 | Home > My Defender > Defender 90 LS/6L80 conversion. step by step! |
 
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221   
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So, next steps.
Getting it home, complete with BCM, ECU, Throttle, cats, loom, gearshifter etc etc. I may/will not use it all but I wanted it to make sure I wasn't missing anything  Click image to enlarge Luckily now there is an off the shelf adaptor available out of the states that allows the LT230 to be fitted onto the 6l80e. The ability to keep the LT is very important to me as I have an Ashcroft Underdrive This is the adaptor. Also in the pic in the background you can see various parts for linkages and gearlever mounts. Click image to enlarge I continued to collect parts. Below is a Lokar shifter: Click image to enlarge Truck (4WD) Sump as the car sump isnt suitable: 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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15th Sep 2016 2:36am |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Most of these conversions are being done in the US. One issue over here is the fact that almost all the engine/box options are out of cars. That means that they have an output housing that isnt any use as it has a prop shaft flange bolted on the back.
So the next step is to convert it to a 4wd (and dry) tail housing Click image to enlarge Click image to enlarge Seal is also fitted in this image (core plugs also fitted in the holes at the top and bottom): Click image to enlarge Threaded section cut off! and 4wd tail housing fitted Click image to enlarge Trial fit of the adaptor: Click image to enlarge I then removed the aircon compressor and started a test fit in the 90: 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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15th Sep 2016 2:46am |
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| Pickles Member Since: 26 May 2013 Location: Melbourne Posts: 3784 
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Brilliant.
Pickles. |
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15th Sep 2016 6:08am |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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so the next steps...
The alternator is low on the passenger side of the engine I needed to move this. Also with this been a very late l77 they dont actually have a power steering pump on the engine. Its electric. The holes are still there however to run a pump if requried. I ended up buying a kit from Kwik Performance which relocated the alternator to the top of the engine on the passenger side, and also allows the fitment of a GM type 2 PS pump Click image to enlarge Click image to enlarge This is with the pump and pulley fitted Click image to enlarge Mounts were next. The Transfer case mount on the drivers side bolts straight back on, and with an earlier Defender the std mount can be used on the adaptor for the LT aswell. On the TD5 this wont work easily. You could cut off the chassis mount and drill and then bolt on the earlier mount with the round rubbers but I didn't want to do that. Luckily a mate has a CNC machine , and I have Solidworks so we made some custom mounts out of 6061 alloy billets Click image to enlarge Adaptor side: Click image to enlarge Engine ones. LH and RH versions of this (the steel work for the chassis part of the engine mounts is being cut at the lasers as I type this!) Click image to enlarge I however made up the one for the adaptor by hand: Click image to enlarge Click image to enlarge For reference this is what the shifter will look like when its fitted in the car. It will fit through exactly the same rubber boot that the r380 lever did 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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15th Sep 2016 6:13am |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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ok, next, Exhaust manifolds.
The car manifolds are cast and quite compact. Unfortunately not quite compact enough. Not very good comparison photo of the overall manifold size between the factory ones and the replacement ones Click image to enlarge Reduction in flange offset: Click image to enlarge Click image to enlarge Passenger one fitted (hard to get a pic of the other one due to stuff in the way): Click image to enlarge One downside to these is the fact that the flange is a different angle to the originals which makes it hard with the catalysts. more on that and wiring 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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15th Sep 2016 6:22am |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Ok wiring and stuff....
This was probably my biggest worry. I need to run the full emissions setup for the engine with cats, pre and post cat 02's EVap, fuel tank pressure sensor etc etc. Speartech in the US can provide me with a stand alone loom for the engine and 6l80 with the exact spec I need. I placed the order yesterday and the turn around should be around 5 weeks. I need to send in my ECU and TCM.... the ECU is easy, The TCM not quite as much! So the issue with the Auto is that it has the tap up/tap down on the gear shift on the left gate. When people fit these engine and boxes in Patrols and the like they tend to run the factory commodore shifter which I didn't want. The Lokar shifter I have only has one plane (i.e no push across to the left for the tap up/down functions) I need them on a separate switch as part of the new loom setup. So, the TCM needs reprogramming... And its inside the auto. So, sump off Click image to enlarge Remove valve body/TCM assembly and strip this down so only the brown bit will be sent: Click image to enlarge Inside the auto with the stuff removed: (old sump is back on for now) Click image to enlarge I have just posted those off to the States.... So that's about where I am at the moment! I have a new deeper sump on order, the wide mouth filter from a Camaro / 6l90e box, along with the Lokar throttle to suit the setup (the guys who are pioneering this stuff in the States aren't far off being able to use a std td5 pedal which will save a decent amount!) 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. Last edited by psimpson7 on 15th Sep 2016 6:37am. Edited 1 time in total |
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15th Sep 2016 6:34am |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Thanks Pickles! 2001 90 HT 6.0LS/6spdAuto. 2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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15th Sep 2016 6:35am |
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| JOW240725 Member Since: 04 May 2015 Location: Suffolk Posts: 7906  
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Great work! You make it seem so easy but I'm sure it's not!
