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charcoal



Member Since: 28 Jul 2014
Location: Hampshire
Posts: 942

United Kingdom 2005 Defender 110 Td5 HT Bonatti Grey
300tdi to 3.5 v8 conversion
Hello all, in March I had my Defender converted from the ordinary 300tdi engine to the more exotic Rover 3.5 v8. Today I will share the process with you. If you're thinking about a similar conversion or just want a good read, keep reading Whistle

First off I should give a bit of back story to why I done a conversion some would consider sacrilegious. I always wanted a 110 station wagon v8, I couldn't find any in good condition and needed transport. I ran the 300tdi for almost a year so I could prepare myself for the conversion. As you will read later on, I still didn't fully prepare myself Rolling with laughter

Anyway, now on to what you're here for. Last year I picked up a Rover 3.5 v8 from a 90 or 110 which supposedly had under 1000 miles on it. I couldn't really believe it was that low but the engine was in undoubtedly good condition and wouldn't have been much higher. I also bought an ex mod reconditioned LT85 gearbox that would've come from a Snatch.


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The bloke I bought the engine from gave me a few free bits, these included a exhaust Y piece and the air filter setup. The engine wasn't without its problems though, the seller confirmed it ran but said it would need tuning, a carb damper was broken, an exhaust manifold was missing and the ignition timing was out.

The tuning and timing could be sorted during the conversion process. The damper was not actually broken and had in fact just came off the carburettor cap, a pair of tweezers got it out the carburettor and I could clip it back into the cap. Lastly there was the problem of the missing exhaust manifold. I found a new genuine one for sale at a fraction of the retail price after some digging!


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Now over the next six months I bought various parts needed for the conversion and found someone to buy my 300tdi and gearbox. I won't go into details.

Right, fast forward to March of this year and I finally had my Land Rover booked into a garage willing to do the conversion. Yes I know I'm not doing it myself, lack of skills, time, tools and so on. Here are a few pictures of my stuff loaded on their van the week before.


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Many thanks to Solent Motors in Havant for the top quality job, would highly recommend and will use them for any future work!

To make life easier for them I removed the bonnet mounted spare, the day before. This was a very rare occasion so I snapped a picture while at work.


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Anyway I got to get to work, doing a write up takes a lot longer than expected! I will continue when I get home Thumbs Up 1999 Land Rover Defender 110 td5 station wagon
1998 Land Rover Defender 110 County Station Wagon ~ Sold
1995 Land Rover Defender 110 V8 Station Wagon ~ Sold Sad
1985 Land Rover 110 ex mod project Tithonus ~ Sold Sad
Post #550883 24th Jul 2016 3:23pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 10751

England 
Thanks for that Thumbs Up I will now look for you in the V8 section Very Happy 1996 Golf Blue 300Tdi 110 Pick up.

Keeper.

Clayton.
Post #550940 24th Jul 2016 8:06pm
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charcoal



Member Since: 28 Jul 2014
Location: Hampshire
Posts: 942

United Kingdom 2005 Defender 110 Td5 HT Bonatti Grey
Good to know L110, before long I'll be one of the forums 'v8 experts' Laughing

Anyway, work continues on making my perfect Land Rover. The old 300tdi engine and gearbox had been removed quickly and they were both sitting outside. I had a guy lined up to buy the 300tdi as soon as it was removed which got me some much needed cash towards this project. They also steam cleaned my engine bay while it was empty which was a nice little touch.


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It's surprising how small the 300tdi is in comparison to the v8, the flywheel looks almost half the size of the v8 one! On my second visit the engine and gearbox were in and they were making the engine mounts.


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A few days later the guy who bought my 300tdi was finally ready to collect it which gave me an excuse to check up on progress once again. The new alternator and ignition coil had both been fitted and the wiring had all been completed.


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A few more days passed before any notable advancements occurred. I did however get a call saying they'd got the engine running. The fuel was over-pressured because I forgot to buy a restrictor but after the fuel pump was turned off and the pressure dropped they said it ran perfectly for a few seconds before running out of petrol. As you can imagine it's good to hear an engine you bought without seeing running actually runs!

After getting that call I decided to go and check on progress the next day. The whole exhaust had been fitted, the fuel tank had been cleaned and the petrol pump fitted, the engine had been plumbed up completely with the exception of the yet-to-arrive fuel restrictor.


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Sadly a few missing parts were brought to my attention these included the correct gear stick, correct power steering pipe and the lower bellhousing cover. No idea how I forgot to buy that Whistle

We'd also only just realised that the ex-Snatch lt85 had a larger drive flange so I had to purchase a new one. Not only that but the front prop had to be send away to be extended by an inch and a half as the gearbox had to sit and inch and a half further back.

A week passed since the missing restrictor was brought to my attention and it finally arrived albeit five days late. Anyway it could finally be plumbed into the fuel lines to complete them. This allowed the engine to be run properly for the first time. Safe to say I was rather excited and hung around the garage for an hour while they done the finishing touches before the first startup. Here is a video of the v8 running for the first time.



