2.5 NA to 300tdi conversion

[ryancr500]

I"m looking for a little extra power out of my 87 110 exmod 2.5 NA. Does anyone have some words of wisdom regarding a 2.5 NA Diesel to 300 tdi diesel conversion? I don't have a motor yet but I'm ready for the challenge.

[swamijake]

I did it. It's not too bad. I stuck with the lt77. If I was doing it again I'd go for the r380 as getting the rear oil seal to work with the 2.5 back plate was a bit tricky.

Don't use the 2.5 fuel filter. It's a silly setup.

[red90]

A Defender 200TDI is a much easier swap. It was designed to be a bolt in swap. Easily done in a day.

A 300TDI requires quite a few modifications and there are various routes to take.

In either case, I suggest getting the gearbox and transfer case that match the engine. It avoids issues with having poor gearing ratios and poor strength to match the TDI. also make sure you get ALL of the ancillary parts that came from the donor vehicle. Missing some of those items is what ends up creating a lot of cost and time.

[ryancr500]

Great tips,thanks for the advice

[radio_05]

I assume your 110 is LHD, correct? RHD 110 may make Discovery 200tdi recycling much simpler.

[ryancr500]

I have a left hand drive 110,

[Low-Range]

Did the same job u r looking at. Really wasn’t that hard. Had to tap one hole on rear of motor, grind a little bell housing around starter. Bought kit from Ashcroft ...made it very easy. It included new engine mounts, new exhaust down pipe, and other little pieces. Spend the money and save the headaches. Also got remanufactured transmission and transfer case... they worked excellently and haven’t had any problems.