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Defender 90/110 Puma LS3 & 6L80 Conversion Kit
A complete UK-spec powertrain package engineered to replace the 2.2/2.4 Puma diesel with a 6.2-litre Chevrolet Performance LS3 V8 and 6L80 six-speed automatic, retaining the LT230 transfer case and full 4x4 functionality. Built for British roads, British workshops, and serious Defender builds.
Why LS3 & 6L80 is the ultimate Defender conversion
Defender owners across the UK are increasingly replacing the ageing Puma diesel with modern V8 power. The LS3 and 6L80 pairing has become the go-to powertrain package as it delivers the drivability, refinement, and long-distance comfort the Defender platform has always lacked, while remaining mechanically straightforward, globally supported, and highly reliable. This conversion is engineered for everyday use: taking the dogs for a walk, towing, touring, overtaking, and daily driving.
The LS3 430 bhp output transforms the Defender while maintaining OEM-like idle quality and low-speed manners. The 6L80 contributes adaptive shift logic, twin overdrive ratios for efficient motorway cruising, and robust internal architecture designed for high torque vehicles. Because this package retains the LT230 transfer case, your Defender keeps its off-road capability, centre diff lock, and familiar control layout.
Huge power increase
Approx. +300 bhp over the factory TDCi, with broad torque and effortless acceleration.
Designed for UK Defenders
Components chosen specifically for right-hand drive packaging, LT230 geometry, and typical British usage.
Long-term reliability
Brand-new GM, Holley, Marks 4WD and Dakota Digital parts. No rebuilt or unknown-history units.
B2C & B2B ready
Ideal for owner-install projects or repeatable workshop conversions, we supply to both.
Complete LS3 and 6L80 Conve...
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LS3 6.2-litre V8 – 430 bhp of modern reliability
The Chevrolet Performance LS3 crate engine is the heart of this conversion. A factory-fresh 6.2-litre aluminium V8 producing 430 bhp and 576 Nm, it offers a balance of power, refinement, and parts availability that suits both daily-driven and specialist Defenders. Its compact dimensions fit the Defender bay cleanly, and its lightweight aluminium block reduces front axle load compared with many traditional cast-iron V8s.
- 430 bhp @ 5,900 rpm, 576 Nm @ 4,600 rpm
- High-flow L92 cylinder heads and performance hydraulic roller camshaft
- Supplied complete with intake manifold, throttle body, injectors, rails and coils
- Drive-by-wire operation for crisp throttle response and easy integration
- Factory reliability with global GM parts support
Upgrades available: 495 bhp and 525 bhp LS3 variants are available for higher-output builds while retaining identical fitment.
6L80 six-speed automatic – modern driveability
The GM 6L80 is an electronically controlled six-speed automatic used in performance cars and high-torque trucks. Its adaptive shifting, wide ratio spread, and twin overdrive gears deliver refined on-road behaviour and improved efficiency compared with older automatic conversions.
- Brand-new SuperMatic 6L80E
- Approx. 2400 rpm stall torque converter for smooth take off without excess slip
- Robust internals suited for 430+ bhp applications
- Wide-ratio gearing for both low-speed work and relaxed motorway cruising
- Includes LS3-to-6L80 installation kit and full installation hardware.
Supplied with a service dipstick and tube so fluid levels can be checked and maintained like a conventional gearbox.
6L80–LT230 adaptor & Defender-specific mounts
The UK Specific adaptor system aligns the GM powertrain with the Defender drivetrain so that the LT230 remains in the correct location and driveline angles stay within specification. The result is a mechanically neat installation that respects the Defender chassis. The majority of readily available kits are designed for Left Hand Drive Defenders. When used on a UK car, these cause issues with steering column interference with headers, ours is designed to fit.
- Precision 6L80–LT230 adaptor housing with seals, bearings and alignment dowels
- 32-spline interface shaft for secure torque transfer to the LT230
- Defender-specific weld-in engine mounts for the LS3
- Transmission and transfer case mounting hardware included
- Supports the factory crossmember layout and driveline geometry
Engine management & CAN-integrated instrumentation
A genuine GM LS3 controller kit manages fuel, spark and shift logic for both the engine and the 6L80. This is paired with a Dakota Digital VHX cluster and CAN interface so that the Defender receives accurate, modern instrumentation without extensive sensor duplication.
- Pre-programmed GM ECU for LS3 with integrated 6L80 control
- Labelled retrofit wiring harness for retrofit applications
- OBD-II diagnostics port for fault reading and future calibration work
- Dakota Digital VHX cluster with analogue-style needles and configurable backlighting
- OBD/CAN bridge module to bring ECU data directly into the cluster
Cooling system – built for heavy UK use
A high-capacity Defender V8 radiator forms the backbone of the cooling package, paired with flex and moulded hoses and correct heater integration. The layout is intended for slow off-road work, towing, and long-distance road use.
