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Thread: Project Roverkill D2a

  1. #1
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    Project Roverkill D2a

    Hi Folks,

    My name is Blair and i am relatively new to this forum but have been lurking for a few years. I am currently studying in Perth W.A, and i plan to document a new project that i will be working on, a newly acquired 2004 D2a discovery classic. Shes a manual v8 and 131,000k on her. I searched my local gumtree website and car sales website for 6 months looking for my new dream rig, but unfortunately the exact combination that i wanted did not turn up.

    After realizing that maybe i was being too picky as nothing was presenting itself, i purchased this D2a in question. This car was everything i wanted; low kays, D2a, v8, priced well, good condition, black interior etc. The only issue being it is a manual, i much prefer an auto, and not LPG.

    I have owned a 93 disco v8, and a 95 2 door disco v8 and loved the cars. only reason to sell them was of moving cities, life changes etc. So this new project has been well anticipated, i have always wanted a D2, and being a d2a is just the icing on the cake.

    The plan for now:
    1. Give the car a really good service, bearings, ball joints, brakes, engine service components, and everything to get the car up to factory spec again.

    2. LPG conversion. Research shows that the OMVL XXI dream kit is the way to go, i have found a good place online to get the kit. The conversion will be put on this thread.

    3. auto conversion. Yes i know, ridiculous.. but research is leading me towards a comp-shift controller from Ashcroft in the UK, coupled with a 4hp22eh from another d2. full control on shift points and pressures will be a real win.

    After all this work gets done, the goodies can start going on! I already have an ARB locker to go in, more lift, tyres, roof rack, lights, exhaust.. you know how it goes.

  2. #2
    Homestar's Avatar
    Homestar is offline Super Moderator & CA manager Gold Subscriber
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    Will follow this with interest - looks like you scored a nice example to as a base to start with.
    If you need to contact me please email homestarrunnerau@gmail.com - thanks - Gav.

  3. #3
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    Hey guys so it has been all go with the disco project, i got a 4 week break from uni so i have had some real time to do some work. So i replaced the headliner:


    I also fitted some cool canvas seat covers, maybe not to everyones taste but i love them!



    I restored the gators on the hand brake, shifter and difflock lever:



    I rebuilt both front an rear shafts with new u-Joints and centering bearing on the front and a new rotoflex coupling and new u-joints at the rear





    I also replaced the shuttle valve and bypassed the plug wiring to the modulator. This mod was actually really easy, i hope this solves those pesky Mexicans coming back.






    I fitted a light holster as well, in the holster sits a super bright LED battery torch. Easy access

    The sequential LPG kit rocked up a few weeks back as well, it is OMVL, and as far as i can see, built quite well. I also started to drill the nozzle holes on a spare intake plenum that i had in the shed. Tomorrow i will start the LPG conversion properly and get into it, there is a fair bit to do!



    And to top this post off, i started to manufacture a switch cluster with two seperate volt gauges for the starting battery and a deep cycle.

  4. #4
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    Another busy day in the shed. Today i turned my attention to the removal of the intake manifold and stripping the engine bay. Once the manifold was removed i then proceeded to finalize how the LPG injectors injector tubes were to be routed. This is not as straight forward as i was assuming. I have done many hours research into the best way to fit the injectors and how to run the hoses. What i believe to be the best solution is shown in the photos below. Research and my own intuition lead me to These desirable criteria that i needed to achieve:

    1. the gas nozzles that enter the intake runner need to be in close proximity to the petrol injector outlets. It is my understanding that the petrol ecm is programmed to spray fuel right before the intake valve opens, therefore if the LPG injectors were to deliver a charge of lpg further up stream of the petrol injectors, the correct fueling charge inside the runners would be delayed per cycle, not a desirable operating outcome. Playing to this theory, the gas nozzles were located right before the petrol injector.

    2. the lpg injector tubing length must be kept as short as possible. This is an interesting one.. i believe that the length of the tube that runs from each individual lpg injector to the intake plenum is desirably kept to a minimum, so this is what i have done. The only downside i have researched is that changeover time from petrol to lpg will be delayed (if the tubes are too long), not a huge disadvantage. The most important thing however is that they are all of equal length for the 8 cylinders. As the length increases, the magnitude of flow restriction increases. what this means is that if the tubes are all of varying length, each cylinder will be given different volumes of lpg with each combustion cycle.

