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Diesel swap OM617 into a Disco.
Posted: Mon May 03, 2010 3:00 pm
by franko
Well i don't come on here much,but I have been lurking around.
I posted my build on our local forum island4x4, but I thought I should post it so that the rover community can see what i am up to.
Maybe I'll be ready for the 2nd trip on the Canol trail, that would be fun but we shall see.
Anyway, this idea came about because the wife wanted a diesel SUV for camping and what not. But not a RHD import. So the search began for a Disco,I was lucky enough to find one in Delta for under a grand and in pretty good shape , besides the leaky sunroof.
Okay so have the truck now the search was on for the motor, was able to buy a running mercedes with the OM617 diesel. Ran great drove for a week or so before pulling the motor, got the whole car for really cheap so that was a bonus.
Okay enough chit chat on with the pics.
The truck in the shop.
http://i302.photobucket.com/albums/nn87 ... 248JPG.jpg
http://i302.photobucket.com/albums/nn87 ... 263JPG.jpg
Gas pot pulled and out.
http://i302.photobucket.com/albums/nn87 ... 270JPG.jpg
And the old beauty herself.
http://i302.photobucket.com/albums/nn87 ... 271JPG.jpg
http://i302.photobucket.com/albums/nn87 ... 272JPG.jpg
http://i302.photobucket.com/albums/nn87 ... 284JPG.jpg
Not a bad way to pull a motor .
http://i302.photobucket.com/albums/nn87 ... 276JPG.jpg
All cleaned up.
http://i302.photobucket.com/albums/nn87 ... 285JPG.jpg
http://i302.photobucket.com/albums/nn87 ... 286JPG.jpg
Disco engine bay all washed and cleaned.
http://i302.photobucket.com/albums/nn87 ... 287JPG.jpg
More pics to come later on.
Also I must give full props to Chester for taking on this project with me and doing most of the work.
http://www.carlislefabrication.com/
The truck is in his shop and he is currently working on it .
Thats all for now.
Posted: Mon May 03, 2010 4:28 pm
by PaulC
Looks like a great project all us soccer mum mobile drivers should be interested in the results.
Engine swap
Posted: Mon May 03, 2010 5:30 pm
by ANDYD
Looks like you are well on your way with the engine swap, it will be all the little things at the end that will give you the headaches!
We apprieciate you keeping a running log / photos of your progress, and look forward to seeing the "beast" come alive!
The members on this forum have done lots of diesel conversions, so if you have any questions then throw them out there!
good luck with your build,
Andy
PS. I gotta get one of those cool engine lifts that you have there! :D
Posted: Mon May 03, 2010 5:35 pm
by red90
So how have you decided to tackle the oil pan problem??
Posted: Tue May 04, 2010 8:48 am
by franko
Most likely we will have build a custom oil pan. But we have not gotten that far yet.
Posted: Tue May 04, 2010 10:51 am
by John
These guys talk about developing a dry sump kit for the OM617 - might be worth a call.
http://www.4x4labs.com/
Posted: Tue May 04, 2010 3:39 pm
by rezdiver
very nice, keep the posts up to date.
Chester is an awsome guy, gotta love his workshop.
If you guys need a hand with anything heavy or rover related give me a shout I am just up the road in Cumberland.
cheers,
Reza
Posted: Thu May 06, 2010 8:42 am
by franko
Well I had to order a bell-housing adapter from a guy on the East coast of the States Robert Davis. Some of you may have heard of him as he has been working with Series Land Rovers for a long time . And just so happens to be putting a OM617 into his Range Rover. So he was able to help me out and ship out his adapter plate , but it did cost me a few pennies.
All this to say that Chester still have to fab up a torque converter adapter. I have to say that he did a great job and it turned out wicked.
http://i302.photobucket.com/albums/nn87 ... 400JPG.jpg
http://i302.photobucket.com/albums/nn87 ... 401JPG.jpg
Below you can see the adapter plate that I had to order from Robert.
http://i302.photobucket.com/albums/nn87 ... 402JPG.jpg
And this is the adapter that Chester made.
http://i302.photobucket.com/albums/nn87 ... 431JPG.jpg
http://i302.photobucket.com/albums/nn87 ... 432JPG.jpg
http://i302.photobucket.com/albums/nn87 ... 433JPG.jpg
Lots more to go later.
Posted: Thu May 06, 2010 11:54 am
by red90
Does this mean you are running the stock Discovery gearbox? Are you planning any changes to the shift points or torque converter to better suit the diesel?
The adapters look great.
Posted: Thu May 06, 2010 12:45 pm
by franko
Yes stock gear box and what not. At this point its all trial and error, but yes we may have to play around with the shift points.
