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GuyanaRover

Defender 300 TDI conversion Parts necessary?

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I hope i'm not violating some rule, if so, please take into consideration i'm new at this site...

I'm looking to convert my 94 Defender which has seen many miles and much abuse into a 300 TDI (wouldn't turn my nose up at a 200, but they seem to be harder to find in good shape) Diesel Defender. Mostly for the offroad torque and of course the mileage wouldn't hurt either, as Fuel (both Petrol and Diesel) are about US $5 / gallon here. I hear its even worse in the UK, you have my sympathy.

ANyway, i've looked over this site and a few others, but mostly this site. I am currently a displaced American living in South America. Guyana (formerly British Guiana, remember that little territory?) Its difficult to get things into and out of here, so i have to do this all in one shot if possible.

I want to get ALL the PARTS NECESSARY in one shot. I'm traveling to London in about 2 weeks and won't have much time there as i'll be traveling with family.

Can anyone help by telling me, besides the motors and all ancillaries, what else i will need to make this conversion? Seems there are different opinions about the amount of work (skilled machinist work, welding etc is available here - fairly reasonable) but not parts! If i don't get it all shipped together, the headache is enormous! Obviously, i need the 300TDI (looking in case anyone has a good one...) I see possibly new motor mounts? all the ancillaries including radiator, pas pump, hoses, fuel lines, etc. is what i have picked up from the forums? But apparently some feel that fabricating a down pipe is not worth it as long as there are available pre made from Steve Parker or similar? Like i said, i'm going to be in the UK for a few days very soon, but i have to grab it and go. I'm also looking for any help anyone might be able to offer on shipping this stuff to Guyana. Anyone know of a reasonable shipper? So far, i have a quote from an ebayer selling a complete 300TDI who says he can get it shipped to the port for 450 British Pounds. WOW, that sounds like a lot of money! Am i being a cheapskate? Its the same price as his motor! Seems like a lot of money to ship. Any ideas? I sure would appreciate any advice from local's who might have had to use shippers before. Around here, they can all quote vastly different prices.

As important as not throwing money away, is getting a good quality used 300 or 200 and all the other parts i need in one shot. If i open the box here and find out then that i need a 'left handled jiggle bolt' and a 'sky hook' , it'll take months to get it, and thats after i FIND one!

I really appreciate any help.

ps - currently i have a 4 cyl 2.5 Petrol and an R380 Trans that work fine, but its a little short on torque. The transmission was rebuilt by a local Landrover specialist with 38 years of experience working on Landrovers almost exclusively. Also the Transfer case. They both work fine and shift rather well, but there is a loud whine in 5th gear at a certain speed (around 55 or 60 mph) that goes away if you either accelerate or decelerate but stays a loud whining noise if you keep a constant speed in 5 th gear. I've been driving it for 2 years with the same whine, so maybe its just that it's my first landrover and ive only had it 3 years and i'll just get used to it? i've alreay gotten used to the drips of oil from everywhere all over the yard! It doesn't affect performance, its just noisy! if its a problem, id like to get it fixed but if not, well, leave well enough alone.

The trans had a new main shaft from Ashcroft Transmissions, a new mainshaft bearing, new baulk rings, seals and a few other parts. Reused many other parts.

again, any help you guys can offer would be REALLY appreciated, especially if it saves me from having the thing down for a few months while i realize after tearing it down, that i should have picked up a $10 parts while in the UK!

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As you have a 1994 special order petrol with R380, you may have a much easier job than you think to fit a 300TDI (and also makes it very difficult to fit a 200TDi!)

What does your gearbox tunnel look like, is it alloy or fibreglass? If it is fibreglass your engine/gearbox is already in the right position for the 300TDi meaning you don't have to mess around with special conversion parts, you just need a standard exhaust and intercooler pipework, and you already have a gearbox designed to work with the 300.

UK shipping should be no more than £100 for a pallet to a UK port

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As you have a 1994 special order petrol with R380, you may have a much easier job than you think to fit a 300TDI (and also makes it very difficult to fit a 200TDi!)

What does your gearbox tunnel look like, is it alloy or fibreglass?

Wow, something thats going to be easier! Thats a change for me...

Attached a few pics of the teardown as they speak a thousand words.

Forgive the filth, i've since power washed it to death and put it back together.

This Rover was brought over by a Holland timber company, is it being a LHD going to be another problem? The current Power steering sector box works okay.

Thanks for the tips. Tried to upload other pics but i've got to figure out how to reduce the size.

What makes it difficult to fit a 200 TDI to this frame/trans?

Ps - its alloy (I thought it was aluminum) under all that filth.

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That looks to me like a short shaft R380 so a 200TDi will be easy to fit IF its a proper defender engine. you'll need an engine with ancileries, fuel pipes, rad, rad pipes and intercooler pipes, fuel filter, wiring loom for the engine, a temp gauge and matching sender, Either a TD or 200TDi complete exhaust depending on what hangers you have, fan cowling and preferably a TDi ignition switch or a way of energising the heater plugs.

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Yes it is a rare and suaght after short bellhousing R380. Ignoire everything I said about 300tdi being easier to fit - If i was in your position I would be looking for a proper Defender 200TDi engine and get everything with it. It will save lots of time and messing about, welding, cutting and extending pipework/exhausts etc. I have sold two this last year on ebay for £800 each with everything you need.

With a proper defender 200TDi and short R380 you will have a very good setup.

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if it is a stumpy bell housing R380, to confirm measure the bell housing from the flywheel housing rearwards to where it meets the actual gearbox case, it should be 11cm overall mating face to mating face.

I have one in my '89110

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any thoughts as to what i might run into if I use a Powersteering box off of the donor vehicle in the UK, since mine is a Left Hand Drive?

Thanks again.

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