This 1994 Defender 90 soft top has come to us for a long list of upgrades and a conversion to 300 Tdi (turbo diesel). It will also be getting on of ECR's new hybrid galvanized chassis. The list of options and upgrades are long, with everything from a Phase 2 intercooler and an Old Man Emu lift kit going in, to additions like Air Conditioning and an updated soft top.
The first step in our frame swap process is to lift the body off the rolling chassis. Here you can see our unique system that allows us to change this D90 to a galvanized frame without having to take the entire Rover apart. The new galvanized hybrid chassis (available only from ECR) will combine all the unique safari cage and fuel tank mounts for the NAS Defender 90, and blend them with the needed mounts for the 300 Tdi!! This gives the best of everything and will make sure that this D90 will be around for a long long time to come.
The next step is to tear down the rolling chassis. As we move the axles and suspension over to the new frame we will install new suspension bushings and fixing any other item that needs service. The running boards and all the other good parts from this chassis will be installed on the new galvanized unit.
The new turbo diesel heart of this Defender 90 is ready to go. Once the axles are swapped over the new 300 Tdi with its new R380 gearbox will be installed and then the body will be lower onto the new set up.
This image shows the new galvanized chassis with some of the suspension being installed. ECR's new hybrid NAS/Tdi chassis combines everything that the unique NAS Defender chassis require, right down to the sway bar mounts and rear fuel tank as well as all the correct 300 Tdi mounts and cross members for an easy bolt in 300 Tdi.
These frames are available for your own do it yourself Defender project as well, contact us for details.
Here you can see the new galv. chassis set up with most of the D90's running gear. The 300 Tdi and R380 gearbox have been installed and all the wiring changes to run the Tdi have been made. The suspension has all new bushings installed and more. We also installed new Old Man Emu springs and Bilstein shocks, as well as an ECR HD tie rod guard and HD drag link. In the image above you can also see the exhaust system is in place. We utilize the NRP full stainless system that we combine with the Tdi head pipe for a long lasting system. At this stage the new galvanized rolling chassis with its 300 Tdi power is ready to be rolled back under the Defender 90 and be hooked up.
In this image the body has been installed onto the new drive train and is ready to be bolted down and all the systems set up, including all the changes needed for the 300 Tdi install. Some other things have been added as well. Notice that the Air Cond. condenser has been installed in front of the radiator/ intercooler as well as the door gutter kit from Badger Coachworks. We've also installed the running boards and numerous other additions at this time. Tie rod guard, OME steering stabilizer, wing top guards and ECR's turn signal conversion kit for use with the upcoming Safari Gard bumper.
This image shows the new 300 Tdi being hooked up in the NAS D90. Many things have to change to install this engine where the EFI V8 used to be, from small things such as removing the V8 air cleaner mounts from the bulkhead and relocating the power steering reservoir, to large things like wiring the glow plug system and changing the entire fuel delivery system. These jobs, large and small, are no problem for ECR and as you can see the engine bay is starting to take shape.
Some of the other additions to this D90 while it is at ECR are a new Safari Gard rear tire carrier that gives you a place for your tire, 2 fuel cans and a Hi-Lift jack. The unit is also stronger than the factory unit and offers a better departure angle, even with larger tires.
We are also adding Air Conditioning to this D90. Here you can see the interior AC set up installed. A number of things have to change in the system to fit it with the 300 Tdi, but it all works great when the custom install is complete. In this image you can also see the new Rockford-Fosgate 6" speakers that we installed. We also fitted a new Clarion head unit and sound down products where ever possible.
We added a number of electronic system to the D90, but we always want to keep a very clean and stock look to our work, so we use the correct switches for the job. Now located on the wiper motor cover are the switches for the dash illumination, the rear work light that works alone, or automatically with the reverse light, and the Allard fueling switch for "economy" mode when you need added fuel mileage with the Tdi.
Along with the correct switches, we also install the correct dash layout on all our Tdi conversions. Here you can see the correct dash binnacle that is correctly wired to run the 300 Tdi like the factory intended, no add on's or odd ball wiring here, our conversions go further than just dropping the motor in, we do the complete re-power.
This image shows the new full top, with the gutter kit that we installed on the D90. Notice how the top seals around the door tops and how large the rear windows are. These really are one of the best upgrades you can do to your Defender soft top.
This image shows a few of our new tricks. As this Defender is used on the beach a lot, the real fuel tank skid plate had completely rusted out. The Safari Gard fuel tank skid plates are made so that you can't use the rear step/tow bumper system, so we designed this new unit to replace the factory steel unit with heavy duty aluminum and still utilize the stock bumper. You can also see the NRP stainless system and get a good look at ECR's hybrid galvanized Defender chassis. The owner of this D90 will never have to worry about frame rust ever again, no matter how much beach driving he does.
Here you can see the nearly completed engine bay with the new 300 Tdi in place of the 3.9 EFI V8. Not an easy swap to be sure, but a nice clean install when everything is done. This D90 now has a simple, long lasting and fuel efficient power plant and a galvanized frame and dozens of upgrades... what could be better.
In this image you can see another of those upgrades we installed, the raised air intake. This unit will keep the air going to that new Tdi clean and will even allow for some deep water action. Unlike the EFI V8s, with this snorkel on the 300 Tdi you can really put it to good use if you desire.
Here you can see the new Safari Gard front bumper and skid plate that we installed with a Warn 9000 winch, and 2 Hella 4000 driving lights to give this D90 even more capabilities.
In this image you can see the skid plate, heavy duty drag link, ECR ROX tie rod guard (for use with sway bars) and the Old Man Emu steering stabilizer installed.We also installed and repaired dozens of things that you don't see, such as: Dual optima batteries, full rebuild of the transfer case, all new brakes, stainless steel body bolt kit, door top easy-offs, repair of the roll cage system, and much, much more.
Here is the completed project nearly ready for delivery to the owner in MA. This 1994 D90 has now been made into a long lasting trouble free machine with its galvanized frame, 300 Tdi powerplant and it also has a long laundry list of repairs and upgrades that have been made to make it even better. 28 mpg, a new chassis, long engine life and NO engine computers!! What could be better!
Let ECR know if we can help you with any of your Defender needs, from mild to wild, 300 Tdi to Pursuit 4.6, we are your custom Rover source!