While the engine is out of the vehicle the following is recommended
Remove the Discovery clutch plate and replace with Series 3, 9½” FRC2297 clutch plate. Vehicles fitted with Series 2-2a gearboxes should use part number 571228 9½” 2A iaphragm clutch pressure plate, Series 3 models use the Discovery clutch pressure plate. We would recommend renewing the spigot bush at the same time. We can supply these if required.
Remove PAS pump, viscous fan and remove treaded section from water pump pulley to clear radiator once engine is installed
It is highly recommended that the bottom four holes on the flywheel housing have fixings to the block stiffener (ladder frame) on the engine to prevent crankshaft oil seal from leaking as the engine and gearbox can cause the flywheel housing to flex when not correctly supported, we can supply these SPCK224BLT which come with instructions for fitting these.
A special exhaust system will need to be fitted as the original system is far too small to allow the engine and turbo to breathe correctly, our system is specially made to fit the original mountings and is suitable for the engine, mounting rubbers come with the system, the system is made from top quality aluminised mild steel, (the best before you go to the expense of fitting stainless steel) and is 2¼” diameter with a 2” tail pipe SWB models. LWB models have a combination of specially made exhaust pipes and standard items and are used to keep the cost down. We recommend mounting the special exhaust down pipe first section on the engine before fitting for ease of access. This requires the cutting down of the three fixing studs for future removal/refitting, leaving the nuts slightly loose to allow for adjustment later.
Remove the Discovery engine brackets from the block and discard. Fit the standard 2¼ (petrol or Diesel) engine brackets in place using the front holes. We recommend renewing the engine mounting rubbers with Series Diesel items (NRC2052), we can supply these if required.
The Turbo alloy outlet housing requires rotating to a new position to clear the inner wing by means of removing the boost control actuator 6mm screws and the large circlip on the otherside of the turbo housing. The turbo housing will need rotating so the outlet points to approximately 1 o’clock, when viewed from the front of the vehicle, the boost control unit will then fit on the other side of the outlet. Mount the actuator in a new position. You will need to drill and tap two holes M6 (use a plug tap) take care not to drill through into the housing. (see drawing) The small rubber hose will need to be replaced with a slightly longer one.
We recommend using the Discovery alternator but will require relocating (if PAS pump is not being used) use the Series 3 alternator bracket and adjuster to relocate. Please note there are both imperial and metric threads used on these brackets, and will require a spacer kit to align the pulley’s, Standard 200tdi Defender alternator belt ETC7939 should be used. We can supply a kit SPCK238ASKS3 which includes the alternator belt and the wiring diagram for guidance.
Next check all the flywheel mounting studs are in the correct location for the bell housing. Remember the threads are M10. Two studs may not line up and are already pilot drilled 4mm, drill these out to 8.5mm and tap out with a plug tap to M10, clean out any swarf then fit the studs in place.
Modifications will be needed to convert the accelerator from a rod linkage to cable on most models, the Discovery cable can be used.
The Discovery radiator will need to be used, the frame will need shortening to house the radiator only, we mount the intercooler as a separate unit, we alter the bottom outlet neck and relocate it on the end tank, this is a specialist welding job, we can supply a modified intercooler for you on an exchange basis, we mount the intercooler horizontal this will allow maximum air flow and also allow the conversion into Series 2 and 2A up to 1967 with lamps in the front panel. The LH side of the front panel will need altering extensively to allow the intercooler pipe work to pass through, we mount the bottom of the radiator on the front chassis cross member, you can use the Discovery top radiator mountings for this (the power steering reservoir mounting bracket will need removing), and fix these to the cross member with nutserts, the top of the radiator frame will need straightening out and this will secure to the front panel. Brackets will need to be made up to mount the intercooler. We can supply the intercooler pipe work etc, the radiator hose kit contains specially made radiator hoses and stainless steel hose clips. Heater hoses will need to be made up. A temperature sensor and adaptor is available for this conversion to correct the temperature gauge.
The air filter will need mounting and pipe work making up, S2 models could mount the air filter on the top of the passenger foot well and the ‘banjo’ pipe fitting on the end.
Once the conversion is fitted, you must inform your insurance company to tell them of the conversion. Some insurance companies will not have modified vehicles on their books, you may have to change companies, other specialist companies will have no problem with this conversion, most companies will ask for a engineers report, most local garages should be able to do this for you, always remember the conversion is only as good as the person carrying out the job, if it looks right and neat you are half way there. Also ensure if the vehicle goes faster it needs to brake better so make sure the brakes are all in good condition. We would also recommend that the gearbox is in good condition and if a reconditioned one is fitted that a quality one is fitted and change the gearbox oil regularly. Also check the half shafts and drive plates for wear and renew as required.