 | Home > My Defender > Defender 90 LS/6L80 conversion. step by step! |
 
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| davew Member Since: 02 Jan 2012 Location: North Yorkshire Posts: 888   
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Never had a problem with the ignition leads on mine but have melted some air line that was sat on top of the chassis so had to put a heat shield around that - it's a good 4-5 inches away from the manifold where it melted through so they certainly throw out some heat ! http://www.yorkshireoffroadclub.net/
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6th Dec 2016 4:02pm |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221  
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Cheers for the tips guys.
One other thing I did yesterday was to draw up the pump setup so I can run an intank pump inside the std td5 tank. It looks a bit complicated but its not really. 2 8mm holes for the electrical bulkhead connectors, 2 m5 caphead holes to hold the spacers, 3 m16 ports to allow the fitment of m16-6an adaptors for the feed, return and a breather as required, and a Standard 5 bolt SAE pattern to allow the fitment of a Fuel Level Capacitance Universal Sender. On the underneath of the middle m16 port is another one on a boss to allow the fitment of an M16-3/8 barb to allow the connection to the pump with submersible fuel hose This should be made this week.  Click image to enlarge I am looking at one of these to simplify the fuel gauge: http://www.speedhut.com/ecommerce/product/...ender-(3-5 I was going to try and use the standard instruments but I am now thinking about possibly using this gauge set (black bezel, GT Font, bar tick style): http://www.speedhut.com/kit/GRM4-6KITGPS-0...hift-light I am wary of the costs adding up however as its already cost a fair bit to get this far! Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated  2001 90 HT 6.0LS/6spdAuto.
2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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6th Dec 2016 8:40pm |
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| davew Member Since: 02 Jan 2012 Location: North Yorkshire Posts: 888
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You could always use a Discovery 300TDi pickup and an external pump... it'll also make it much easier when you have to add a second fuel tank
 http://www.yorkshireoffroadclub.net/ |
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6th Dec 2016 10:23pm |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Done a bit more.
Fan fitted. Click image to enlarge Power steering pump -> steering box lines and fittings done. Click image to enlarge Click image to enlarge Billet fuel rails. Click image to enlarge Most of the rest of the fuel system is on order. Main wiring harness is simplified as much as I think I can so will refit that soon. Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated 2001 90 HT 6.0LS/6spdAuto.
2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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20th Dec 2016 5:50am |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Replacement gear cable turned up from Lokar (Excellent service)
Click image to enlarge This one works perfectly: Click image to enlarge Click image to enlarge Click image to enlarge Also sorted out the upper radiator mounts. Click image to enlarge Click image to enlarge Interior progress: Click image to enlarge Fuel pressure regulator also arrived along with a heap of fittings. Click image to enlarge I have a heap more stuff on order for the fuel system including about a dozen more fittings and 7m of 200series hose, the evap valve and cannister and a few other bits and pieces Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated 2001 90 HT 6.0LS/6spdAuto.
2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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3rd Jan 2017 1:15am |
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| LR90XS2011 Member Since: 05 Apr 2011 Location: bickenhill Posts: 3639  
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brilliant DEFENDER 90 TDCI XS,
I hope everyone is well and your land rovers make you happy |
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3rd Jan 2017 6:43am |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10733
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+ 1
 1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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4th Jan 2017 9:47pm |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Thanks Guys,
Done a little bit more as stuff arrives. Fuel lines done including the bypass regulator at the outlets of the rails into the return line. I have an inline filter after the pump aswell. Click image to enlarge Click image to enlarge Click image to enlarge Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated 2001 90 HT 6.0LS/6spdAuto.
2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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6th Jan 2017 7:10am |
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| GREENI Member Since: 22 Aug 2010 Location: staffs Posts: 10379
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Nice details going on
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6th Jan 2017 7:12am |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Thanks Greeni!
Everything seems to take so long now! Even the small stuff which you can hardly see. Having said that I also fitted some much larger items over the last few days including all the front end panel work and the engine cover Click image to enlarge Starting to look a lot more complete now. Sorry for the rubbish pictures. Click image to enlarge Click image to enlarge Couple more pics showing the air intake roughly set up. Need to feed both rocker breathers into this between the MAF and TB. I have a 3/8 aluminium barb which I will fit into the aluminum joiner tube that connects the 45 and 90 degree hoses. I am not sure if the K+N filter will stay but for now it will do. Click image to enlarge Click image to enlarge I have also finished the powersteering hoses so thats one thing that is actually completely finished! I need to order about 30 hose clamps now and go over all the hoses. Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated 2001 90 HT 6.0LS/6spdAuto.
2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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9th Jan 2017 10:02pm |
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| GREENI Member Since: 22 Aug 2010 Location: staffs Posts: 10379
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Looking well. I know how much time the small things consume. It took one night after work to sort the air intake, measure it up and draw how it would go, then find and order things online!!
I spent far too long lining up fresh jubilee clips, I'm not really OCD, but I thought I might as well get it looking right. |
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9th Jan 2017 10:25pm |
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| Pickles Member Since: 26 May 2013 Location: Melbourne Posts: 3782 
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Engine cover looks good,..gives it the "factory" look.
Too many leave 'em off, even in Aussie, where LS 1,2,& 3 are common, many modified engines are minus the engine cover, which looks "untidy",..imho. Pickles. |
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9th Jan 2017 11:23pm |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Thanks Pickles.
I had been doing some research on how to set up the emissions stuff. I wasn't really sure and confused myself a bit but I think I have it nailed now. Basically Tank breather ---> Larger connection of pair on EVAP canister Smaller connection on EVAP canister ---> Purge valve on Engine Fuel tank pressure sensor (to read pressure from fuel system - I will probably fit this in the EVAP canister) Vent valve ---> larger connection on own on EVAP canister Filter line on Vent valve ----> vents to atmosphere. When the engine is off this allows the tank to release pressure out of the system via the filter line. When the engine is running it feeds the tank emissions through the EVAP canister, then to the purge valve which when it sees fit releases it into the throttle body. I also have to change a couple of electrical connectors. The fuel tank pressure sensor plug was wrong. It looked like it should use the identical looking e85 fuel flex sensor type plug so I ordered one of those (I could get this locally so figured it was worth a gamble). Typically the shape of the plug was very slightly different so I tweaked it with a dremel and file. The pin spacing and height luckily was 100% I then swapped the plug over. This is the one that was on the loom. Click image to enlarge You can see the sensor in the background. Click image to enlarge New connector pins: Click image to enlarge Click image to enlarge Click image to enlarge Need to change the one on the vent valve section of loom next. Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated 2001 90 HT 6.0LS/6spdAuto.
2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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23rd Jan 2017 7:19am |
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| Andy80 Member Since: 31 May 2013 Location: Essex Posts: 490 
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I like how your 90 looks, could be (and was) just Td5 hardtop with tube wings and roll cage!
Everyone loves a sleeper!!! Working towards Carry on camping! |
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23rd Jan 2017 7:55am |
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