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Defendermatt

Member Since: 15 Sep 2016
Location: Derbyshire
Posts: 312

Defender 90 Toyota V8 swap

Welcome to my build thread!

I am converting my 1989 Defender 90 to a Toyota 4.3 V8 as found in the Lexus LS/SC/GS430.

It is nearing completion so not really an update of what I’m doing at current, but covid has allowed me some free time to do a bit of a write up. I’ll try pick out the most interesting parts of the build but let me know if there’s anything in particular you want to see.

This is the 90 going under the knife. It underwent a full restoration a couple of years ago with a tuned 200tdi, all new drivetrain and a large number of new body panels. It boasts a number of mods prior to the engine swap including Ashcroft ATB’s front and centre, Quaife rear diff 110 casing, big brake kit, puma dash conversion, td5 rear tub, alive suspension setup.

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This is the engine, quite a world away from a 30y old agricultural diesel. 4.3, quad cam, vvti, 300hp/325lbft out the box. Should give the old girl some get up and go.

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First job is give the engine a look over, clean and replace a few seals. Supposed to be a low mileage JDM import, but I opted for a new timing belt kit and water pump also. Then get it mated to the R380 adapter (Synchro gearboxes) and fabricate some new mounts.

Click image to enlarge

Click image to enlarge

With the motor sitting in the engine bay it’s time to think about how it’s going to be run. It is possible to use the factory loom and ecu, but switching to aftermarket engine management just unlocks so much more.
Plus - who doesn’t like building a whole engine harness from scratch

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Planning, planning....oh and more planning! Wooo, time to cut wire. Laying the wires on a 1:1 pegboard

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After cutting to length (adding some spare of course) the wires are hand twisted to create compact flexible bundles.

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Always mocking up to check fitment.

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Adding heatshrink, labels and terminating connectors.

While building the engine harness I also worked on moving the PAS pump. Located above the alternator in factory position, this is giving interference issues with the steering box and puma airbox. Since I am ditching the AC compressor I machined a new bracket for the PAS pump to sit there, and a idler for above the alternator. Quick 3D print to confirm before pressing the button in aluminium.

Click image to enlarge

Well, I made a start!

i will try to make more updates to this thread regularly.

Ciao for now 1989 90 4.3 V8
2012 L405 OF
2014 D4 HSE Lux (SOLD)
2015 90 HT (SOLD)
@d9o.mf

19th Jun 2020 8:35am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8008

2011 Defender 110 Puma 2.4 USW Stornoway Grey

very smart. you have more patience with wiring them me too Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

19th Jun 2020 8:38am

Shroppy

Member Since: 25 Feb 2016
Location: Shropshire
Posts: 866

1986 Defender 130 V8 Petrol HCPU Aintree Green

This looks ace!

Can't beat a bit of Japanese engineering, I strongly considered the same engine before I dropped on my RV8 4.6.

I'd be interested to see how you went about fitting the puma dash? 1985 127 V8 Build Thread
Series 2 109"
Series 1 80"

19th Jun 2020 10:23am

bear100

Member Since: 22 Mar 2010
Location: South Wales
Posts: 1913

2010 Defender 110 Puma 2.4 USW Santorini Black

Now that is a neat looking engine bay!

2016 Range Rover Autobiography 4.4 TDV8
2010 110 XS Utility 2.4TDCI
2010 Range Rover Sport TDV8 (gone)
2007 Discovery HSE TDV6 (gone)
1993 110 csw 200 tdi (gone)
1994 90 HT 300 tdi (gone)
1994 discovery 300tdi (gone)
90 hybrid 3.5 v8 (gone)
Range rover bobtail 3.5 v8 (gone)

19th Jun 2020 10:49am

Matt110

Member Since: 29 Jun 2014
Location: UK
Posts: 680

That wiring is a work of art - great work and following with interest.

19th Jun 2020 11:17am

90 Dreamer

Member Since: 13 Jul 2019
Location: Oop North
Posts: 2141

2016 Defender 90 Puma 2.2 HT Corris Grey

Looks a fantastic project

19th Jun 2020 7:59pm

Pacha

Member Since: 23 Feb 2020
Location: North Yorkshire
Posts: 772

2008 Defender 90 Puma 2.4 HT Stornoway Grey

Love this thread!. Rgds.

Chris

19th Jun 2020 8:19pm

Zed

Member Since: 07 Oct 2017
Location: In the woods
Posts: 3256

2010 Defender 110 Puma 2.4 XS CSW Santorini Black

Nice. Love the attention to detail. WARNING.
This post may contain sarcasm.

19th Jun 2020 8:25pm

Defendermatt

Member Since: 15 Sep 2016
Location: Derbyshire
Posts: 312

Thanks for the comment guys.

