So I started in October... I've got a bit of catching up... A "part time" project, putting a TD5 in a D1..
This is the beginning.. Having the proper crossmember helped locate the engine. The downpie and exhaust from the V8 D1 bolted right together!
Since this point I've had Roadsiderob rebuild the LT230 and put bigger bolts in teh intake manifold.

A pic from the side shows it's a pretty long engine but still sorter than the V* with all the ancilleries.
The radiator is out of a V8 D90 modified to use factory Radiator hoses.

Going to have it done by this weekend?

Makes me miss my tuned TD5 1/2 way across the world!

Good luck! :flipoff2:

Where's all the empty beer bottles?:D

Where's all the empty beer bottles?:D


I cleaned up for the photo's :flipoff2:

"Going to have it done by this weekend?"

Well tonight I have to clean all the junk off the Dirveway so the place looks semi respectable for the weekend, I'll get a little done on the car though..

Friday I'll start cooking for you sorry sods! so no work Friday (but I'm sure I'll put down a few beers!)

Makes me miss my tuned TD5 1/2 way across the world!

Good luck! :flipoff2:


In the end it should be a stellar wheeler.
TD5 (tuned to about 180HP) New 5 Speed, 4.3: MD t case gears, 4.10 Toy cable locker rear, ARB front, Longtracks (of course) 7100's. And......



















23MPG.... Why is that so exciting?

4.3: MD t case gears

Fitted already?
Post pics of the process if/when/so...!

Fitted already?
Post pics of the process if/when/so...!

Already fitted... It's easy to do... Follow the MD instructions, they're quite accurate..

In the end it should be a stellar wheeler.
TD5 (tuned to about 180HP) New 5 Speed, 4.3: MD t case gears, 4.10 Toy cable locker rear, ARB front, Longtracks (of course) 7100's. And......



















23MPG.... Why is that so exciting?

Sounds GREAT!

Tires?

Yes it will have tires too! Really cool!

It's Karen's truck so It will be mild in that respect, right now it has 32-10.50 Swamper Radials, She want's to keep it low so she'll probably wear these out and get some 33's But we'll see.. She likes to keep my fab skilz honed by battering the bottom of the truck.. Hey as long as she's wheeling!

33"s? hmmm...33" IROK radials on 18"ers? Wouldn't mind that set-up...

I'm still hoping to convert the DII to a TD5 in the next 18 months or so. Been reading about 25MPG and a 500+ mile range. Makes me drool!

I know i am only a neewbie but if you need any help on this i am a diesel mech and have owned TD5 since they been released.Word of advise your injector harness ,make sure you seal it properly with a high temp resistant non conductive silicon ,once the oil seeps in and starts heading up your engine loom,it brings a world of trouble.

I know i am only a neewbie but if you need any help on this i am a diesel mech and have owned TD5 since they been released.Word of advise your injector harness ,make sure you seal it properly with a high temp resistant non conductive silicon ,once the oil seeps in and starts heading up your engine loom,it brings a world of trouble.

Where are you located?

I know i am only a neewbie but if you need any help on this i am a diesel mech and have owned TD5 since they been released.Word of advise your injector harness ,make sure you seal it properly with a high temp resistant non conductive silicon ,once the oil seeps in and starts heading up your engine loom,it brings a world of trouble.

That happened to me on my TD5 - replaced under warrantee with a revised loom...

Good call

Where are you located?

Congo Africa a bit far i know but i can give as much as i can on the forum,i will be back in Doyelstown Pen in late nov-jan

I appreciate the warning. I have heard it many times from the mass of guys I've been talking with in the UK, they actually are the ones that talked me into trying the TD5. I have the updated harness and plan to seal it up good..

I'm still hoping to convert the DII to a TD5 in the next 18 months or so. Been reading about 25MPG and a 500+ mile range. Makes me drool!

Pony up. I'm game.

can u put one in mine first...or just get me a td5...

I'm curious...where do you find Td5's?

That sure is a purdy engine when you are up close and personal like. Nothin like drinkin beer, eatin ribs and roast, and talkin diesel!http://www.landroversonly.com/forums/images/smilies/beer.gif

The downpie and exhaust from the V8 D1 bolted right together! .

not sure I'd use the V8 exhaust....to restrictive....high EGT's .....very bad.

can u put one in mine first...or just get me a td5...

Yep

Got a low mile unit and some others on hand. For display purposes and what not.

JP

pm sent...

pm sent...

Ditto!