Progress seemed slower and slower as missing bits failed to arrive on time and more missing parts surfaced. Before I knew it a month had passed without my Land Rover. The next major milestone is probably when the correct power steering pipe finally arrived. This allowed the radiator and the front grill to be fitted.


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Eventually the propshafts were sorted along with the rest of the engine bay and the end was in sight. That was until out of nowhere there was a weak spark going from the coil to the distributor. I immediately thought it'd be a problem with the king lead as it look pretty crap so I went to get a set of new leads. Upon delivery of the leads to the garage the problem had been resolved, the distributor wasn't being earthed so an earth cable was connected. Now we were back on track and just needed an air filter and the carburettors needed tuning. The original air filter would not fit due to the engine siting an inch and a half further back so one from an MG ZR was retro fitted and the engine bay was complete.


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The garage tried to contact a few carburettor tuners but the only one that replied was not willing to do it. It was perfectly usable without a proper tune so I finally got her back, some seven weeks later! Turns out the required tuning consisted mainly of balancing the carburettors. I found this out the hard way while joining the A27 in rush hour Embarassed It wasn't a problem as long as I could resist fast acceleration and didn't surpass 60mph though!

After getting her back something was really bugging me and needed attention as soon as possible..


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Much better Laughing

So that's it. Over a year in the planning and I finally have my perfect Defender, a white 110 station wagon with a v8 Cool

The adventure doesn't end there though, in the future I plan to replace the LT85 with an LT77s which is the correct gearbox for a mid 90's v8 Defender (in Africa at least), this will also push the engine forward and inch and a half allowing the proper air filter to be fitted and therefor a raised air intake connected!

I may add a few posts about replacing some engine control cables and balancing the carburettors in the future. For now though, I hope you all enjoyed Thumbs Up 1999 Land Rover Defender 110 td5 station wagon
1998 Land Rover Defender 110 County Station Wagon ~ Sold
1995 Land Rover Defender 110 V8 Station Wagon ~ Sold Sad
1985 Land Rover 110 ex mod project Tithonus ~ Sold Sad
Post #551003 24th Jul 2016 10:50pm
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Retroanaconda



Member Since: 04 Jan 2012
Location: Scotland
Posts: 2645

Scotland 
I see they cut the middle out of the gearbox crossmember in order to allow the exhaust to fit.

Did they replace it with the proper V8 assembly? I'm not sure I'd want to run without any cross-bracing there at all.
Post #551199 25th Jul 2016 7:57pm
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charcoal



Member Since: 28 Jul 2014
Location: Hampshire
Posts: 942

United Kingdom 2005 Defender 110 Td5 HT Bonatti Grey
Ah yes, I forgot to mention.. It was cut out because it was in the way of the exhaust. A new one was fabricated to the same dimensions as a v8 gearbox crossmember and fitted in the correct place. I don't have any pictures with it in as they'd taken it off the ramp by then. 1999 Land Rover Defender 110 td5 station wagon
1998 Land Rover Defender 110 County Station Wagon ~ Sold
1995 Land Rover Defender 110 V8 Station Wagon ~ Sold Sad
1985 Land Rover 110 ex mod project Tithonus ~ Sold Sad
Post #551209 25th Jul 2016 8:37pm
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Pickles



Member Since: 26 May 2013
Location: Melbourne
Posts: 3784

Australia 2013 Defender 90 Puma 2.2 CSW Keswick Green
Good thread Charcoal, Thanks for posting,..I hope you get a good run out of your V8.
I noticed that the muffler looked like an ordinary standard item,...a big bore exhaust, say 2.5", with a nice "straight through" muffler will give you a bit more performance, AND a MUCH better sound!! ( a MAJOR benefit of a V8!)
And make sure those carbies are right, if they're not, wrong mixtures etc, there is a possibility of some engine damage in the long term, plus of course, a lack of performance.
There's NOTHING like a V8!!, Pickles.
Post #551240 25th Jul 2016 10:32pm
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charcoal



Member Since: 28 Jul 2014
Location: Hampshire
Posts: 942

United Kingdom 2005 Defender 110 Td5 HT Bonatti Grey
Glad you enjoyed it Pickles Thumbs Up

The whole exhaust is standard. I agree that a big old exhaust would sound excellent but it's not quite for me. To be honest when spending six or more hours driving it'd give me a headache! The stock exhaust still sounds pretty damn good and putting your foot down still give a noticeable roar. I balanced the carburettors myself a few weeks after getting her back, they are still running a bit weak though and I'm too scared to do any serious tuning. Despite being weak she still goes like sh*t off a shovel Laughing Will take her to a professional with a rolling road eventually to get the most out of the engine.

