This conversion is to fit the Land Rover Discovery 200TDI engine into a Series Land Rover, Short Wheel Base or Long Wheel Base
Our conversion kits are designed to be used with standard Land Rover chassis with leaf springs and the series gearbox. Using the Discovery engine, radiator and intercooler. All our conversion kits come with instructions on how to fit them
While the engine is out of the vehicle the following is recommended
Remove the Discovery engine brackets from the block and discard. Fit the standard series 2¼ (petrol or Diesel) engine brackets in place using the front holes on the engine and the standard series 4 cylinder standard chassis brackets, long wheel base and short wheel base. We recommend renewing the engine mounting rubbers with Series Diesel items (NRC2052), we can supply these if required. All our kits are designed for the engine to be in this position including our exhausts
Remove the Discovery clutch plate and replace with the correct ones in our instructions. We would recommend renewing the spigot bush at the same time. We can supply these if required.
Remove PAS pump, viscous fan and remove threaded section from water pump pulley to clear radiator once engine is installed
It is highly recommended that the bottom four holes on the flywheel housing have fixings to the block stiffener (ladder frame) on the engine to prevent crankshaft oil seal from leaking as the engine and gearbox can cause the flywheel housing to flex when not correctly supported, we can supply these SPCK224BLT which come with instructions for fitting these.
A special exhaust system will need to be fitted as the original system is far too small to allow the engine and turbo to breathe correctly, our system is specially made to fit the original mountings and is suitable for the engine, mounting rubbers come with the system, the system is made from top quality aluminised mild steel, (the best before you go to the expense of fitting stainless steel) and is 2¼” diameter with a 2” tail pipe SWB models. LWB models have a combination of specially made exhaust pipes and standard items and are used to keep the cost down. We recommend mounting the special exhaust down pipe first section on the engine before fitting for ease of access. This requires the cutting down of the three fixing studs for future removal/refitting, leaving the nuts slightly loose to allow for adjustment later.
The Turbo alloy outlet housing requires rotating to a new position to clear the inner wing
We recommend using the Discovery alternator but will require relocating (if PAS pump is not being used) use the Series 3 alternator bracket and adjuster to relocate. Please note there are both imperial and metric threads used on these brackets, and will require a spacer kit to align the pulley’s. We can supply a kit SPCK238ASKS3 which includes the alternator belt and the wiring diagram for guidance.
Next check all the flywheel mounting studs are in the correct location for the bell housing. Remember the threads are M10. Two studs may not line up and are already pilot drilled 4mm, drill these out to 8.5mm and tap out with a plug tap to M10, clean out any swarf then fit the studs in place.
Fit engine.
Long Wheel Base models will require the engine raising up 6-10mm for the turbo to clear the chassis. Alternatively a 300Tdi turbo manifold can be used along with our exhaust system EXHS3LWBD200300
For Left Hand Drive Models the steering box will require packing off by an inch. We would recommend using the 300TDI manifold and exhaust system as above.
Modifications will be needed to convert the accelerator from a rod linkage to cable on most models, the Discovery cable can be used.
The Discovery radiator & frame will need to be used. The frame will need shortening to house the radiator only, we mount the intercooler as a separate unit, we alter the bottom outlet neck and relocate it on the end tank, this is a specialist welding job, we can supply a modified intercooler for you on an exchange basis, we mount the intercooler horizontal this will allow maximum air flow and also allow the conversion into Series 2 and 2A up to 1967 with lamps in the front panel. The LH side of the front panel will need altering extensively to allow the intercooler pipe work to pass through, you can use the Discovery top radiator mountings for this (the power steering reservoir mounting bracket will need removing), Brackets will need to be made up to mount the intercooler. We can supply the intercooler pipe work etc, the radiator hose kit contains specially made radiator hoses and stainless steel hose clips as well as fitting instructions SPCK238WS3 & SPCK238CS3 . Heater hoses will need to be made up.
A temperature sensor and adaptor is available for this conversion to correct the temperature gauge (SPCK224TADAPS3).
The air filter will need mounting and pipe work making up, S2 models could mount the air filter on the top of the passenger footwell and the ‘banjo’ pipe fitting on the end.
Also ensure if the vehicle goes faster it needs to brake better so make sure the brakes are all in good condition.
We would strongly recommend uprating the headlights and the vehicles braking system. Zeus Engineering manufacture front disc conversions Land Rover Series Brake Kits
We have also fitted a remote servo kit lockheed part number LE72696 for models without a servo for better braking. This then retains the existing brake master cylinder and pedal
We would also recommend that the gearbox is in good condition and if a reconditioned one is fitted that a quality one is fitted and change the gearbox oil regularly.
We would recommend checking the half shafts and drive plates for wear and renew as required.
Once the conversion is fitted, you must inform your insurance company to tell them of the conversion. Some insurance companies will not have modified vehicles on their books, you may have to change companies, other specialist companies will have no problem with this conversion, most companies will ask for a engineers report, most local garages should be able to do this for you, always remember the conversion is only as good as the person carrying out the job, if it looks right and neat you are halfway there. It is also a good idea to update your logbook and send to DVLA with your new engine number and fuel type if changing form petrol to diesel
See the photos below courtesy of Don, one of our customers who converted a Series 1 88″ with the Discovery 200 Tdi. This brought some extra challenges as it is a Series 1