Mate you should stick with the V8, when the TD5's spit
the dummy they cost $$$$$$$$$$$$$ to repair, I know
its costing me over $6000 Aus. to fix mine.....
The turbo let go & took out the timing gear..
Last diesel for me, next time a V8 on LPG.
Good luck
Jeff

Mate you should stick with the V8, when the TD5's spit
the dummy they cost $$$$$$$$$$$$$ to repair, I know
its costing me over $6000 Aus. to fix mine.....
The turbo let go & took out the timing gear..
Last diesel for me, next time a V8 on LPG.
Good luck
Jeff

Generally speaking when you lose a turbo in a Diesel you will lose the engine as well. Maybe you can expand on your issues rather than just throw out that the TD5 is a bad choice...

Generally speaking when you lose a turbo in a Diesel you will lose the engine as well. Maybe you can expand on your issues rather than just throw out that the TD5 is a bad choice...
Why is this? I can see it if you don't have an intercooler and pieces get sucked in from the compressor, or if you continue driving with the same fuel and no boost to support it. But other than that, why would you lose the engine? :confused:
Mate you should stick with the V8, when the TD5's spit
the dummy they cost $$$$$$$$$$$$$ to repair, I know
its costing me over $6000 Aus. to fix mine.....
The turbo let go & took out the timing gear..
Last diesel for me, next time a V8 on LPG.
Good luck
Jeff
How did the turbo take out the timing gear?

Generally speaking when you lose a turbo in a Diesel you will lose the engine as well. Maybe you can expand on your issues rather than just throw out that the TD5 is a bad choice...

If you run an EGT gauge (a must on any modified diesel IMO) then it'll tell you the instant that your turbo is having issues.

I lost the turbo oil feed line about a year ago on an uphill section of motorway (top gear, full throttle), had to shut the engine down from full steam when the oil light came on (made a hell of a mess too)

Fixed the oil line, drove around for a week and the turbo seemed fine.

Then almost exactly a week later on almost exactly the same spot of highway, that turbo gave me the finger.
The first warning I got was the EGT shot to 800 deg, I lfted my foot, then I heard the rumble, then I saw the boost gauge drop, then the truck starting blowing blue smoke (turbo oil fed into the exhaust).

No engine damage, the early warning meant that the turbo could be salvaged with a rebuild kit instead of picked out of the engine and exhaust in tiny pieces.

what year is your disco 1. I am thinking about undertaking a diesel swap. What ecu's or other computers are required for the swap, and did you have to switch your master cylinder
thanks
jason
98 disco 1

This swap is being done on a 97. It doesn't matter what year as you will have two seperate systems. the engine system and the body system. Just get the ECU and the AS10 from the donor car along with the engine if you go TD5. a 300 TDI is a much easier swap could do it in a week if I had no interuptions. If the car was a 95 i would have seriously considered a 300Tdi

What are the spec's for the TD-5? (hp and torque)

jC

This is Defender version so I think it's 122HP and something like 245ftlbs of torque. available at som silly Low rpm. It won't stay that way for long. I be boosting things up a bit once it's running.

This is what they told me when I sent it in after the turbo let go.
Because the engine over revved,[ I couldnt shut it down as it was running
on the engine oil being sucked in by the turbo] or pumped in by the oil pump] the plastic guides at the top of the timing gear broke & caused
the alloy casting at the bottom of the timing chain to break also. It was
these bits that did the damage. How much damage is still being checked.
The head was coming off today to check bores & rocker gear.
So I'm hoping that side of it is ok. I find out tomorrow.
I was pissed off as the car has only done 146k's & I've only had it
a bit over a year. But while it was going it did go well for a diesel, I
had the chip upgrade done, made it drive heaps better. I'm just blown
away buy the price of diesel parts, makes driving a V8 economical.
Good luck Jeff

Ok, that makes some sense. I was imagining a piece of turbo shooting away from the shattered remains and thinking that even if by some act of God it made it through the timing belt cover, which I don't think it has a straight shot at anyway, how the hell would it take out a gear? Well, hopefully you only need to replace some valves. I know the pistons for mine are well over $100 a piece, IF I can even find them.

More stuff done. Inter coller mounts and AC coil and the worlds coolest shop light!

Since i'm using a bunch or pretty silicon hose and running hoses and pipes in places where there never were any before I'll end up using some couplers. In the ricer stores these couplers are like $35!!! Being a consumate cheap bastard i decided to make a tool to crimp the ends of the tubing so the hoses won't blow off. Jim it's ready for you to use whenever you are ready!
Oh and here's a pic of the PS res bracket.

