98 D1 V8 auto to 300TDI 5 speed conversion

I have a '95 5spd truck that a friend of mine and I did a 300TDI conversion in. We got the donor motor from a Disco with the 5spd as well. As far as wiring goes, the 300 just needs a starter and a hot with ignition on to open the shut down solenoid and glow plug timer. The wiring in my truck was pretty hacked up to begin with so I rewired for the alternator and starter using late model Ford as my model. I added an electric low pressure pump using the factory fuse for the old fuel pump as the power source, added electric rad fan using the ABS fuse as power and adding a thermostatic controller and manual on switch both through a relay. I have AC and used the factory condenser fans and switch in the coolant neck. I abandoned the following, cruise control (wiring burned up previous to 300), ABS, ECM, factory sound system. I added VDO temp gauge, oil pressure, volt meter, EGT, and manifold pressure gauge. The PO added D2 power seats that I am junking. My dream is to pull a D1 down to the shell and rewire it so that it makes sense and delete about 40% of what they came with. About the only parts of the V8 wiring you can use are, starter, alternator and AC. Most of that should just about hook up to the 300 components.

Hi, as my D1 is a LHD 300TDI, it can be a source of some information, so feel free to ask for pictures or details
Regards

"My dream is to pull a D1 down to the shell and rewire it so that it makes sense and delete about 40% of what they came with."
That's my dream with a p38 including the unobtanium manual transmission.

ankeneering said:

That's my dream with a p38 including the unobtanium manual transmission.

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Not unobtanium.

http://www.paddockspares.com/range-rover-p38-reconditioned-gearbox.html

I did my 1999 Disco 1 SD conversion from V8 to 300tdi with 5 speed manual transmission back in 2010 and I don't remember all the electrical details particularly well. I do remember however that I used the existing V8 wiring and I just figured things out one at a time with a Fluke meter. Everything worked and still does, including a/c and cruise control and it was all fairly simple and uncomplicated. I use a two speed electric fan from a Volvo diesel car and control it with a temp switch from UK in the lower hose, switching on the fan full time in low speed for the a/c, with the stock a/c controls. I do not use the OBD.
I use an oil pressure gauge with 1/8" diameter plastic hose and on Shell Rotella T6, I see 52 psi on startup idle and about 15 psi idle when hot.

I live in the NC mountains and we get down below zero F at times so I ended up replacing the starter power cable with a larger copper section (close to 1/2" diameter) so the voltage drop was not as big in the quite long cable length round the back of the engine from the battery in the V8 front location, to the starter. The original cable would not turn the engine over fast enough in sub zero temps. Bosch starter is original.

I also designed my own adapter plate so I could mount the stock V8 a/c compressor sort of like its mounted on the 300tdi on the top of the timing case but I set it inline with the stock serpentine belt for water pump, alternator etc and I use a longer length Multi-vee belt. The stock 300tdi set up uses a second belt to drive the compressor from the crankshaft pulley but I had trouble getting those parts so I made my own set up. I just had two a/c hoses made as the V8 compressor is now in a different location. It works just fine and has for seven years now with stock wiring.

My original 60 amp italian Marelli alternator that came with the engine died so I use a 100 amp alternator from an early Saturn as it fits well in the same location and parts are easy to get and I fitted the pulley from the Marelli.
Cruise control uses the original vacuum actuator from the V8, adapted for the VE injector pump and works very nicely.

If you are interested in any of my mods, send me a PM. I get mileage in the mid 20's up here in the Blue Ridge. When i occasionally go down to lower parts, I can run in the high 70's on the interstate very comfortably.

Feel free to shoot me an email with any questions, I did this 2 years ago, with the r380 swap. Zack@Roversnorth.com

Here's one for you, Zack: how many hours did it take you to complete this job and what was the total cost of parts/shipping/special labor? If you don't mind sharing, of course.

Oh man! That's hard to say for sure. I did it over the course of maybe 8 months? Just when I was free really. There's almost no way I would have done it without a friend of mine Brandon moving to the area and being a huge help. A lot of the time I was waiting on random little parts to get in that were holding me up. I was replacing almost every part I could, 90% genuine parts, it got pricey. I probably spent around $10k including the engine/trans, which I got for pretty cheap. If I had every part I needed, and knew what I do now, I could probably do it in 2 weeks comfortably, possibly less. I'm not a quick, or skilled mechanic.

I really never use cruise control, I didn't bother trying to make it work in the diesel. There is an open spot on the injection pump to add another accelerator cable, which could be utilized for cruise control, or hand throttle.

The cruise control has its own module and a small dedicated vacuum pump, not ECU controlled. I sent my module off to a specialist company and cleaned the trash out of the vacuum pump. It works well on an arm extension on the VE injector pump just like it did on the V8.

Reviving an old thread because I'm about to take the plunge! (Though I previously converted from V8 auto to V8 R380, so I at least have three pedals already). My first question is: what have people done for motor mounts? I'm guessing some 300TDI-specific brackets need to be welded to the frame, which would then interface with stock 300TDI motor mounts. Any guidance or shared previous experience would be helpful so I am not cutting and welding with the new motor staged in place. Thanks!

Thanks for the information. Was this the eBay kit by chance? https://www.ebay.com/itm/225472350259. Some say Defender only, and some like this one say Defender, Disco, and RR.

It is hard to see in the photo, but it's a Disco 300tdi R380.

terryjm1 said:

You should be able to do well selling your V8 R380 if you include the Gems flywheel.

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Once I pull the V8 GEMS drivetrain, I intend to sell the 4.0 complete with the R380. It has 200k, is still a good runner, but the top end has a characteristic RV8 tick when it's warm. But hopefully I'll recover some of the cost of the conversion.

Thanks for the information about the motor mounts. Good to know that's similar to what you used. More questions likely to come, but first I'll get the motor in there.