S3 109 200tdi alternator mounting - Defender Source
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  #1  
Old April 16th, 2016, 05:13 PM
Robbiekb
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Robbie Booth
2004 Discovery V8
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Join Date: Apr 2015
Location: Seattle, WA
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S3 109 200tdi alternator mounting

Hey all, as I've mentioned in previous posts, I have a 200tdi from a discovery in my 83 109.

I replaced the crank pulley this morning (thanks to Brian at defenders northwest for the pulley and belts) after the front axle remodeled it in my first jaunt off the beaten path with it.

I have a couple of questions on the 200tdi into a series swap that I haven't found after digging through Terri Ann's website.

Alternator mount. The mount on the truck doesn't look like the stock disco 200tdi alternator mount. As it stands, there's not enough adjustment on the alternator bracket for me to get the belt back on. Any insight here on an alternator mount that will work? (I think that what I have right now is the series alternator bracket mount)

"Military" bump stops. Does anyone have a part number for these? Is this the same as the bump stop extender that yrm sells?

Parabolic leaf springs- I was going to get mine from Rocky Mountain up in Vancouver. Can anyone who is running their springs let me know what they're running on the front of their 200tdi equipped 109? As things stand today with the old worn springs, I have maybe 2" to the bump stop. In addition to protecting the pulley from future abuse, I want to ensure that there's enough suspension travel for some mild off-roading.

I'm off to the uk tomorrow so hoping to get everything ordered to fit when I get back.
I'll post a pic of my alternator mount shortly.

Cheers!
Robbie
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  #2  
Old April 16th, 2016, 05:46 PM
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Macker
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Mack Crouch
1988 110 LS 5.3
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I ran the alt on my series with disco 200tdi the same place I have it here on my defender- on the top sort of above the injection pump. It's mounted using a steel bracket that screws into the four threaded holes on the timing cover. I happened to have a defender 200tdi exhaust manifold on it. I had rocky mountain parabolics and the ride height was fine. Seemed like it was slightly taller than stock.
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Old April 16th, 2016, 06:33 PM
Robbiekb
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Robbie Booth
2004 Discovery V8
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Join Date: Apr 2015
Location: Seattle, WA
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I wanted to add a few pics to illustrate the issue.

As you can see, the axle will hit the pulley before the bump stops so need to address that.

The belt I thought was the correct size (ETC7939) is 11mm X 1030mm

It's too short for this setup as there's not enough adjustment in the alternator bracket.

A 1044mm belt i sourced from Napa is a little on the big side, heading back there now to split the difference in sizes.

This is all because i lost the belt when my axle pancaked the original pulley so i don't know what size belt was on the truck from the previous owner.
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