200 tdi crank pully and my front axel

iv just put a 200tdi in my s3 iv herd that i need to exstend my bump stops to stop it hiting my crank pully in extreem off roading by my messurements i need to lower them 18mm which isnt goin to leave me with much axel movement befor hitting the stops my mates put a 200tdi in his s3 but has fitted extended shackles in an atempt to lift it and his axel has been hitting his bump stops with no problem when you look down at it it dose look clear of it. any advise thanks.

you could try extended bump stops or get some parbolic springs and new longer shocks to compensate , never have liked using extended shackles as it loads the bushes and pins a lot more .

i was thinking of extending them but what im asking is do i need to its only something id herd thanks

I don't have any experience of fitting a 200tdi into a series 3, but I'm planning on doing this conversion in the next few months. I do have experience of fitting a Transit engine to a series III, and it took a bit of fiddling about to make sure the front diff and propshaft would not hit the engine when the front suspension was fully compressed. It can be very difficult to guage if there is enough clearance, so I made a very simple tool for checking the clearance. What I did was measure the distance between axle and bumpstop and then cut a metal rod to that length. You then put one end of the metal rod on the areas of the axle which are likely to come into contact with the engine and keep the rod vertical - hopefully the top of the rod will not touch the engine - or even better will have some clearance to allow for the bump stops and engine mount rubbers compressing. It's not quite that simple though because the axle moves backwards slightly as the suspension compresses and it also rotates a bit under breaking and acceleration.

Could the problem be solved by lifting the front of the engine slightly, or machining the pulley perhaps? I don't like the idea of lowering the bump stops as that will make the suspension even crapper than it already is!

i bet thats why then with the axel moving back abit aswell i dont think theres out you can do with pully but i did think of lifting the engine which i think would be better to but i havent got the time as im out on saturday and "THE BOSS" only alows me so much time at a time to work on it and i just thought puttin a bit of steel between the bumpstops and chassis would be quick and esy rather than liftin the engine.

i used this as a guid for my converstion did somethings my own way if you want any pics of out let us know
"200Di" diesel conversion for Series Land Rovers - by Glencoyne Engineering