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Ranger 6

Member Since: 17 Jan 2019
Location: Yorkshireman trapped in a Surrey postcode
Posts: 205

1988 Defender 90 V8 Petrol CSW Rimini Red

3.9 exhaust on a 3.5 - manifolds and system

Well the collection of parts has nearly come to an end. I started with manifolds (thanks Mo) and worked back from there.

What started with a thought of a quick change turned into a longer process as I hadn't researched properly and found I needed a D1 crossmember. That was the final part and joins the RRC downpipes and Y piece and the TD5 system.

Now all the bits are sitting in a pile......

Click image to enlarge

It's where it all becomes a bit real. Work will start soon, but I'm struggling to find the right clamps for the Y-Pipe. I'm getting the gaskets ERR6733 and ETC4524.

The other bits I'm struggling with are some decent brass (or high temp) nuts to fit the manifold studs.

Does anyone have some specs/links for these bits please? 90 V8 CSW - 1988

9th May 2020 3:41pm

GREENI

Member Since: 22 Aug 2010
Location: staffs
Posts: 10383

Rimmers do a stud and nut kit

9th May 2020 3:51pm

Ranger 6

Member Since: 17 Jan 2019
Location: Yorkshireman trapped in a Surrey postcode
Posts: 205

Thanks - will have a look. Don’t want the studs at this point. 90 V8 CSW - 1988

9th May 2020 4:41pm

Ranger 6

Member Since: 17 Jan 2019
Location: Yorkshireman trapped in a Surrey postcode
Posts: 205

So - from a bit of research here's a list so far.....

Manifold to head fixings:
Manifold bolts - SH506101L
Washers - 3036L
Locking plates - ERC7321

Manifold to downpipe fixing:
Nut - GHF252 (not sure if it should be LR019197P)
Washer - WP105

Exhaust clamp x 2 - GEX9008
Exhaust bolt x 2 - BH108101
Nut x 2 - GHF252 90 V8 CSW - 1988

11th May 2020 8:15am

Romadog

Member Since: 07 Jul 2011
Location: Powys
Posts: 1750

Olive required between y section and silencer?
Also bracket Ray to support rear of y section by gbox mounting.

Have you modified D1 xmember yet??

Have you the Td5 bracket for a frame xmember?

11th May 2020 1:27pm

Ranger 6

Member Since: 17 Jan 2019
Location: Yorkshireman trapped in a Surrey postcode
Posts: 205

Thanks for that - I'll add the olive to the list and the rear hanger is another on the radar, just haven't found the right part number.

What are the mods required to the cross member? 90 V8 CSW - 1988

11th May 2020 9:22pm

Romadog

Member Since: 07 Jul 2011
Location: Powys
Posts: 1750

Defender chassis is deeper than Disco.
Fit xmember in chassis on top holes.
You will see that bottom holes don't line up.
Weld strip of metal to xmember both sides, squaring it up as one corner is chopped off.
Mark holes and drill them out and paint

12th May 2020 6:56pm

Ranger 6

Member Since: 17 Jan 2019
Location: Yorkshireman trapped in a Surrey postcode
Posts: 205

Perfect - thanks

90 V8 CSW - 1988

13th May 2020 9:43am

Lodelaner

Member Since: 04 Feb 2010
Location: Lambourn
Posts: 635

1988 Defender 90 V8 Petrol ST Shire Blue

Ranger 6 wrote:
Thanks for that - I'll add the olive to the list and the rear hanger is another on the radar, just haven't found the right part number.

What are the mods required to the cross member?

ESR 3294 is the exhaust bracket - std for Td5 and 300tdi.

Just got a few photos of the same conversion on mine, I reused the downpipes of my D1 V8 and had flexi-joints welded in to replace the cats. Exhaust from Y piece back is Td5/TDci.

Gearbox crossmember is D1 extended, and I've added pics of the exhaust bracketry if that helps.

Click image to enlarge

Click image to enlarge JB

@Lodelaner Instagram

Youtube greenlaning and other LR related content

13th May 2020 12:01pm

Ranger 6

Member Since: 17 Jan 2019
Location: Yorkshireman trapped in a Surrey postcode
Posts: 205

That's excellent - very useful, thank you.

Any chance you could do a couple more of the crossmember and where it bolts in at the bottom. 90 V8 CSW - 1988

13th May 2020 5:19pm

Lodelaner

Member Since: 04 Feb 2010
Location: Lambourn
Posts: 635

Tricky to photograph!

JB

@Lodelaner Instagram

Youtube greenlaning and other LR related content

13th May 2020 6:49pm

Ranger 6

Member Since: 17 Jan 2019
Location: Yorkshireman trapped in a Surrey postcode
Posts: 205

No, that's perfect - I know exactly what's needed to modify

Many thanks 90 V8 CSW - 1988

14th May 2020 12:38pm

Ranger 6

Member Since: 17 Jan 2019
Location: Yorkshireman trapped in a Surrey postcode
Posts: 205

After some time it's an update.....

It's all on - the last piece is going to be the hanger for the middle box which is yet to go on.
There was a bit of fettling to be done to get it to fit properly.

Click image to enlarge

Click image to enlarge

The final piece has been to fit some new needles so the engine breathes properly. I chose BBW as the standard BGC were OK, just felt a bit weedy and low rev response was suffering. 90 V8 CSW - 1988

6th Mar 2021 6:47pm

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