Keith, When I repowered my Motorhome I used my bead roller on exhaust tubing to roll the bumps for the intercooler tubing. Like yours it was one of a kind, so there was no off the shelf parts for it. I used a Ford 9000 Truck Radiator and Intercooler on it and it never gets hot.

Been watching your build as I'm a big LR fan. Even though I build Isuzus. I'm about to repower two different vehicles to diesel. Both Turboed.

This will be my third conversion of five planned.

Almost had the wife convinced to get herself an LR2. But she decided to help me pay off the Motorhome first. Darn it. I was sure looking forward to driving that LR2. But having that Motorhome free and clear will give me for fule money for off road trips with my Rodeo.

Anyway, I wanted to post up so I could get on the mailing list to follow you build.

Curtis

Very cool Keith. I'm having a hard time figuring out the crimping tool from the pic though. Looks pretty jagged and stuff versus the results shown. Maybe I'm just too stunned or something. Can you explain it a bit?

This is Defender version so I think it's 122HP and something like 245ftlbs of torque. available at som silly Low rpm. It won't stay that way for long. I be boosting things up a bit once it's running.

Yowza!:eek:

Been watching your build as I'm a big LR fan. Even though I build Isuzus. I'm about to repower two different vehicles to diesel. Both Turboed.

Which Isuzu's?

Very cool Keith. I'm having a hard time figuring out the crimping tool from the pic though. Looks pretty jagged and stuff versus the results shown. Maybe I'm just too stunned or something. Can you explain it a bit?


It's butch stuff man!

I machined a "hollow" (cavity) in piece of steel which ended up being welded to a set of old vise grips i never used. On the opposite side i dilled a .25" hole in the "lower jaw" of the VG into which I pressed a .25" pin (grade 8 bolt cut off) with a radius ground on the end that mates with the cavity. The lower jaw has a piece fo key stock welded on as a stop to keep things even and it's a matter of "crimp rotate, crimp rotate" around the tube. Takes about a minute to do a 2" tube while enjoying a beer. if the pin hadn't stuck so well when i drove it in i would have added a radiused end (kinda like a hammerhead shark) to the pin. I'll still do that and perfect the device adding material with the Tig Welder and filling it down.. Toolmakers! we're crazy!

Stupid question. It looks like those crimps could be done in seconds on my HF bead roller. Why didn't you just use a bead roller?

Or, do you just prefer to make your own tools and reinvent the wheel?

PT

Since i'm using a bunch or pretty silicon hose and running hoses and pipes in places where there never were any before I'll end up using some couplers. In the ricer stores these couplers are like $35!!! Being a consumate cheap bastard i decided to make a tool to crimp the ends of the tubing so the hoses won't blow off. Jim it's ready for you to use whenever you are ready!
Oh and here's a pic of the PS res bracket.
If you mean me Jim, I had already made mine and done my pipe before I came up for the BBQ. If you mean another Jim, well then never mind. :flipoff2:
Find the other caliper yet? Mine may be on the road today. It won't be finished, but should be drivable.

Stupid question. It looks like those crimps could be done in seconds on my HF bead roller. Why didn't you just use a bead roller?

Or, do you just prefer to make your own tools and reinvent the wheel?

PT

I don't have a bead roller it was Saturday and I felt like reinventing a wheel..

I reality I'm a Series guy, that could explain a lot..

In a case where I might need a Bead roller every 10 years and the cost of $70 an old pair of Vise grips with a strange set of jaws served nicely with a bunch junk around the shop to make the "gizmo:

"Series Guy" ... :laughing:

unrelated ... walked by the tee vee this morning and thought I saw you, nope - Bob Seeger :laughing:

Oh yeah, that's "Texas tee" believe per Messr's Flatt & Scruggs.

Which Isuzu's?

I have an 89 Isuzu Trooper that is going to get a 2.2L C223 TD engine and a "new" flanged MUA5 loaded with Tera Low 3:07's "T" case gears, and a 89 I Mark 5 Speed Sedan that will get the TD 1.5L. I have already aquired all the vehicles, engines and trannys for these conversions. Just needing time to get them done. In addition, I also have a 2.3L Gas Turbo 240 horse engine I built for my wifes 89 Trooper. That Truck will be running a 4L30 E 4 speed tranny with 4 wheel drive and a lock up torque converter. We're prepping that one for paint now.

My 5th planned diesel conversion will be a Turbo Diesel Street Cruiser Motorcycle which I'm gathering parts for as I type.