Looking forward to the finish!  James
MY2012 110 2.2TDCi XS SW Orkney Grey - http://www.defender2.net/forum/topic43410.html MY1990 110 200TDi SW beautifully faded Portofino Red - https://www.defender2.net/forum/post743641.html#743641 MY1984 90 V8 Slate Grey - https://www.defender2.net/forum/post744557.html#744557 Instagram @suffolk_rovers |
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15th Sep 2016 6:54am |
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| GREENI Member Since: 22 Aug 2010 Location: staffs Posts: 10382
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Nice!
Watching with interest. I'm in the middle of the wiring stage on my GEMS engine and it's a pain. If I knew then, that I know now, I would have gone for the LS route, they're really simple to wire in! |
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15th Sep 2016 7:35am |
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| davew Member Since: 02 Jan 2012 Location: North Yorkshire Posts: 888  
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Really like that alternator bracket, not seen that before. Is your power steering pump one with a combined reservoir ? Trying to figure out if I'd need to change to a remote reservoir to fit that bracket...
One thing I'll point out to you now, just in case, the inlet manifold is symmetrical and I've found that having the throttle body sticking out of the front and makes fitting the air intake pipework, especially with a snorkel, very difficult. If you have room between the back of the engine and the bulkhead (I'm guessing you will have to fit the transmission in) it's worth considering turning the manifold through 180 degrees so all you need is a simple 90 degree pipe to route the intake either to the original grill or to a snorkel to either side. I didn't know about that when I fitted mine in 2007 and it cost me a lot of time and money to route/fabricate the intake as a result. It's been on my list of things to "fix" ever since ! Click image to enlarge http://www.yorkshireoffroadclub.net/ |
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15th Sep 2016 1:10pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10756
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Thanks for the thread, watching with interest, great read
1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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15th Sep 2016 8:02pm |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Thanks Dave,
The pump I have does have a remote reservoir but I believe they do a number of brackets, including one to suit the pumps with the attached reservoir. I am aware of the space issue with the inlet. The loom I have ordered takes into account the reversed manifold and one of the next jobs on the list to turn it around! Rgds Peter 2001 90 HT 6.0LS/6spdAuto. 2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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15th Sep 2016 8:28pm |
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| Pickles Member Since: 26 May 2013 Location: Melbourne Posts: 3784
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Mr. Simpson,...more "brilliance"!!...Where & how did you learn the skills,..what do you do for a dollar?
Top stuff, Pickles. |
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15th Sep 2016 10:00pm |
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| psimpson7 Member Since: 20 Nov 2013 Location: Gold Coast, Qld. Posts: 221
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Hi Pickles,
Mechanical Engineering is my background, and I am still in that industry. In terms of how I learnt, I was lucky growing up and learnt a lot of stuff from my Dad on our farm in the UK, and I have a habit of just trying things and see what happens. I've had heaps of cars over the years that have required 'dedicated' ownership including a Caterham Superlight R and a Lancia Delta Integrale Evo so I am used to getting stuck in! Some of this project has been quite easy so far, but some has been quite hard! I have spent the last 2 hours with the entire bulkhead wiring loom in bits in the front room removing the 10as unit and associated wiring, the now redundant OBD2 port and its wiring and as much stuff as I can that I think I wont need. I think I have about another 10 hours work to go on that! I wonder if I may get frustrated and just start a new loom, but I don't particularly enjoy wiring so I will see how I get on! 2001 90 HT 6.0LS/6spdAuto. 2003 90 td5 soft top. 2014 90 XS SW 2.2. |
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16th Sep 2016 11:45am |
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