300tdi into Series 3 with 2.5n/a

Hi guys,

I've got a Series 3 that currently has a 12J motor in it.

The 12J has gone bang so ive bought a 300tdi engine to put in.

Are there any modifications i'll need to make to get the 300tdi in? or will it be a straight swap as it already has a 12J in???

Thanks guys
Shabs

Heres something by someone who's already done it, the background makes the text a bit hard to read but you can see what he's done

300Di Conversion

Thanks buddy!

Anyone else got anything?

Thanks
Shabs

I've just fitted a 300tdi into my s2a swb.. It's certainly do-able but a few things to bear in mind:
Engine mounts will need cutting off the chassis and replacing with ones suitable for the 300tdi (as the drivers side std one goes exactly where the oil filter is... This isn't hard but you need to be a competant welder.. or just willing to keep trying like I did.
I went down the route of replacing the 300tdi flywheel housing with one from and N/A (with new seal).. Although you can cut the 300tdi one up a bit to make it fit (the reinforcement fins underneath fowl the cross member & prop) the n/a option is a lot easier (especially as you already have one)
Clutch wise.. I've used a HD 9.5" S2 desiel unit..
And finally getting the rad and intercooler in has proved a bit more indepth... I've ended up using a TD5 intercooler mounted infront of the the 300tdi rad as I just couldn't get the 300tdi cooler in and leave enough space for all the pipework.
Oh.. and you may want to change the diffs for RR/disco 1 10 spline units (if you have not already).
If you want I can take some pics of my project as it is currently to give you an idea...
Good luck.. Jim

Thanks Jim,

I ended up figuring it out myself...lol, the hard way

used the std clutch, cut the housing, used std mount on exhaust side, modded other side. just gotta do rad and pipework and some wiring...

i'll post again with more info...


Thanks
Shabs

Okay, for the benefit of anyone searching for this in the future...

I have a Series 3, which was fitted with a 2.5n/a defender engine (12j). I bought a defender 300tdi engine to replace it.

First i swapped the clutch plates, so i had the plate i was running originally (the spines were different- Series has less splines).

I didnt swap the flywheel housing, i just cut the lugs of the bottom.

There are 3 bolts on the housing, where the gearbox bellhouse mates which do not line up (3 at the bottom)

I used the std series engine mount on pass side,

I modified the drives side mount - quite easy tbh. the 300tdi mount is about 8 inches further back

I swan necked the exhaust manifold right at the top to miss the engine mount

i used std 300tdi rad, and mounted the intercooler above engine (i will replace it for a bigger and thinner one with fan at a later date)

I used all the 300tdi pipework, just cut bits shorter etc

The 300tdi engine i bought, didnt have the viscous fan, it just had a crappy broken leccy one, which i replaced with a bigger, stronger version from a honda.

i wired the fuel solenoid to come on with the ignition

i used the std series throttle link, and extended the rod by 70mm

i think thats about it, i cant think of anything else....

It took me 3 evenings to do it, i had a little help.

You will need a welder, lifting gear (i used a fork truck), basic hand tools and loads of degreaser is always useful! As is wd40.

Its quite straight forward and easy imo...

Thanks
Shabs