Anyway, Back on topic.

Keith, the vice grip bead roller trick was a nice touch. Very inventive!

I love problem solving.

Great build BTY. Keep the pictures coming. Too bad your not in Noth Central Texas. I'd love to swing by and assist.

Curtis

why not just run a bead of weld around the tube? Granted it's a cool tool but with a lathe on low and a mig gun you could make a pretty nice bead. That's what I did on my chevy cummins conversion running around 40 psi and it holds. Just another random way to do what you've all ready done. cool stuff

-ben

No Helium, no special liner for the Mig torch, no aluminum wire, I suck at welding aluminum (even with the tig).

I did however make a couple of reducing Tee's out of stainless in that fashion.

I have an 89 Isuzu Trooper that is going to get a 2.2L C223 TD engine and a "new" flanged MUA5 loaded with Tera Low 3:07's "T" case gears, and a 89 I Mark 5 Speed Sedan that will get the TD 1.5L. I have already aquired all the vehicles, engines and trannys for these conversions. Just needing time to get them done. In addition, I also have a 2.3L Gas Turbo 240 horse engine I built for my wifes 89 Trooper. That Truck will be running a 4L30 E 4 speed tranny with 4 wheel drive and a lock up torque converter. We're prepping that one for paint now.

My 5th planned diesel conversion will be a Turbo Diesel Street Cruiser Motorcycle which I'm gathering parts for as I type.

Anyway, Back on topic.

Keith, the vice grip bead roller trick was a nice touch. Very inventive!

I love problem solving.

Great build BTY. Keep the pictures coming. Too bad your not in Noth Central Texas. I'd love to swing by and assist.

Curtis

Can you smuggle a 4JB1T into the country?
They're common as dirt over here, but I know many old trooper owners would kill for one in the US.

Keith, the vice grip bead roller trick was a nice touch. Very inventive!

I love problem solving.

Curtis
Oh, don't let him take the credit, he stole the idea from me.:flipoff2: And I stole it from a VW Diesel forum. :flipoff2::flipoff2:

Hey now... Just acted apon your words maybe... I think stolen is a bit harsh:)

Great idea on the "bead grips" - what is the wall thickness on that tube?

If you are wondering how thick of tubing it works on, I used it on exhaust pipe for mine. So it should work on most any aluminum you would use.

I'll be using it on a bit of .065 304SS here in a bit, I'll report back, If it doesn't work I'll be doing a little welding..

I don't have a bead roller it was Saturday and I felt like reinventing a wheel..

I reality I'm a Series guy, that could explain a lot..

In a case where I might need a Bead roller every 10 years and the cost of $70 an old pair of Vise grips with a strange set of jaws served nicely with a bunch junk around the shop to make the "gizmo:

Hhmm, I'm kind of a Series Guy. The pile(s) of parts and trucks would attest.

But, I'm also a fabricator of more than just stories for Pendy to fawk with me over. My $99 HF bead roller has turned out to be one of the best investments I've made and just like a lathe, you'll be surprised every time you find a need for it. Well worth the $99 I spent on it, even though I think Shopboy may have scrapped most of the dies whilst I was in PDX.

I'm saving for a set of Dimple dies and a roll forming machine..

Then I can really be dangerous!

After many trails and tribulations, parts coming from the UK via Rowboat, one bad ECU and less support than I would have expected it runs!

Thanks to Pendy and Rob Dassler helping me troubleshoot some wiring (with the help of their magic boxes) this truck is sorted and on the road!

All told when I finally 'finished' the wiring I had missed 2 wires that needed to be connected, one due to my outdated Rave wiring diagram (new one is now present) and one beause it was probably cold and I was pissed off!

Driving impressions? This is a fun little engine! It makes the 300tdi seem a bit pokey, and the V8 just bites when you compare torque. The torque is very impressive and you need to be careful not to chirp the tires into 3rd gear!

Time will tell and I still have a few details to clean up but I'm thinking this whole endeavour will be worth the wait!

Congrats. Now I have to remember not to drag race your wife anymore when she's driving that.

The wiring in its experimental stage resembled a plot of arson. I'm sure it was sorted after its engine made fire though.

The concoction of gases and flammable lubricant for flame on was interesting as well. Glad its burning fuel again.

Is the 5.0 running yet?:flipoff2:

How long till Karen gets her first exhibition of speed ticket :laughing:

Damn, finally Keith! Will Karen be driving it to Moab in a couple of weeks?

