Defender 90 rebuild newcomer

Harry2000 · Jul 24, 2022

Hello all,
Just a bit of back story. I’ve just had a new chassis put on my defender as well as a few other bits, by engineering students. However they haven’t managed to get it finished in term time so I’ve got it back home with a few jobs left to do to it ( a lot of questions very few answers)
Jobs left to do are
- exhaust gasket
- bleed brakes
-re fit trim and have so holes to fill inside
- light wiring

Which I can do all mostly myself, however I keep finding the odd questionable pipe that hasn’t got a bracket so I was just wonder how you all fit yours , cheers

(300tdi)

miktdish · Jul 24, 2022

Those pipes (steering pump flow and return) are normally held on the back the the front cross-member (below where your picture shows them)...
https://yrmit.co.uk/product/air-con-clips-land-rover-defender/

steve24v · Jul 24, 2022

I used some rubber lined p clips to fix mine when I rebuilt my 90 {as I had loads kicking about). As said above fix it on the back of xmember

Flossie · Jul 24, 2022

From memory, your old chassis would of had rivnuts which the power steering pipe clips would have bolted to. Your new chassis has probably got the holes but with no rivnuts, they need fitting after galving as galving generally wreaks them. The holes are probably hex shaped. You won't have much room there now with it all built up to get a rivnut tool in but you can do it with nuts and bolts but use aluminium rivnuts for ease.

Harry2000 · Jul 26, 2022

Thankyou can anyone tell me what these wires do?

Flossie · Jul 26, 2022

Not got a 300 but that plug looks aftermarket to me?

Harry2000 · Jul 26, 2022

Possibly is , the only engine work I know about on it is an egr delete but surely that would remove wires not add them, one of them does come from the alternator tho

miktdish · Jul 26, 2022

Harry2000 said:
Thankyou can anyone tell me what these wires do?

EGR .... If you lift the cover off the top of the e4ngine there is a temp sensor in there.
The other connector you show goes to the rheostat on the fuel pump.

Have you still got EGR ?

miktdish · Jul 26, 2022

Just looked closer at your pics ...

The EGR Rheostat on the fuel pump has been removed .... not sure what the 2 wire plug is - where is it ?

Harry2000 · Jul 26, 2022

miktdish said:
Just looked closer at your pics ...

The EGR Rheostat on the fuel pump has been removed .... not sure what the 2 wire plug is - where is it ?

The 2 wires are near the top of gearbox / handbrake drum

Harry2000 · Jul 26, 2022

miktdish said:
EGR .... If you lift the cover off the top of the e4ngine there is a temp sensor in there.
The other connector you show goes to the rheostat on the fuel pump.

Have you still got EGR ?

I don’t have an egr since I’ve owned it and no engine cover to take off?

marjon · Jul 26, 2022

Harry2000 said:
The 2 wires are near the top of gearbox / handbrake drum

Reverse switch?
Hi/Lo switch?
both in that area.

1 has 12v, 1 goes to earth?
Bridge them with a jumper and see ~~where~~ ~~the smoke comes out~~ what light comes on

J

Flossie · Jul 26, 2022

Did a 300 have egr?
Yes, as said, 2 wires will be rev switch or diff lock or maybe handbrake light, all in that area.

slomofo · Jul 26, 2022

Flossie said:
Did a 300 have egr?
Yes, as said, 2 wires will be rev switch or diff lock or maybe handbrake light, all in that area.

Yup - later model 300tdi had EGR, the control ECU lived under the centre seat. That engine bay plug connected to the EGR (now absent) on the exhaust manifold

miktdish · Jul 26, 2022

Harry2000 said:
I don’t have an egr since I’ve owned it and no engine cover to take off?

Ye, sorry, the photos clearly show it's not there ......
Is there a connector, plastic thingy in between the inlet maifold and the rocker cover, about hlf way along ?
That's the EGR temp sensor which went to the other connector.

@marjon and @Flossie have the other one sussed, I think it's the handbrake indicator ...

Harry2000 · Jul 28, 2022

So I should just tie the connectors out the way in the engine bay? And my hand brake light works so prehaps it is hi lo box switch light

miktdish · Jul 28, 2022

Yes just tie the connectors up.
There is no high/low indicator lamp but there is a LT230 diff lock (2WD/4WD) lamp ... perhaps it's that ?

Defender 90 rebuild newcomer

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