Posted: Thu May 06, 2010 4:49 pm
by red90
Might be worth talking to Ashcroft about what revalving is normal for the 300TDI as that would be closer.
Posted: Tue May 25, 2010 11:51 am
by franko
Posted: Tue May 25, 2010 8:08 pm
by seapotato
Posted: Wed May 26, 2010 8:14 am
by franko
Thats a great link, thanks for that.
Posted: Thu Aug 05, 2010 11:32 am
by franko
Posted: Thu Aug 05, 2010 9:40 pm
by franko
Posted: Tue Aug 10, 2010 3:08 pm
by franko
Posted: Tue Aug 10, 2010 6:28 pm
by PaulC
I may be getting old but I'm not currently farting......so here is my comment Bravo!...are you still going to have full suspension articulation? Transmission are you just going to try out the stock shift points see how it works?
Posted: Tue Aug 10, 2010 7:25 pm
by franko
Well we will be making bigger bump stops, and I just ordered my OME heavy duty lift so those 2 things should help with clearance issues. And yes will try out the stock trans, and see how it shifts and go from there.
Posted: Tue Aug 10, 2010 8:10 pm
by red90
If you are adding longer bumps, then I would suggest shortening the shock towers to get the lost travel back. You may need spring retainers and longer brake lines, though, if you do this.
Go frank Go!!!!.
Posted: Sat Aug 14, 2010 11:33 pm
by Dreslerdisco
dude
your truck is rad. I am so glad we have time to disco soon. you into party? maybe some logging roads? some camping.
get it done!
Posted: Mon Aug 16, 2010 1:00 pm
by franko
Weirdedst thing happened.
Posted: Mon Aug 16, 2010 7:50 pm
by Dreslerdisco
So I have to put a new gasket on my oil pan... leaks a bit. I was poking around down there and I brushed my hand against something and all of the sudden I was doused with about three or four cups of water... I was soaked by my truck. I am thinking it was some kind of air conditioning drain nipple... so I checked for another one on the other side... soaked. At least I didn't have my mouth open.
Posted: Sat Jan 01, 2011 8:20 am
by Skookumchuck
An interesting engine swap how is the truck running now that it is complete?
Discovery Diesel Isuzu 4JB1T conversion
Posted: Fri Jan 28, 2011 10:03 am
by romayama
Hello,
I've always been curious about those MB engines fit into Discos. Did you manage to get it driving? How is the power of it?
Here are some pictures of my on-going Isuzu 2.8 turbo diesel conversion:
http://design-engine.ca
My engine is running poor so I'm going to rebuild it soon.
Regards,
Roman
Posted: Fri Jan 28, 2011 2:56 pm
by franko
Well to tell the truth is STILL not finished,not much left but its a never ending project. ALthough I can see the light at the end of the tunnel.
Should at least have it running soon maybe by mid Feb. Will keep you all posted .
Posted: Sat Jan 29, 2011 6:37 am
by rezdiver
LOL,
the light at the end of the tunnel ususally dims down once you put the motor and tranny under the tunnel and close the hood to block the light.
any more pictures?
franko wrote: ALthough I can see the light at the end of the tunnel.
Posted: Sun Jan 30, 2011 8:50 am
by franko
haha right right, na not really any progress pics. But I have a few other ones I could post up I guess.
Posted: Mon Mar 07, 2011 9:20 pm
by rezdiver
Franko,
you done yet? I am. first big drive after the swap was today in the Iltis. I was going to drop by and have a look at the progress, are you going to be up to the shop anytime soon?
Posted: Sat Apr 09, 2011 2:01 pm
by franko
So did you ever make it by the shop? Its still a work in progress,but Its coming along for sure little bit at a time. Chester also is building a house so that takes up some of his time for sure.
How did yours work out,do you like the 1.9 VW swap? Oh and if you still have those wheel spacer I may still take them.
Cheers
Posted: Sat Apr 09, 2011 4:13 pm
by Doc Tari
Franko,
Looks like it's coming along great. Look forward to seeing it perform on the trail.
Reza, how about a few pictures of your conversion?
Posted: Sat Apr 09, 2011 6:23 pm
by rezdiver
Franko,
Unfortunately the spacers sold a few days ago.
I never made it to the shop yet, not enough time in a day, gonna go soon, i have not chatted with Chester for a while.
the swap is good so far, lost a bit of top speed but i still have not changed any gearing, i think i will change out 4th gear if i can find a matching old tranny from an old audi 4000 or a porsche 924.
she has way more power than before and i dont need to go fast anyways. she is happy between 90 and 95 on the highway.
working on veggie oil conversion as we speak.
will post up some pics on a new thread so i dont clog up Frankos build.
Posted: Thu Nov 24, 2011 8:19 am
by franko
TEASER VID.