Indeed nothing beats a v8! After seeing and hearing a ninety v8 mid restoration a few years back I knew I needed a v8 in my life Cool 1999 Land Rover Defender 110 td5 station wagon
1998 Land Rover Defender 110 County Station Wagon ~ Sold
1995 Land Rover Defender 110 V8 Station Wagon ~ Sold Sad
1985 Land Rover 110 ex mod project Tithonus ~ Sold Sad
Post #551246 26th Jul 2016 12:13am
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Electron



Member Since: 28 May 2016
Location: Bideford
Posts: 46

 
Interesting read !!

One small comment - ask the rolling road if their building is tall enough for a Land Rover !!

I drove to Guildford to find mine didn't fit !! Still looking for a four wheel rolling road for mine so if you know of one in Hampshire or close I'm all ears Smile

Chris
Post #551299 26th Jul 2016 9:25am
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charcoal



Member Since: 28 Jul 2014
Location: Hampshire
Posts: 942

United Kingdom 2005 Defender 110 Td5 HT Bonatti Grey
This tuner I know has dealt with a few Land Rovers over the years so the building height should be fine. That would be embarrassing if you couldn't do business because of the height Embarassed
Sadly I don't know of any four wheel rolling roads, do they even exist? I'm just planning on going to a two wheel one and removing the front propshaft. 1999 Land Rover Defender 110 td5 station wagon
1998 Land Rover Defender 110 County Station Wagon ~ Sold
1995 Land Rover Defender 110 V8 Station Wagon ~ Sold Sad
1985 Land Rover 110 ex mod project Tithonus ~ Sold Sad
Post #551337 26th Jul 2016 1:00pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 10751

England 
Enjoying the good read there Charcoal, 4X4 rolling roads do exist, there was one not to far from me Thumbs Up 1996 Golf Blue 300Tdi 110 Pick up.

Keeper.

Clayton.
Post #551392 26th Jul 2016 5:47pm
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charcoal



Member Since: 28 Jul 2014
Location: Hampshire
Posts: 942

United Kingdom 2005 Defender 110 Td5 HT Bonatti Grey
Glad you liked it Clayton! That's lucky for you, I'm sure a 2wd one will do the job and there is a bloke not too far from here with one who specialises in carburettors which is perfect Thumbs Up 1999 Land Rover Defender 110 td5 station wagon
1998 Land Rover Defender 110 County Station Wagon ~ Sold
1995 Land Rover Defender 110 V8 Station Wagon ~ Sold Sad
1985 Land Rover 110 ex mod project Tithonus ~ Sold Sad
Post #551459 26th Jul 2016 8:49pm
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 10381

United Kingdom 
Fab, it's nice to see people going against the flow.
V8's are having a bit of a resurgence I think.
Post #551461 26th Jul 2016 8:58pm
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charcoal



Member Since: 28 Jul 2014
Location: Hampshire
Posts: 942

United Kingdom 2005 Defender 110 Td5 HT Bonatti Grey
Yes, I think so too. They seem to be selling and selling for decent prices now, at least on ebay. No idea why because it still costs a kidney to run Laughing 1999 Land Rover Defender 110 td5 station wagon
1998 Land Rover Defender 110 County Station Wagon ~ Sold
1995 Land Rover Defender 110 V8 Station Wagon ~ Sold Sad
1985 Land Rover 110 ex mod project Tithonus ~ Sold Sad
Post #551473 26th Jul 2016 9:42pm
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 10381

United Kingdom 
Winning isn't cheap Thumbs Up
Post #551475 26th Jul 2016 9:59pm
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Pickles



Member Since: 26 May 2013
Location: Melbourne
Posts: 3784

Australia 2013 Defender 90 Puma 2.2 CSW Keswick Green
charcoal wrote:
Glad you enjoyed it Pickles Thumbs Up

The whole exhaust is standard. I agree that a big old exhaust would sound excellent but it's not quite for me. To be honest when spending six or more hours driving it'd give me a headache! The stock exhaust still sounds pretty damn good and putting your foot down still give a noticeable roar. I balanced the carburettors myself a few weeks after getting her back, they are still running a bit weak though and I'm too scared to do any serious tuning. Despite being weak she still goes like sh*t off a shovel Laughing Will take her to a professional with a rolling road eventually to get the most out of the engine.

Indeed nothing beats a v8! After seeing and hearing a ninety v8 mid restoration a few years back I knew I needed a v8 in my life Cool

I did "enjoy it"mate, & I shall continue to enjoy your "journey", particularly how you find things on the dyno.
I don't know much about Rover 3.5/3.9 engines, but I believe some of the "Landrover" engines as distinct from the "Range Rover" engines had "restrictors" somewhere in the inlet, to restrict power?....You didn't find any of these?
As far as the exhaust is concerned, yes, I hear what you say, but that (too much noise) should not happen with a properly mounted & designed system, which should make "noise" only when you want it, ie, when you "put the pedal to the metal". There is nothing worse than a badly designed & installed exhaust.
V8s?...love 'em, Pickles.
Post #551477 26th Jul 2016 10:04pm
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