It's taken you so long, I'll bet most of us forgot you were even doing this swap. Talk about being thorough!:D
I know I did!:D:laughing:
Nice to hear that it's running. I got my I Mark diesel running last spring. Boy, was that a change in performance. It went from 130 hp to 80hp.
But the fuel mileage jumped from 26 mpg to 43 mpg. It now sports a double overdrive transmission too.
Since the build was for a reliable WVO commuter it was all good.

Now, we need to see a vid of the thing actually running like this one of my I Mark.
http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/th_MOV00428.jpg (http://s31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/?action=view&current=MOV00428.flv)

Congrats, I still have my TD Trooper conversion to do. But it is still on hold, been slowly working on the wife’s Turbo Gas Trooper. It is painted Yellow now and the wiring harness is spread all over the place. Glass is back in and the electric windows are working. Summer is my busy season and I've been working my arse off. Looks like after tomorrow it will slow down and I can get some more quality shop time.


Great job on the conversion. Sure feels good to get it finally going doesn't it? Did you have a hard time getting it registered as a diesel? Mine was easy.
I didn't title it in Texas until I had it running on diesel. Then just registered it as a diesel. The inspection was a breeze. No fuss no muss.

Curtis

SSSRodeo

Great news Keith!! Bet Karen is quite happy now. Now you need a celebratory party as it has taken so long.:smokin:

Hee Hee... Speeding tickets? Nahhhh That's why I haven't bought a tuner for it yet!

Karen will be driving it to the rally, I've got a week to finish up the details. so far the wiring has been properly crimped soulder heat shrunk, taped and covered with loom cover, of course promptly after I did that I found that the Brake switch and the clutch switch are very important to the drivability of these engines! so they where added.

This one took longer than I expected, on that note I suppose having little support on this side of the Atlantic from enthusiasts or tech types made it a challenge. Being forced to learn and re-learn is a pita but we worked it out.
I am glad it's (for the most part) done, still I'm sure that little problems will pop up as I work through the final details.

Super News on the I Mark.. Remeber 80 Diesel HP blows the doors off 130 Petrol HP.. While this motor is only supposed to has 122 HP compared to the 180 (?!?!?!?!) of the 4L motor, it outperforms it by leaps and bounds. The other day I took it to work motoring down the Highway I thought 'geeze I'm just poking along, 75MPH on an (what I thought was) uncalibrated speedo. So I took it up to 90 just to feel like I was moving, the car took it in stride and had plenty more. Come to find out the the speedo was only 5MPH fast as compared to the GPS... OOps!

Best calibrate it to be 5 mph fast and tell the boss it is spot on!

Hee Hee... Speeding tickets? Nahhhh That's why I haven't bought a tuner for it yet!

Karen will be driving it to the rally, I've got a week to finish up the details. so far the wiring has been properly crimped soulder heat shrunk, taped and covered with loom cover, of course promptly after I did that I found that the Brake switch and the clutch switch are very important to the drivability of these engines! so they where added.

This one took longer than I expected, on that note I suppose having little support on this side of the Atlantic from enthusiasts or tech types made it a challenge. Being forced to learn and re-learn is a pita but we worked it out.
I am glad it's (for the most part) done, still I'm sure that little problems will pop up as I work through the final details.

Super News on the I Mark.. Remeber 80 Diesel HP blows the doors off 130 Petrol HP.. While this motor is only supposed to has 122 HP compared to the 180 (?!?!?!?!) of the 4L motor, it outperforms it by leaps and bounds. The other day I took it to work motoring down the Highway I thought 'geeze I'm just poking along, 75MPH on an (what I thought was) uncalibrated speedo. So I took it up to 90 just to feel like I was moving, the car took it in stride and had plenty more. Come to find out the the speedo was only 5MPH fast as compared to the GPS... OOps!

I would be interested in what MPG you get and how fast it can go up to Eisenhower Tunnel.

My 300 tdi seems to be able to go about 65 mpg up to Eisenhower tunnel without running the EGT over 900. If I push it harder the EGT goes too high.

thanks
Ed

First bits of fuel measured to about 18 MPG, but keep in mind there was a lot of drag racing and sitting in the driveway running. I finished up a load of details over the weekend that improved drivability a ton and filled her up! I set the trip meter on the GPS so we'll see how it does! I plan to install two egts this week, one in the 110 and one in the Disco. Unloaded the 110 pulls Eisenhower at about 55

So my Series will whoop the 110, but the school bus will now burn the Series. Well at least when my rebuilt turbo arrives...:(