few questions on fitting 300Tdi to NAS d90 - Defender Source
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  #1  
Old June 12th, 2006, 10:43 AM
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George Kase
1983 110 200Tdi CSW LHD
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few questions on fitting 300Tdi to NAS d90

We're running into a couple of puzzles as we're trying to hook the M&D engine kit up...(by the way, I'll post some pix of the engine install in a chit chat thread later today for those that might be curious)...anyway...
For those that have installed a 300Tdi:
1. there's a tapped hole in the bottom of the timing cover but nothing in it...what goes there?
2. there is a 4 foot long hose coming off of the bottom radiator hose thru a "t" type connection...what's it supposed to hook up to?
3. the duct work from the air cleaner to the turbo seems about 3" too short...any ideas as what we're doing wrong? I know it's a long shot to ask but maybe this is a common issue.
4. can I just use the "check engine" light in the instrument cluster as a glow plug warning lamp? (s8 on your diagram). I saw in searching that Dmarchand says he did it, but will the circuit board take this load?
5. The flange holes for the exhaust pipes they supplied don't match...what have others done?
any help you might offer would certainly be appreciated.
Thanks
George
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  #2  
Old June 12th, 2006, 11:35 AM
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Ian McCormack
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Can't help on some of the conversion issues as I'm in the UK but

the tapped hole on the bottom of the timing case is a drain which should be left open unless wading, next to it the should be a plug to fit into that hole.

With regards to the duct work from the air cleaner to the turbo, on a 300TDi the air cleaner is mounted to the left of the cylinder head when viewed from the front of the engine bay and the flexi duct runs arountd the back of the block to the turbo( Attached a pic showing the rear of a 300TDi with air intake routed to turbo from the air cleaner)

The long hose from the bottom of the rad runs back to the bottom of the coolant header tank

Follow-up Post:

with regard to the check engine light, it should be perfectly ok as the glowplug illumination on the dash is fed from a feed an the glowplug timer relay, so it isnn't the full glow plug circuit current
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  #3  
Old June 12th, 2006, 11:59 AM
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Patrick M.
D90 '96 300Tdi 5 speed
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You can find helpful the following pics

http://img396.imageshack.us/img396/5...ntcover4ud.jpg

http://img377.imageshack.us/img377/2...gsystem1dl.jpg

Try to get the Rave Workshop manuals (CDs), you can buy them on eBay UK, pretty cheap.

Pat
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  #4  
Old June 12th, 2006, 01:41 PM
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George Kase
1983 110 200Tdi CSW LHD
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coolant header tank?

thanks for those great bits of info...looks like that 4' hose goes nowhere on my NAS since my coolant header tank doesn't have a fitting at the bottom...should I get a 300Tdi coolant header tank?
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Old June 12th, 2006, 02:24 PM
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Patrick M.
D90 '96 300Tdi 5 speed
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if you are talking about the hose that goes from the Y piece (12 on the picture) and the Expansion Tank (13 on the picture)
and your expansion tank has not the recovery inlet, you definitely need a 300tdi Expansion Tank.

The cooling system works under 15 psi but if this pressure is exceeded at the radiator top or at the thermostat housing, that pressure excess "goes" to the Expansion Tank avoiding loosing coolant. If the temperature rise too much there are also two plastic caps/plugs at the top of the thermostat housing and radiator acting as last resource pressure fuses, keep always an eye on them.

Pat
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  #6  
Old June 12th, 2006, 03:05 PM
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George Kase
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Pat,
I'm talking about #8 on the picture...it's a rubber hose about 4' long going from bottom of radiator to bottom of expansion tank...
thanks very much for this further clarification...very useful!
George
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  #7  
Old June 12th, 2006, 03:50 PM
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Patrick M.
D90 '96 300Tdi 5 speed
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sorry, you said 4', not 4" ;-)
well it seems in your case getting the 300tdi expansion tank is the way to go.
In the past they where black, impossible to check w/o opening the cap and prone to fail at the seam.
The new ones are white solving all those old problems.

Pat
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  #8  
Old June 12th, 2006, 10:35 PM
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Jim Cheney
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You definitely need that 300tdi tank - its a lot larger than the tiny metal v8 one. I answered you exaust question in that other thread. I cant explain any shortness in your turbo plumbing. I think my rebuild thread has some pix that show that area before the bulkhead went on.
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  #9  
Old June 12th, 2006, 11:03 PM
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George Kase
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Thanks again Jim...where did you source the 300Tdi tank?
George
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  #10  
Old June 12th, 2006, 11:25 PM
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Buck
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Hi George,

I don't know how much 300Tdi specific tanks are but you can source pretty much anyone from a junkyard or a new AL unit from summit. Or if you want all rover, rds probably has them. www.roversdownsouth.com
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  #11  
Old June 13th, 2006, 07:04 AM
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dunno what Mr Marchand is talking about with the CEL being the glow plug light as he has the genuine 300Tdi idiot light cluster in his truck ( right now it's hanging on the floor whilst I get to messing with d-90 electrickery again). No reason you can't use the CEL light. There is also a blank spot on the lower left of the cluster that can be made into a glow plug light with a bulb and a little creative sharpie work.
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  #12  
Old June 13th, 2006, 03:17 PM
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George - damn near all my parts came from George at RDS.
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