So before I can even get it moving I run into this issue.
The trans will not go into gear; the t-case is in gear and I can feel the trans grab very slightly when shifted into forward or reverse but it's not fully engaging. There is ATF in it. I don't think it's a transmission shifter or linkage adjustment issue because I can slowly move it through the gears and it doesn't ever seem to fully engage. It does not engage enough to ever move the truck; only enough to barely bump it ahead or back. This could be a dirty trans filter causing the pump to not get enough oil or maybe something else. It is not likely electrical.
Anything that you guys can think of that we have not done or forgotten to do. Hoping that rezdiver has my answer and can swing over and get it moving lol.
Posted: Wed Jan 04, 2012 9:37 pm
by e.prevost94
Any progress lately?
Transmission issue
Posted: Fri Mar 30, 2012 10:59 am
by romayama
Could not figure out the PM reply, sorry.
I'm having exactly the same transmission issue with my conversion to Isuzu 4JB1T. It started howling at idle and ended up not catching the gear at all.
http://design-engine.ca/vehicles/Diesel/
http://design-engine.ca/vehicles/Diesel/Rebuild/
Also working on dual tank WVO conversion. Can share the drawings for custom under body tanks (2 x 25L).
I also bought a used tranny and currently contemplating a swap.
I, however, suspect one thing that could have caused the trouble: Drive plate to Torque convertor gap - is yours same as it use to be with gas guzzler? If incorrect, this may have destroyed torque converter.
I bought an ATF pressure gauge off ebay for $46 and going to run a pressure line test prior to doing a transmission swap. There is also a tap for Torque converter pressure check, i just have to figure out which one of two.
Posted: Sat Mar 31, 2012 4:16 pm
by HeadDamage
Sounds like a torque converter problem or some other line pressure issue.
Tranny
Posted: Sat Mar 31, 2012 10:37 pm
by romayama
Sounds like it. Thanks.
I'll conduct the series of pressure tests and will post my findings soon.
Re: Diesel swap OM617 into a Disco.
Posted: Tue Aug 14, 2012 7:48 am
by franko
Just a short teaser vid,she runs drives and shifts smooth.. More updates to come.
http://i302.photobucket.com/albums/nn87/franko_6962/th_IMG_1462.jpg
Re: Diesel swap OM617 into a Disco.
Posted: Sun Nov 04, 2012 10:09 am
by franko
Re: Diesel swap OM617 into a Disco.
Posted: Sun Nov 04, 2012 10:15 am
by franko
Oh and do any of you,have any tips on to how to deal with this mess? :evil:
http://i302.photobucket.com/albums/nn87 ... G_1596.jpg
http://i302.photobucket.com/albums/nn87 ... G_1595.jpg
Does anyone locally stock the boot floor replacing kit?
Re: Diesel swap OM617 into a Disco.
Posted: Sun Nov 04, 2012 10:16 pm
by e.prevost94
None that I know of. That rot is nothing compared to my disco. The twat that owned it before me thought it would be best to repair the rot with ROOFING TAR! Sometimes you gotta wonder. I just ended up paching it up with sheet metal.
Re: Diesel swap OM617 into a Disco.
Posted: Sun Feb 10, 2013 1:05 pm
by kentworks
franko... I see that you dumped the A/C compressor because it interfered with the steering box... lucky for you, you live in the great snowy north. But for those of us in in the sunny south, what are your thoughts on keeping the A/C intact?
Is there a spot on the opposite side of the engine from the steering box where it could be mounted... over where the LR compressor was? Like adjacent to the alternator, below where your air intake filter currently sits? Could you somehow keep the original LR compressor in its same general location, or possibly mount the Mercedes compressor over there? Is there any room to the left of the alternator, slightly above (10:00 position) or slightly below (7:00 position), or even directly to the left (9:00 position)?
Or perhaps could you move the Mercedes compressor out and up from it's original location, so that if sits just above the steering box, and to the right of the power steering pump.
Of course you'd have to custom fab brackets, but I'm wondering if there is even enough space to fit it in there?
Re: Diesel swap OM617 into a Disco.
Posted: Sat Sep 14, 2013 8:46 pm
by kentworks
Franco.... an update please. Was it worth it in the end? Does it drive well? Is the power of the OM617 matched well to the weight of the truck?
Re: Diesel swap OM617 into a Disco.
Posted: Mon Sep 16, 2013 9:26 am
by franko
Hey, yeah sure you could mount the AC on there just fine lots of room. We didn't bother with it,don't really need it up here.
And yes drives great power is not bad for what it is. Could use a rebuilt torque converter to get a better power band.
But so far its not to shabby.
I'm selling it as we speak ,just don't have time to tinker on it anymore with the new born and all.
Cheers
