300tdi Conversion

As most will know mu rebuild is 1997 110 with Disco 300tdi and LT77. so Engine is about 6 to 7 inches further back. Wished Id just picked a straight forward rebuild for my first time but never mind learning all the time, with help and advice from here.
Put my rad in place today just to trial fit and got this in pic, so another problem to solve along the way.
Is there a conversion kit for this, or can I join pipes somehow ?
Have not tried the Cooler Pipes in place yet suppose they will need altering too

Have you tried Steve Parker as they do all the parts necessary to fit the Disco 300TDi into a Defender?
You can of course source pipes etc separately but far easier if someone has already produced them.

Litch said:

Have you tried Steve Parker as they do all the parts necessary to fit the Disco 300TDi into a Defender?
You can of course source pipes etc separately but far easier if someone has already produced them.

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Yes seen them but Running out of funds now so was hoping there was DIY way of doing it.

Just measure diameter and go on ebay and buy a length to fit. Check all the rest first and get them at the same time. Looks like a straight piece will fit.

Gmacz said:

Just measure diameter and go on ebay and buy a length to fit. Check all the rest first and get them at the same time. Looks like a straight piece will fit.

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Been reading up on different posts and some use a length of exhaust pipe to join . Need to measure diameter and see from there.

Mines a disco 200 into 110 but similar issues. I used some stuff wire to get the angles correct then used steel pipe cut to follow the wire then welded it all up. Short
Silicon hose to join the rad/intercooler and what not.
14 years now running the same set up.
No experience of the 300 though but the exhaust looks easy compared to the 200.

Short term solution is to use plastic waste pipe from wickes or bñq and put a join in the top hose, the bottom one will reach just fine

The EGR equipped 300tdi has a steel section with rubber hoses at each end rather than the one single pipe.
I used the pipe you have attached to the inter-cooler, then used a shortened steel section, with a short rubber section at the engine end.
I cut a section out of mine and re-welded it, the branch for the EGR went in the bin at the same time. I suppose that it may be easier to lengthen it if you have a bit of steel pipe knocking about.
It is worth noting that the engine is lower down at the front as well as being 6" further back so it is not just a case of adding 6".

You also have to lengthen the top hose and the lower inter-cooler hose, I used swaged alloy connector pipes from ebay and an additional section of hose. I did try it on the upper inter-cooler pipe but it needed a bend in it hence the chopped steel one.
The standard 300tdi lower radiator pipe will fit.
You also have to lengthen the oil cooler pipes, there are two types, one is easy to re-pipe using jubilee clips to secure them the others are not. If you have the facilities you can lengthen the steel section of the oil cooler pipes.

Found this pic of what others have done. Bit untidy but could make Neater.

Suppose it's just a case of finding bits and pieces that fit and join them together. Save a few quid on conversion kits.

IMHO it's important to use hoses that are readily available if you have an emergency for example.
All my hoses are straight or 90 Deg, the weird bends are made with the cut and welded steel pipe on my 200. Using a rubber pipe found in the corner of your shed which fitted quite well but no idea of its origin could bite you in the ass on the hard shoulder 2 years on.

The short sections of rubber hose from the top inter-cooler pipe, EGR spec 300tdi are good for straight connectors.

I wouldn't use straight exhaust tubing, if you use pipes without swaged ends you risk it blowing off the hose. (Don't google that).

Rougharse Racing said:

The short sections of rubber hose from the top inter-cooler pipe, EGR spec 300tdi are good for straight connectors.

I wouldn't use straight exhaust tubing, if you use pipes without swaged ends you risk it blowing off the hose. (Don't google that).

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Yes.
I run a bead of weld round mine or on some thick wire brazed around it.

Thanks Will be keeping my eyes open all week for something suitable to use. Think Ive got a good idea now.

Rougharse Racing said:

You also have to lengthen the top hose and the lower inter-cooler hose, I used swaged alloy connector pipes from ebay and an additional section of hose. I did try it on the upper inter-cooler pipe but it needed a bend in it hence the chopped steel one.
The standard 300tdi lower radiator pipe will fit.
You also have to lengthen the oil cooler pipes, there are two types, one is easy to re-pipe using jubilee clips to secure them the others are not. If you have the facilities you can lengthen the steel section of the oil cooler pipes.

Click to expand...

The kits for cooler pipes are to dear so will have to try and extend mine. Which ones are easier to do?

The pipe off the 2.5na fits the top coolant pipe (I cut and put the electric fan temp switch there)

The bottom standard 300tdi fits


Edit - sorry just realised you meant the oil cooler pipes I just bought those,

Rather than extending all the pipes, is it viable to move the radiator back instead? Then everything's in the original position and would all fit together as standard.

Conveniently the attached image from Steve Parker's ebay advert shows both types. From memory, on one type the crimped portion is part of the pipe (the crimp with straight sides) and is not easy to modify. The other (with wavy sides) has a separate crimped collar, which when cut off reveals a standard barbed push on fitting which can be secured with a jubilee clip once you have fitted longer rubber sections..
Please note it is 3 years since I did my conversion, so I'm not too sure that I dismantled the straight sided one.