Hi Guys
Can anyone help , maybe with photos of there 300 tdi engine installation into a defender.
Ive got stuck finding a good poisition for the air box , turbo trunking etc ? should i use the cylinder air filter from my NA engine or the boxy 300 TDI air box ?
also exspansion bottle , i have the 300 TDI exspansion bottle but no brackets to mount it ? can anyone help
cheers

I used the 2.5 N/A expansion tank. but I had to fabricate a reducer for the 22+mm pipe that exits the tank to reduce down to 15mm.
If you want to use the 300tdi expansion tank you need ESR2313 a bracket to steady it, although at £56. you will probably fabricate something. The main bolts just bolt to the inner lip of the wing
I extended the 300tdi lower turbo to intercooler pipe using alloy hose joiners off ebay and extended the top intercooler hose with a combination of a non-egr top intercooler hose and a shortened version of the steel section of an egr equipped 300tdi top hose.
While you are doing this you will notice that the front of the 300tdi engine is lower when fitted to an LT77 gearbox than it is when fitted in the normal factory 300 tdi position.
I have got a temporary solution for an air filter using the 2.5N/A element as nothing seems to fit. I have spent hours with the Discovery square air box and the 2.5N/A canister and haven't sorted anything yet.
Have you sorted your exhaust yet?
https://www.lrworkshop.com/diagrams...eating/cooling-system/expansion-tank_52965#12

Hello again Rougharse

I still have my NA exspansion tank bolted in to the drivers side inner wing so thats good i could still use that with the reducer.
I think i will use the cylinder NA air filter on its side laid down above the turbo , in that area there as i cant see how a square 300 tdi box could fit, my engine is tight back to the bulkhead ( R380 box ) so maybe it could fit between radiator and engine with lots of trunking ??
i would like a snorkel soon as i did ingest water in my last engine .
the exhaust i ended up buying a steve parker drop pipe , i modified the military x member to allow the exhaust to pass through and made my own connector pipe out of sttraight sections to then a standard 300 tdi centre box and standard 300 tdi read box . i just used the military exhaust mounts as per standard N/A
i used the steve parker intercooler pipe kit as had a little cash to spend .
im still struggling to get fuel to prime system ? i got crank in right place for manual pumping but doesnt seem to feel much pressure yet.
Also do you know if i need to change no4 Injector , my engine was from a auto and no 4 injector has a electrical connection on it ? I replaced the injector pump for a manual 300 tdi one and it aslo has electrical connections on some kind of diaghram top ? i havent no supply or need for this , i was told it was for the 300 tdi immoboliser and wont affect anything ??
Cheers

I'm afraid that I don't know if you have to replace No 4 injector, but I believe that these injectors are no longer available, so it may have a value if you do replace it. I'm sure that someone more knowlegable will be along soon.
If your fuel pump has extra wiring on the top I suspect that this will have been something to do with the EGR management system rather than the imobiliser. Mine had what was possibly a throttle position sensor held on to the diaphram housing by the front two bolts.
The extra wiring for the imobiliser is at the back of the fuel metering pump where the fuel shut-off solenoid is. As standard they have a plastic cover and three black wires leading to it. If you still have this you need to whip it off, I believe that there is just a standard shut-off solenoid beneath. Mine had all this removed when I got it and there was just the one wire to the solenoid. I would make doubly sure that nothing has been damaged and that you have still got 12 volts to the shut-off valve or it is never going to start.
Even if you need to swap No 4 injector, I would expect it to fire up on 3 cylinders if it was getting fuel.
I have in the past rplaced the fuel tank, sedimentor and fuel fiter on mine and never really had much issue bleeding the system, for example I have never had to cack the injector pipes etc. From memory the priming lever on the bottom of the lift pump does not offer much resistance. Did you fill the fuel filter with diesel before you fitted it?
In the past I had no end of problems priming a reluctant Citroen diesel after a re-build, I sorted that one by giving it a tow-start.

I used the n/a air filter mounted on its side on a bracket fitted to the top of the timing chest, where the air con pump would have been.
Snorkel comes into the front of the drivers wing and only a short bit of pipe will be needed to connect the snorkel to the air filter.






Mine is a 300tdi fitted to an LT77 which is why there is such a lot of room between the engine and the radiator.

The pipe work from the filter to the original turbo pipe is 2.5” . No adapters or owt needed.
The air filter inlet is 3”.

Fantastic , good idea .
looks right there too . cheers guys your a goldmine of knowledge .

300TDi conversion into my 1986 90.
All stock parts.

cheers guys , looks good

Hi Litch,A mate has his aircleaner mounted where yours is. A while ago we had to remove the it to do another job and I was surprised to find it was fitted two head bolts!
To what/where is yours fitted ?

Mine uses stock parts (LR Genuine Parts retrofit kit) so will match any factory TDi.

Looking at the photos it appear that the bracket does indeed bolt to a pair of head bolts, I haven't ever taken any photos to show that specific part but the bracket is visible in these photos from when I was having my bulkhead galvanised..

Thanks Litch,Guess it's right then. Bit odd though.