Discovery 200TDi conversions - done properly

For Land Rover 90, 110 and 130 - by Glencoyne Engineering


 

 

"Just to let you know the trip home (120 miles) went without a hitch... the engine and power delivery were superb.  Back at home the fluids were all as they were when we left Thetford and there are no leaks. BRILLIANT :)!! The power improvement is stunning. To use that often used phrase - it pulls like a train! It seems like I've got a new vehicle.  Many thanks for the work and efforts you put in. I'd have absolutely no hesitation in recommending your company." - SM, London

"I just wanted to let you know that I'm really pleased with my 90 following the TDi transplant, it has absolutely transformed the performance and generally improved the vehicle." - DB, Norfolk

 

When Land Rover launched the first series Discovery in 1989, they had an instant smash hit on their hands.  It may have looked like the result of an illicit mating between a Mitsubishi Shogun and a Mk2 Transit, but the underpinnings were pure Range Rover, and in the new 200TDi power unit Land Rover at last had a diesel which was as powerful, durable and economical as anything the Japanese had to offer.  But as owners are now finding, seam sealant and protective wax were alien substances to Solihull in the early 1990s.  The Discovery was shoddily built from poor quality materials, badly finished and lacking in any kind of corrosion protection.  For a vehicle based on the old Range Rover body structure (itself already notorious for rot) this was bound to end badly.  End result is that the scrapyards are now filling up fast with terminally rotten Discos. 

That is all bad news if you own an early Discovery with a short MoT, but great if you have a Ninety or One Ten with a poorly engine.  The Discovery TDi engine is very similar (though not identical) to the unit used in the Defender from 1990 onwards, and can be made to fit the earlier vehicles, usually at no more cost than repairing your old engine.  Fitting a TDi will transform the performance of any older 90 or 110 (or indeed 130) whether it has the four cylinder petrol engine, 2.5 diesel or even the '19J' turbo diesel.  The Disco 200TDI will give you 111 bhp and 30+mpg, against 85bhp and 23-25mpg for the old turbo diesel.  And it will run on vegetable oil.  Enough said.

I have done a fair few of these conversions now, replacing 2.25/2.5 petrol, 2.5 diesel and turbodiesel.  I do the conversion properly, including the long through bolts in the bottom of the flywheel housing.  Many people don't bother with these, which explains why so many TDi conversions leak oil from the back of the engine.  I use top quality OEM engine mounts which make a huge difference - four times the price of the cheap 'pattern' mounts that most people use, but why spoil a good conversion for the sake of a few quid? My conversion uses the Discovery air filter, mounted so that the filter element can easily be changed without having to dismantle half the vehicle to get to it.

Every conversion is different, so I have broken down the conversion price to ensure that you only pay for the items you need.  Engine is supplied on an exchange basis - if you wish to keep the old engine, add £100 to the cost.

Basic conversion - includes engine (second hand, inspected and tested), new timing belt kit, crankshaft front and rear oil seals, strengthened clutch release fork, new engine mounts, filters and fluids, radiator and intercooler, all pipework etc, road test and 3 months warranty.  £1,395

Electric fan: you will need this if you do not already have one fitted.  Includes thermostatic control unit. £150

New clutch: The TDi will take the same clutch as your old engine, so if you have recently had the clutch replaced I can swap it onto the new engine.  But if your clutch has done a significant / unknown mileage I recommend replacement. Price is for a 3-part clutch kit from a reputable manufacturer.  £90

Exhaust: If your old engine is the 2.5 turbodiesel I can reuse your old exhaust provided it is in good order.  For all other engines I will have to replace the exhaust with a 2.5TD type.    £120

Heater plug timer and wiring - required when converting from 2.25/2.5 petrol.  For diesel conversions I retain the existing key-operated heater plugs.  £40

Air filter modification - required on early 2.25 vehicles with the oil bath air filter.  This is not suitable for the TDi, so I use a Discovery air filter attached to a bracket above the injection pump.  £50

Power steering pump delete kit: required if fitting a TDi to a vehicle without power steering - mainly early 110s and military vehicles. (Note: I can fit power steering if required - please ask for a quote.)  £30

Non-standard vehicles: If your vehicle has any unusual options such as front-mounted winch, auxiliary lights, extra heating equipment etc that may make the conversion more difficult, any additional workshop time required will be charged at my standard hourly rate.

Power steering conversion: I can easily accommodate this at the same time as fitting the new engine. Price to include reconditioned steering box and drop arm, new pipework, reservoir, good second hand pump etc £450

 

Quite a few Land Rover specialists are now advertising Disco engine conversions, and some of them are a bit cheaper than my conversions.  But before you decide who to use, make sure you ask the following questions:

  • Does the price include a new timing belt, tensioner and rollers?

  • Does it include new engine mounts?

  • Does it include an oil change, new oil, air and fuel filters?

  • Is the flywheel housing drilled and tapped for the four extra studs needed to bolt the gearbox to the engine all the way round the bellhousing?

  • Is the flywheel housing counterbored to take the four long bolts at the bottom which secure it to the block stiffener?

  • Is the completed vehicle comprehensively road tested?

  • Does the conversion come with a 3 month warranty?

If the answer to any of these questions is 'No', then the conversion isn't as good as it should be.

Don't forget, a TDi-engined vehicle will always be worth more than any other Land Rover engine option - provided the conversion has been done properly.

My workshop is located in Thetford, Norfolk - see contact page for details.  If your vehicle requires other work I can usually deal with this at the same time as the engine conversion - ring me on 07776 287953 for a quote.