    3. metal-rubber abrasion must be dealt with accordingly. There is a potential that fretting corrosion can occur between the rubber injector hosing and the cast alloy intake plenum/intake parts. An effort should be made to de-burr all surfaces and use insulating materials.

    After all this was considered it then took some thinking and tinkering to get the desired outcome. I struggled to find a suitable injector hose, it needed to be 6mm O.D, but also heat resistant and flexible enough to duck and weave through all the metal parts, i used a vacuum hose that i picked up from coventrys auto supplies.







    Because of the location of the passenger side injector rail, I relocated the IAV intake hosetail. the IAV will be replumbed down the track to accept this new position.

    Last edited by DieSchnelleKafer; 6th July 2016 at 10:53 PM.

  5. #5
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    This is how I did my first Thor injection install. Without a body lift your bonnet clearance is limited.



    Proper 6mm LPG injection hose isn't hard to find, even ebay has it. About double what I pay for it but small change in the grand scheme of things..

    Brand NEW LPG GAS Vapour Injection Hose 6mm X 1 Meter | eBay

    As for change over time, I had no problems with 300mm hoses. Some software allows you to to add a small amount of overlap. Sequential changeover means it swaps over one injector at a time anyway, makes it very smooth.

  6. #6
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    I believe you can get some sort of spacer plate to go under the manifold.

    That's what I've got I think


  7. #7
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    Hey folks so here is another update. I had 4 weeks off uni so it has been a productive time.
    1. managed to get the UHF working (installed the missing aerial)
    2. fit 2 VDO gauges, Water temp and oil pressure. (see photo of pressure sensor)
    3. get the LPG full installed and signed off. This turned out to be a real task to get someone to fit the high pressure gas line and sign it all off, I dont blame anybody for turning the work down, but i received a very rude response from a shop that frankly, left me feeling a bit bruised. never the less i met a bloke more than happy to help me out and teach me many things along the way.
    4. replaced the LH engine mount
    5. fit an ARB air locker in the rear.

































    Here is a photo of the spaghetti under the dash. I managed to fit the AEB lpg computer directly on top of the bosch m5.2.1 unit. i then proceeded to splice and solder all the necessary wires together, lots of coffee and lots of double checking!




    And here is the difflock install:









  8. #8
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    So how does it run on LPG?

    the answer is great. As soon as my lpg man switched it to lpg the first time it ran great. i was shocked. we did an automatic calibration and then took it for a drive, no dead spots, no rough running etc. Now that was a week ago, and tests have come back with 20l/100km. Bare in mind that this is only with a rough auto calibration.


    Before we embark on a full tune (driving while adjusting) i need to carry out the following:
    1. new leads
    2. new iridium plugs
    3. fix the exhaust leaks that are forward of the O2 sensor.

    I actually want to install 2 fuel/air gauges one for each bank). I intend on tapping into the m5.2.1 wiring to take advantage of the sensors that are already in place. Has anybody had experience with items such as below:
    Black 2inch 52mm CAR Motor Digital 20LED AIR Fuel Ratio Gauge AU Stock | eBay

  9. #9
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    Looks good.

    What sort of grief did they give you about the LPG? I don't understand why someone would turn down the work - or was it a 'Land Rover' thing?
    If you need to contact me please email homestarrunnerau@gmail.com - thanks - Gav.

  10. #10
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    Quote Originally Posted by Homestar View Post
    Looks good.

    What sort of grief did they give you about the LPG? I don't understand why someone would turn down the work - or was it a 'Land Rover' thing?


    When i had completed as much work as i felt i could do safely, i started to look for someone who could finnish the job off. I went down to our local LPG vehicle shop (the last one in town i might add, all of them had closed down in recent years). From what i can gather, the bloke was offended that i had not just come straight to him to do the whole job. Once i realised he wasnt interested in the work i asked if i could at least buy some of the low pressure gas line that connected the converter to the injector rails, he was even less happier about this and began to pay out on me for that fact that i needed to have a fitters licence to buy the tubing. He then proceded to tell me how i looked like i had little experience with anything mechanical/electrical and how i should bugger off.

    Damn.

    Luck would have it that i got given the phone number of a gentleman who was prepared to help me out by a freind. We organised a day to do all the remaining work and then got down to it. He was also an absolute rover nutter and we got along well. It was an absolute win.

    As someone who does every little bit of work on their cars, i believe anything can be accomplished with research and coffee, this mind set doesnt change in regards to an LPG conversion.
    Last edited by DieSchnelleKafer; 3rd August 2016 at 03:02 PM.

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