HS2800 Transplant

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Service Manual - (.pdf in self extracting .exe)

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Out with the old

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HS2800 development

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Front view Right hand Left hand Front right Top
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TGV turbo Fuel pump Turbo & vacuum pump oil returns Ford sump and oil pickup Comparison between oil pickups.
The 300Tdi is the lower one
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300Tdi sump fitted Fitting new clutch Uprated intercooler
Standard tanks, fatter core		 Comparison between the old and new Almost ready to install
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IT'S IN! A little help from my Land Rover mechanic Top view Turbo inlet plumbing 2 1/2" exhaust
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2 1/2" system with glasspack muffler to rear A/C lines just clear pump
Note high tech spacers.		 Tidying up wiring with corrugated tube.
Glow plugs reconnected 		 Vacuum hose installed. Fuel pump linkages reconnected Installed turbo air outlet - guard view
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Installed turbo air outlet - top view Engine bay - 
left view		 Engine bay - front view Right side view Radiator and lower turbo plumbing


Modifications

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Marking out to fit 300Tdi  engine mounts Tapping M12 holes for mounts Fitted 300Tdi oil pickup Remote oil filter head Oil filter on acme bracket #1 installed in old fuel filter location
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Terminated PCV oil return Removed alt and turbo to drill and mount 300Tdi dipstick Dipstick installed Fabricated turbo and vacuum pump oil return.
 Modified oil return installed

 
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Air filter  plate Air filter  mounting Fitted air cleaner mount.
Oil pressure sender replaced with a switch		 CAV fuel filter assembly 
# 110-301R
with filter		 New fuel filter location
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Fuel filter lines connected.
 Oil filter hoses connected Oil cooler coolant return line "T" piece Replaced coolant temp. sensor with 300Tdi unit Turbo air outlet 1-3/4" to 2" expander adaptor

Things still to be done after engine install

  1. Replace viscous coupling
  2. Fabricate new exhaust system
  3. Fabricate oil filter bracket and install in old fuel filter location
  4. Re-fit air conditioner compressor
  5. Fabricate remote oil filter plumbing
  6. Re-install electrics
  7. Relocate fuel filter
  8. Re-connect vacuum system
  9. Reconnect power steering supply  plumbing
  10. Replenish power steering fluid
  11. Install fuel lines to filter
  12. Modify 5/8" tee to fit 3/4" coolant return from oil cooler
  13. Install modified coolant hose layouts
  14. Fit reconditioned radiator and new intercooler
  15. Fabricate turbo air outlet 1-3/4" to 2" expander adaptor
  16. Modify inner guard to allow clearance of turbo air outlet plumbing.
  17. Install turbo air plumbing
  18. Install radiator plumbing
  19. Replenish coolant
  20. Prime fuel filter
  21. Bypass existing electric fuel pump
  22. Test crank engine to prime oil filter and pump (oil light to go out)
  23. Modify top mounting spigots on uprated intercooler to fit top locating plate
  24. Replace OEM coolant temp sensor (500ohm) with 300Tdi unit (2,000ohm)
  25. Fit belts and mechanical fan.
  26. TEST DRIVE!!

Postscript ...... A few changes have occurred since the original build

  1. Replaced the red general purpose vacuum pump line with a higher rated black one
  2. Replaced the angled turbo outlet pipe with a silicone elbow and straight 1/3/4" to 2" adaptor
  3. Substituted a Discovery transfer case to give better road cruising with it's 1.22:1 high range
  4. Had to have the crankshaft/flywheel re-engineered to allow the fitment of a standard 300Tdi spigot bush.

Modifications still needed as a result of issues since the original build

  1. Heavier duty clutch
  2. A higher capacity radiator needed to cope with towing in hilly terrain during the Oz summer.
  3. A higher capacity intercooler
  4. Better engine coolant and temperature monitoring
  5. Bite the bullet and import the angled oil cooler mount to replace the current remote mounted unit.

Items 2 and 3 may be solved by fitting an almost "bolt in" Td5 Defender radiator/intercooler assembly.