Now or Never - out with the Tdi300 - in with the 4BD1

[IMH]

Victim for the operation is a 97 Defender 130.
It has literally been years in the wishing and now is the time to make good all the threats.
Posting this for general comments and hoping for help along the way - also hoping it might help someone else on their journey.

Vehicle:as mentioned above is a 97 Defender 130 ex drilling company support vehicle, ex many hours under the bonnet keeping it rolling.
Engine: 4BD1- ex hydraulic-ed Frontline Machinery Auction prize - rebuilt with another Frontline Machinery Auction brand spanking new Turbo block, (I think the correct title is) Elfin Pistons, oil piston cooling jets and non return valves.
Turbo: still in the dream time - as haven't successfully figured out what turbo to purchase to give around 20 psi boost
Gearbox: supposed to be a Bushranger box with a PTO and yes - another prize from Ex-Military auction
Location is not the best - photo description to follow
A wise old man once told me that I will need to source a different seat box to go over the different gearbox. Hopefully another wise person can confirm this for me.[smilebigeye]
wish me luck

[IMH]

Here is a couple of shots for set up as promised

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looking at 130
standing beside a 110 with a lifting attachment for the operation

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the back shows at edge of a bank
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extracting the gearbox from storage
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couple of pics of inside gearbox transfer case

had previously dropped a detent spring into gearbox so had to fish it out
also discovered that the hi-low transfer lever inside the box was missing - will be able to borrow one from a gearbox out of a Range Rover (I think)

[rijidij]

I can help you out with laser cut, pre fabricated engine mounts to suit 4bd1 to Defender chassis.

[Bazzle218]

I can help you out with laser cut, pre fabricated engine mounts to suit 4bd1 to Defender chassis.

Highly Recommend Quality product.

[p38arover]

Turbo: still in the dream time - as haven't successfully figured out what turbo to purchase to give around 20 psi boost

KLR Turbo Kit 4BD1 for 4x4 Perentie - KLR Automotive (https://klrautomotive.com.au/klr-turbo-kit-4x4-perentie/) ?

[Blknight.aus]

holset hx30, makes the arkie haul....

[IMH]

I can help you out with laser cut, pre fabricated engine mounts to suit 4bd1 to Defender chassis.


[smilebigeye] Hi Murray - I purchased them from you already - you sent them to Yeppoon. There the best.
Cheers Ian

[IMH]

Thanks for all replies guys

sorry to be slow to answer as have been away and sidetracked.

I just had a look at the KLR kit and appreciate the complete solution and quality etc but trying to stay to a little smaller budget (which could have an early demise)

since original post - I was talking to a diesel fitter working in a compressed air workshop and chating about my side hobby - he told me about his mate that put a Mazda BT-50 3 litre - variable vane turbo onto a 4BD1 engine fitted into a Landcruiser - tuned by ear only and was making good power with up to 30psi boost.

Would like to hear if any one has had experience or heard of this.

[IMH]

171589
found and convinced a local mobile AC guy to come down and vacuum the AC so I could open the lines with a clear conscience - great service and he will be getting the job to get it going when the time comes

171590
as you can see have taken guards and stuff off so I can walk up to the engine without any hassles
I enjoyed being able to stand beside the chassis to work and thought it was worth the effort.

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engine lifter I made - hooked up and ready for lift off

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first attempt to lift - showing a bit of air under the downhill wheel [bighmmm]
found the engine mounts to be hanging up which meant I was trying to lifting the entire front of vehicle - so unbolted to fix
plus I adjusted the A frame up to give better leverage etc

171593

looks like its taking off

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pic of transfer case clearing

171594

big sigh of relief
engine complete with transfer case out and showing balance point

so that's is it for now - waiting on HD clutch and pressure plate kit to arrive
intend to bolt all together before attempting to put in as don't want to do it twice.
will follow the advice of Rijidij to mount gearbox up to fit / place engine mounts in right place before welding.
Also found a bit of rust that will need repair before job completion.
One thing for sure is that the engine leveler made the job easy compared to alternate method of rigging a chain block to change angles as required.

Hope you enjoy the pics

One thing that has me thinking a bit is that the Isuzu engine is heavier plus the Lt95 is heavier so hoping my set up can lift the combined weight - time will tell
planning on moving both to the front of the vehicle before joining together in order to minimise travel with the slope and all not to mention that the tight corner from the driveway is a major negotiation .

Something else I believe to be true and better mention.
Warning - any one trying to do this with a Toyota chassis think really hard before proceeding as I've heard that they bend when trying to equal the feats of a Land Rover Defender [biggrin]

[Vern]

Thanks for all replies guys

sorry to be slow to answer as have been away and sidetracked.

I just had a look at the KLR kit and appreciate the complete solution and quality etc but trying to stay to a little smaller budget (which could have an early demise)

since original post - I was talking to a diesel fitter working in a compressed air workshop and chating about my side hobby - he told me about his mate that put a Mazda BT-50 3 litre - variable vane turbo onto a 4BD1 engine fitted into a Landcruiser - tuned by ear only and was making good power with up to 30psi boost.

Would like to hear if any one has had experience or heard of this.I have done a few different turbos on 4bd1t's, garret2260 vnt, td04hl-19t, garret tb2568, garret t25 and t28.
The vnt and td04hl-19t were the best, both punching out about 30psi, but for a more realistic tune, the current tb2568 at 20psi works very well, and is standard fitment for late 4bd1t and 4bd2t. Would my my choice for a reliable and economical build.