice 1 matey!!!

The power upgrade is amazing i can still remember mine from last year!! A big grin on my face right foot down, plenty of smoke!

No smoke, it runs really well apart from it decided to blow the bottom intercooler pipe off on the A38 at five o'clock this morning cos I hadn't lengthened it enough. D'oh:doh:

Haha mint. If that's all that's wrong then **** hot mate

Went to Craddocks on the way home and bought a longer intercooler pipe, fitted it in the car park and what a difference...I got 75+ out of it on the A38 on the way home and some of the hills that the 19j used to decelerate on going up I can now accelerate up. No smoke plenty of poke.....

Pig doggin' power steering box has started leaking now and I only had it in September