disco 300tdi engine into 1990 defender - any mods

lee 90 · Feb 7, 2010

in the next three weeks i am returning to the uk where i have been given a 2.5 na 90. i am going to put my 300 tdi engine and auto box from my disco engine into it. are there any mods i need to make this happen.
any replies are much appreciated

hughesy · Feb 7, 2010

Engine mounts need changin to fit the 300tdi. The auto box will also require more messing about than most people can be bothered with. Use the LT77 that's already in the 90

lee 90 · Feb 7, 2010

i owed my mate the engine and gearbox so hes having that from the 90. do the oil cooler and radiator pipes need messing with. the gearbox problem is the tunnel inside?

Pikey · Feb 7, 2010

lee 90 said:
i owed my mate the engine and gearbox so hes having that from the 90. do the oil cooler and radiator pipes need messing with. the gearbox problem is the tunnel inside?

If it's owt like the disco gearbox the levers will be between the front seats.

lee 90 · Feb 7, 2010

yep thanks. not a problem got a welder and plenty of sheets of steel.

Pikey · Feb 7, 2010

lee 90 said:
yep thanks. not a problem got a welder and plenty of sheets of steel.

yup except a defenders made mainly of ally not steel.

lee 90 · Feb 7, 2010

i dnt do the weldind a freind of mine dus dnt know the first thing about but but i gues that will all change soon! i know u cant weld steel to ally so is it ok to pop rivet?

landowner · Feb 7, 2010

redhand said:
If it's owt like the disco gearbox the levers will be between the front seats.

Any idea eggsakly where the levers pop up, cause I'm goin to have this problem when I do mine.

Pikey · Feb 7, 2010

landowner said:
Any idea eggsakly where the levers pop up, cause I'm goin to have this problem when I do mine.

with an lt77 they appear in the middle where the cubbybox or centre seat would normally fit.

jamescronin · Feb 7, 2010

Why not just pop rivet ally?

Seems like a huge job to do, a 200tdi would be much easier - whynot flog the 300 on ebay and get a decent 200tdi engine that will drop right in?

And yes you will need a new radiator and surround, an intercooler, new hozes for the intercooler (about 60 quid of ebay - or make them yourself for less - if you have the right tubing), you will also need to mess about with the electrics and ECU for the 300 + lots more.

Not the nicest job in the world.

Also will be a strange setup to have the gear leaver where the cubby box is - may reduce the resale value a bit - maybe a lot more than getting a 200tdi engine will cost ????????

robint · Feb 7, 2010

landowner said:
Any idea eggsakly where the levers pop up, cause I'm goin to have this problem when I do mine.

you can get a conversion kit ive only ever seen 1

Pikey · Feb 7, 2010

jamescronin said:
Why not just pop rivet ally?

Seems like a huge job to do, a 200tdi would be much easier - whynot flog the 300 on ebay and get a decent 200tdi engine that will drop right in?

And yes you will need a new radiator and surround, an intercooler, new hozes for the intercooler (about 60 quid of ebay - or make them yourself for less - if you have the right tubing), you will also need to mess about with the electrics and ECU for the 300 + lots more.

Not the nicest job in the world.

Also will be a strange setup to have the gear leaver where the cubby box is - may reduce the resale value a bit - maybe a lot more than getting a 200tdi engine will cost ????????

Why the fook do ya need to change the rad & intercooler tis the same as on a 200tdi. ya just lower the mounting brackets approx 30mm and what ecu? that's only on the late 300's and is a piece of **** to sort out.

landowner · Feb 7, 2010

redhand said:
with an lt77 they appear in the middle where the cubbybox or centre seat would normally fit.

That was what I was thinkin, just about on the join where the seatbox meets the tunnel.
I was goin to try extending the gearlever and cranking it forward so that it was a sort of down movement to get 1st etc and pull up and back for 2nd etc. Used to have an old truck like that.

Pikey · Feb 7, 2010

if you;ve got the old defender lt gearbox you could try changing the output shaft and bell housing as I'm 99% convinced that they are the only things different on a disco box.

Drizz · Feb 7, 2010

He said Auto? So you can mount the cable shifter where you want???
And Diff lock doesnt have to be perfectly positioned as its not ideal as standard?

jamescronin · Feb 7, 2010

redhand said:
Why the fook do ya need to change the rad & intercooler tis the same as on a 200tdi. ya just lower the mounting brackets approx 30mm and what ecu? that's only on the late 300's and is a piece of **** to sort out.

Because he has an N/A in there not a 200tdi so either way he going to have to change the rad, and fit an intercooler!

I was more concerned with the fitting on the auto box causing a huge mess inside the cab.

lee 90 · Feb 8, 2010

thanks for the replies guys. sorry had to leave the forum out lamping last night. can i not use my disco radiator? once again thanks for the replys much appreciated.

disco 300tdi engine into 1990 defender - any mods

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