Engine swap advice for Disco 300tdi into 1995 Defender 300tdi please.

KEVLAR1 said:

Dear All,
I have the chance of getting a 300tdi Disco engine to go in as a replacement on the Defender 1995 Mreg.
This must have been asked a hundred times before, but I cannot quite see a definitive answer anywhere after a ten minute search, so here goes!

What changes are needed to a Disco 300tdi engine to make it fit a Defender please?
Main concern of mine is engine mountings...are these identical etc?
Thanks
Lazy Kev

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KEVLAR1 said:

Thank you Discomania & Grem for answering, seems too good to be true almost!
I will just be doing a straight engine change from the flywheel housing forward & keeping all my existing standard Defender ancillaries in the rebuild.
Cheers Kev

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mojo247 said:

if it's got one, I suggest keeping the 100amp alternator, especially if you have a rev counter, as the pulley diameter is different for the 65amp and you get a higher rev reading. or at least swap the pulleys!

I know from experience and much time fiddling with the rev counter to reconfigure

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discomania said:

Go for it. Will be straightforward enough - remember to change the temp sender too.

As touched on above, with regards the alternator pulley size, if they are different sizes between the Disco and Defender fit the smallest pulley you can to the highest output alternator of the 2, if you don't have a rev counter, if you have a counter use the same pulley as was originally in the Defender but still use the bigger alt if. I have a Disco 300tdi in my Defender and have a 100A alt but I swapped it to the smaller pulley to increase revs at idle and thus increase charging at idle. They did this later on in the engine / alt production - there was a slightly shorter belt too which I have written down somewhere, but the longer belt does still work, it just means the tensioner needs to travel a bit further and the belt may squeak a bit when older.

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