I’d say there is probably 200 hours in the engine harness manufacture and probably the same in planning. My profession is in aerospace and motorsport harness design so I kind of know what I’m doing

The puma dash conversion was done as part of the restoration, and a total nightmare! I didn’t get a full puma bulkhead (which would be the easiest way to do it) I only bought the dash and the heater matrix, then fitted that to the tdi bulkhead. It still uses the tdi heater blower which isn’t really capable of pushing the air through all the ducts which means heated seats are a must! 1989 90 4.3 V8
2012 L405 OF
2014 D4 HSE Lux (SOLD)
2015 90 HT (SOLD)
@d9o.mf

19th Jun 2020 8:47pm

Co1

Member Since: 19 Aug 2018
Location: North Yorkshire
Posts: 3671

Looking forward to hearing this!!

20th Jun 2020 6:26pm

Bobtailkev

Member Since: 17 Mar 2016
Location: Suffolk
Posts: 109

2011 Defender 110 Puma 2.4 USW Buckingham Blue

Excellent you are one very talented guy I look forward to the next up date

20th Jun 2020 7:40pm

Procta

Member Since: 03 Dec 2016
Location: Sunderland
Posts: 5150

i did an engine conversion in a rover metro 10 years ago, from what info is now video wise, i would have had a go at doing the full electrical harness rather than have someone do the engine loom for me, which turned out that i could have done it my self for the sake of switching 6 earths over. Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

Success is 90% Inspiration and 4 minutes Preparation # you can make it!

21st Jun 2020 1:10am

Defendermatt

Member Since: 15 Sep 2016
Location: Derbyshire
Posts: 312

First job after getting the engine was a deep clean, not that it was particularly dirty but I took the opportunity whilst it was on the stand. I bought the lump as a low mileage, JDM import. Since there was no history I changed the waterpump, timing belt kit, and some gaskets for piece of mind. Timing belt was a pretty easy job, no locking pins. Just turn to set position, remove tensioner and replace belt. I changed all 8 spark plug tube seals as they were all hard and brittle. Treated the cam covers to a nice candy red powder coat too.

Click image to enlarge

Click image to enlarge

I had all the front end stripped off, this made life a lot easier for mocking up with the engine fitted to the box. The gearbox sits on original tdi mounts so no need to worry about prop lengths or swapping seatboxes, just some fresh engine mounts. Both mounts took quite a bit of work to get right, they’re handed to start. Plus the NS has next to no space, unlike the OS which you could fit any size mount you like. I did a few test prints in ABS to confirm fitment then off to be machined. My CNC guy was out of action and I was booked in to have a full exhaust built the week after so I was desperate. I switched the CAD to sheet metal and sent the files off to the laser cutter, along with some machined collars for the bushes to sit in, they all got tigged together.

Click image to enlarge

Click image to enlarge

Not sure I’m fully happy with the choice of bush, but I was concerned about them being very hard and feeling every vibration through the car. I might change them to a smaller bush when it’s up and running, we’ll see.

I had the td5 tank from the tdi days, great for use with the puma dash as it uses the ROW 300tdi fuel sender. But now comes the added complexity of needing to fit a fuel pump. External pumps such as the Bosch 044 are good for big power but don’t like to suck fuel unless fed from the bottom of the tank, so I decided to go with an in-tank pump. Bring in the DW200, more than adequate of suppling the 3UZs fuel needs. I pinched the mounting idea off a US forum member who was fitting an LS3, he also suggested the Nissan 350z kit as the pre filter was a great fit in the swirl pot.

Click image to enlarge

Click image to enlarge 1989 90 4.3 V8
2012 L405 OF
2014 D4 HSE Lux (SOLD)
2015 90 HT (SOLD)
@d9o.mf

29th Jun 2020 4:10pm

Welshsurferdude

Member Since: 23 Feb 2012
Location: Newport
Posts: 2398

Awesome work!

Very tempted to get a 'yota V8 into a NAS spec soft top

great summer pub car then lol 2008 Santorini Black 110 XS USW (Sold)

2015 Discovery 4.5 Black pack Firenze red XS

2008 Corris Grey 110 XS USW (sold)

2011 Santorini Black 110 XS USW (Sold)

29th Jun 2020 7:34pm

Pickles

Member Since: 26 May 2013
Location: Melbourne
Posts: 3782

2013 Defender 90 Puma 2.2 CSW Keswick Green

A very unusual engine choice, but congratulations on some magnificent work, especially the loom & re-wiring etc, absolutely exceptional,....looking for more of this story.
Well done, Pickles.

29th Jun 2020 11:44pm

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