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Tdi conversion

Discussion in '300 TDi' started by Caldiniho, Jan 27, 2019.

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  1. Caldiniho

    Caldiniho New Member

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    Hi all,

    First of all apologies if this is somewhere else but I have a slightly less common situation and I’m after all the answers in one place.

    The back story is, I have a 1989 defender 110 which a previous owner has done a fantastic job converting it to a defender 200tdi, great! A few owners later and I have it, the lt77 gearbox was tired and had a broken layshaft. I swapped this out for a stumpy r380, great!

    The issue I currently have now is the engine block is cracked and leaking water, it’s not in an ideal position either so it can’t really be repaired.

    What I want to do is get hold of a 300tdi, overhaul it and fit it as reconditioned. I believe one option is use the 200tdi flywheel and housing/engine back plate and use the existing stumpy gearbox. (I believe this means the engine sits further back) This would cause hose length problems at the front of the engine which I do not want.

    This makes me then want to convert my gearbox to the longer bellhousing and input shaft which will bolt straight on to a 300tdi so everything is in the right place. My goal is for it to fit and look like a standard 300tdi that has always been there. Obviously the engine mounts will move, the questions I would like an answer to are;

    Will the gearbox and transfer box be moved at all/will the mounts for these have to change or do they stay where they are?

    If the above changes is it just a case of new mounts and swapping the propshafts for 300tdi props, also will having a Salisbury rear axle affect this?

    Do I need to change the top plate on my gearbox to put the gearstick in the right place?

    Or can I simply disregard the above, change the bell housing and input shaft, mount the engine further forward and everything like air pipes, water pipes, oil pipes and fan cowling fit?

    I’m not work shy and have a workshop with all the tools and equipment for this, just need some advice from all of you out there with more experience and who knows their stuff

    Thanks in advance!
     
  2. Chopz

    Chopz Member

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    Hoses no problem
    You should just fit the 300tdi as you discribed using the flywheel and back plate off the 200tdi
    I've done it
     
  3. Caldiniho

    Caldiniho New Member

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    Oh great, so it just sits where a 300tdi should sit and all the defender 300tdi hoses and fan cowling fit?

    Do you have any photos?
     
  4. 300bhp/ton

    300bhp/ton Well-Known Member

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    Seems a lot of work and hassle for zero gain. You do realise that a 200 and 300 Tdi perform almost identically. If you were getting something like more power, better refinement or better mpg at the end of it, then I could see the logic.

    Tbh with all the work you are looking at doing, a TD5 conversion would arguably be much more sensible.
     
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