Discovery II Diesel Conversion

jpc1818

Adventurer
I love my DI and will keep it forever, however i have a great opportunity to get a DII 2003 with 40k miles at a super low price :) . The only problem is that the truck has a bad engine.

Rather than replacing this engine with a stock gasoline one, does anybody know if replacing this engine with a diesel one would be super tricky? :snorkel:

By what i have read, it seem that a 300tdi, minor tank modifications, minor engine mount modifications and a compatible bell housing is about the extent of it.

Thanks,
 

DNTL740

Adventurer
From what I understand it is much more complicated than that, if it were that easy we would see a lot more D2 Diesel conversions on the road.

Just my 2 cents.
 

rrhyne

New member
From what I've read, the DII is much more receptive to a TD5, which is the factory diesel that shipped with these trucks in saner places.
 

LtFuzz

Explorer
There's a thread on Pirate4x4.com, I think, about a guy that put an Isuzu diesel into a DII. It was a gorgeous, spared-no-expense conversion, but if I remember correctly the amount of time/money he put into it was mind-blowing.
 

dcwhybrew

Adventurer
Look at discoweb.org too and search for RovingBeetle. Same guy (I think) that LtFuzz is referring to. Dweb has an indepth thread on it. Note the DII on dweb wasnt licensed/registered for on road use.

Regards to the 300tdi, I dont think that will work with an OBDII engine. Plus you may find problems passing emissions testing if you have that requirement.
 

jpc1818

Adventurer
Thanks guys, so it looks like its a bit more complicated.
I was hopping it would be a easy ~5k job.
If it does happen, i will start a build thread.
 

dcwhybrew

Adventurer
I dont think any diesel conversion is going to run that low, especially doing it yourself. Also, a D1 or RRC diesel conversion is technically illegal but the age of some of the swaps places the vehicles in a grey area depending on their location. A DII is definitely not going to be legal after a diesel swap.
 

lwg

Member
There is a kit available in the UK for a 2.8L conversion for the DII. One would presume that the basics of this kit would also allow a 300TDI conversion for the same vehicle.
 
It's definitely a complicated job. But can be done. Success or failure would also depend on your definition of success. If you just want it to run, and move under it's own power, and that's about all you care about, it's not too hard with a 300tdi. Having the vehicle run, and be reliable like it came that way from the factory is a whole other matter. To get a 300tdi installation to integrate with the factory computer systems would be difficult. For example, if you want to retain the ZF auto transmission, you'll probably need a Compushift from Ashcroft. Getting all the functions of the dashboard to work might be a practical impossibility. For example, the tach is driven from the ECU. The ECU will not work at all if you have a 300tdi installed. So, the tach will be innoperative. The speedometer is driven by signals from the SLABS system, and the SLABS system wants to see signals from the ECU. So if the ECU is not working properly... Coolant temp gauge also comes from the ECU.

Another proposition is to install a Td5 engine. This, I believe is more complicated to get running than a 300tdi, but easier to make it fully-functional (even to include cruise control) and offer factory reliability since the finished job should use all OEM parts, nothing cobbled.

The best way to go about this would be to acquire and entire D2 Td5 from Europe. Cheaply done if you purchase a wreck or MOT failure. I'm not sure of the logistics of shipping such a vehicle, but you could also pay to have it cut up and shipped in a crate. The list of parts is extensive, and you'd really be taking the entire front of the truck. Plus the fuel tank and fuel filter.

One complication to consider here is that most higher end trucks in Europe came equiped with the factory alarm system. A Td5 ECU with a factory alarm will want to see a BCU with an alarm. So, you need to swap over the BCU from the diesel truck as well. That also means you need the alarm sensors from the donor, such as the volumetric sensor which is located on one of the B pillars.

It may seem like a lot of work, but I think it actually ends up being easier than bodging in a 300tdi.
 

REDROVER

Explorer
why not a volvo diesel or mercedes 300td? they will bolt right in with your transmission. ( zf22)

i dont know about the power theY make. but they wil fit eazy

ERIC
 

ChristopherP

New member
A member of Texas Rovers with a 2004 D2 that suffered an oil pump failure was offered a diesel replacement under warranty by LR Dallas. Only problem was he had to pay $9K for the conversion "bits".
 

lwg

Member
A member of Texas Rovers with a 2004 D2 that suffered an oil pump failure was offered a diesel replacement under warranty by LR Dallas. Only problem was he had to pay $9K for the conversion "bits".

This is a very interesting statement. There are many, many obvious questions but the one that I can't understand is why didn't he do it? That's cheap and one would assume came with a factory warranty.
 
Yeah, that's a pretty fishy story. Frankly, I can't believe a dealership would undertake such work. I've seen dealers balk at changing rear end gears to another factory optional ratio.
 

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