Thread: 300TDI into 6cyl SIII 109

Originally Posted by jerryd

Hopefully about to start my 300tdi conversion quite soon, although it's to a four cylinder model. I'm using a defender 300tdi onto the original gearbox.
I've probably got heaps of unanswered questions so you might get a few messages come your way
I'd like to see your vehicle in the flesh sometime if that's possible.

How are you mating the 300tdi to the gearbox? (All I have read states a 200tdi flywheel cover is required).

Do you intend to keep the turbo? If so what intercooler are you attempting to use and what radiator? I will try the standard radiator and engine driven fan and initially lower the boost and use no intercooler then as time and $$ permit add a WTA intercooler.

Originally Posted by Shepp

Ok just to clarify. I had 6 cylinder series 3 matched it to the original gearbox using 200 TDI bell housing. Didn't move gearbox mounts but did fit new engine mounts. Slight trim of firewall to accommodate turbo.
Very neat fit and heaps of room up front I fit electric thermo fan.
Thread on GCLRO under Rambover in members rides if you want a look. Happy to post up more pics if something specific you need to see.

How do you find the gearing?
What size tyres are you running?
Did you fix the overheating with the shiny radiator?

Cheers, Adam.

Used late model 109 v8 diffs currently running original tyres and rims but will change soon. Overheating prob fixed with shiny radiator.

I can bring vehicle to next club meeting for those who want to view it.

Originally Posted by kreecha

How are you mating the 300tdi to the gearbox? (All I have read states a 200tdi flywheel cover is required).

Do you intend to keep the turbo? If so what intercooler are you attempting to use and what radiator? I will try the standard radiator and engine driven fan and initially lower the boost and use no intercooler then as time and $$ permit add a WTA intercooler.

I've altered the Series gearbox bell housing to mate up to the 300tdi flywheel, basically welded on some extra material at the bottom and had to drill some new holes to line up with the bottom flywheel holes. I've had to cut off a fixing point on the flywheel so it clears the front drive shaft.
I'm certainly keeping the turbo I'm hoping to install a P38 power steering set up (steering box on the outside of chassis rail) which will enable me to use the defender radiator and intercooler side by side, I'm going to try and keep it looking like a factory fitment if possible.

I've overhauled the gearbox and will drive with care so hopefully the gearbox won't explode

Here's a pic of the engine / gearbox trial fit.

Originally Posted by Shepp

I can bring vehicle to next club meeting for those who want to view it.

Is this a monthly meet on the Gold Coast ?? Evenings or weekends ?? I'd certainly like to see your handy work and have a chat

First Thursday of every month. Really great bunch of people and heaps of knowledge I couldn't have done this project without picking a few peoples brains.

Oops forgot to mention it is at Parkwood Tavern opposite new Hospital 7pm.