My 300 tdi - Checking it over and Fitting in 90

Might need some help with this job so here we go.

I have taken the 200tdi and box boxes out of the 90 so she is ready to accept the 300tdi and disco boxes I bought last year for the 110. She is stood outside in the cold at the moment bonnet, rad, intercooler and egineless.

I got the 300 inside on a trolley and split it at the bell-housing so as I could inspect the clutch. Clutch almost new and it has had a rear crank oil seal fitted recently which is a bonus.

Bought a new cambelt which is now fitted, also got a new heavy duty clutch fork just in case.

So, the engine and boxes are now back together with new clutchfork, new cambelt on and the oil ( mud ) drained from the engine.
The oil was the consistancy cold custard and the sump plug was very stiff to get out so I took the sump off to have a look.
What a mess, thick black goo lined the sump so I cleaned the lot out in the parts washer and checked the sump plug which after a bit of attention will be servicable.
Just need to clean the strainer in the oil pickup pipe.

That's where I am at the moment, one potential problem I have noticed is black oil lining the turbo pipes and the inlet manifold so maybe it might be wise to swap the turbo or fit new seals.

yu fitting disco boxes to a 90?

The Mad Hat Man said:

yu fitting disco boxes to a 90?

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Yes, it had disco boxes behind the 200tdi and yes the gear lever was behind the transfer box lever instead of in front and it came up exactly on the leading edge of the seatbox so the tunnel had to be altered.
But.... it was a dream to drive, the gearlever had an extension piece welded to it and it was not too far back and easy to change.

Thing is, because of the longer bellhousing, all the pipes and oil cooler pipes etc fitted without modification and the washer bottle could be mounted in the warm behind the engine on the bulkhead..

I will have to tidy up the conversion though when it goes back in.

Had an hour today and put the sump back on
Thought I would check round the water pump and found rusty water marks at the back of the water pump carrier so decided to take it off.
Guess what....snapped a bolt off and one not moving at all so left it soaking in plus gas. The pump squeaked when turned as well so I presume that it has dried out after standing for eighteen months in the shed.

So looks like I'll be needing a new water pump and 'P' gasket along with a turbo and manifold gaskets.
This is getting to be expensive:doh:

.

Well I was right, the turbo spindle has a little play in it there are and black sticky deposits in the intercooler pipes so will have to swap it for a new one. Turbo ok but might as well get it done now and then it'll do me the rest of my lifetime. Bought a turbo on a manifold from Craddocks which was ex military and turned out to be new so result.

Got the two snapped off bolts drilled out today and removed the ally casing so as I can renew the 'P' gasket and fabricated a new engine mount. Pictures later when its on and painted.
Need to find some new long bolts or maybe threaded rod so as I can bolt the water pump casing back on.

Done it...

New 'P' gasket and water pump fitted.

New Turbo fitted and EGR blanked off.

Off side front engine mount sorted.

Just got tappets to set and sort the wiring out.

You do know that you can mate up a 300tdi to the defender LT77 gear box??

sible88 said:

You do know that you can mate up a 300tdi to the defender LT77 gear box??

Click to expand...

Is it done by swapping the flywheel housings over?

My 300 was coupled to an R380 and Disco transfer box so it's going in as is with new clutch fork etc. Hoping to get it between the chassis on Thursday.

Not done much today but noticed that the transfer box has an electronic speedo drive so will have to see if I can swap it for the 200tdi one.

Also...Not happy with the wiring loom on the 300 as there are bloody wires everywhere. Think I'll take it off and use the 200 loom and fit it when the engine is in the chassis.

Oh and I cant find me down pipe, must be under some junk somewhere

And... I am wondering if the Disco handbrake cable will fit on to the Defender handbrake lever....hope so