fenby1976
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The ideal engine to use would be the 200Tdi engine fitted to Defenders as this version has an exhaust manifold which positions the turbo high up on the engine. They are not as readily available or as cheap as the 200Tdi Disco engine though. Another option might be to buy a Disco 200Tdi engine and replace the exhaust manifold and possibly the turbo to one from a 300Tdi. I've never done that, so I'm not 100% sure it is possible but I've heard it is. If I were doing a Tdi conversion on a 109 I would put the extra effort into avoiding notching the chassis rail. It's a fundamental and highly stressed part of the chassis and notching it is surely bound to weaken it to some extent. It just seems like a bad principal to modify the design of a proven component with the result that you know it will be weaker, but think it will probably be OK. I think that with some extra effort the Disco 200Tdi engine with original exhaust manifold and turbo could be made to fit without notching the chassis: Make a 90 degree adapter to go between manifold and turbo and fit the turbo upside down with the exhaust exiting forwards.