- Four-row Defender V8 radiator without internal oil cooler
- Polished 24 inch flex upper hose with silicone ends for routing flexibility
- 90 degree elbow adapter to avoid hose kinking in tight spaces
- Moulded lower hose based on Defender V8 pattern
- Heater hose adapters (three-quarter to three-quarter and five-eighths to three-quarter)
Electric fan and shroud solutions can be specified separately and controlled by the LS3 ECU fan output.
Fuel system conversion to EFI
The Puma diesel system is replaced with a high-pressure in-tank petrol pump and appropriate wiring and hoses, delivering a stable feed to the LS3’s returnless rail at approximately 58 psi.
- High-pressure in-tank EFI pump suitable for modern unleaded and E10
- Fuel pump strainer and Defender-specific wiring pigtail
- Submersible corrugated 8 mm hoses from pump to top plate
- Returnless regulation compatible with Corvette-style filter/regulator assemblies
- Engine bay 3/8 inch quick-connect adaptation to LS3 fuel rail
Exhaust – LS block hugger manifolds
Compact cast-iron block huggers provide reliable clearance of the chassis rails, footwells, and right-hand drive steering shaft while giving a solid foundation for a custom stainless system.
- Cast iron manifolds with 2.5 inch outlets
- Designed for tight Defender engine bay packaging
- Support for oxygen sensor mounting close to the outlets
- Suitable for fabrication into bespoke twin or single systems
Shifter & cabin controls – precision and familiarity
The 6L80 is operated using a floor-mounted shifter designed to appear correct within a Defender cabin. The gated layout provides precise mechanical engagement, while the 72 inch cable offers a smooth, durable linkage suitable for Defender routing.
- 6L80 shifter with 8 inch single-bend lever and brushed mushroom knob
- Positive PRNDL gating with reverse and park lockout
- Heavy-duty 72 inch shifter cable with correct end fittings
- Supported reverse light and neutral safety integration
- Suitable for Defender tunnel and centre-console locations
Accessory drive, A/C compatibility & finishing components
The Holley accessory system establishes reliable alternator and power steering operation, packaged to avoid interference with the Defender bonnet and inner wings. Additional components support retention or addition of full cabin air conditioning.
- Holley low-mount alternator and power steering system (HLY-20-156)
- 150 Amp alternator suited to auxiliary electrical loads
- GM Type-II power steering pump calibrated for Defender steering characteristics
- Holley A/C compressor bracket and installation kit
- LS-series starter motor and correct mounting bolts
- LS3 straight intake tube and filter assembly
- Red Corvette LS3 fuel rail covers with mounting studs for a clean engine bay
Who this conversion kit is designed for
This complete LS3 and 6L80 package is engineered for a wide range of Defender owners and specialists across the UK. Whether the project is a daily-driven 90, a long-wheelbase 110 tourer, or a high-value bespoke commission, the system is designed for predictable, professional integration.
- Defender owners: A coherent package that removes uncertainty and component mismatch when upgrading from the Puma diesel engine.
- UK garages and workshops: A repeatable, kit of proven parts designed for reliable installation processes.
- Performance and restoration specialists: An OE-grade powertrain with support for modern instrumentation and refined road manners.
- Export builders: A globally recognised engine platform with wide parts availability and straightforward ongoing maintenance.
Technical specification summary
| System | Key components | Representative SKUs |
|---|---|---|
| Engine | LS3 6.2L crate, 430 bhp, DBW throttle, high-flow heads | |
| Transmission | 6L80 2WD with converter, install kit, dipstick and tube | |
| Adaptor & mounts | 6L80–LT230 adaptor, Defender weld-in mounts | |
| Electronics | GM controller, OBD-II, Dakota VHX cluster with CAN bridge | |
| Cooling | Defender V8 radiator, flex and moulded hoses, adapters | |
| Fuel | In-tank EFI pump, strainer, pigtail, submersible hoses | |
| Exhaust | Cast block-hugger manifolds, 2.5 inch outlets | |
| Controls | Shifter, PRNDL gating, heavy-duty 72 inch cable | |
| Ancillaries | Holley low-mount drive, A/C brackets, starter, intake, dress covers |
Your LS3 Defender conversion starts here
Whether you are preparing a high-end restoration, undertaking a personal upgrade project, or delivering repeatable workshop conversions, this complete LS3 and 6L80 bundle provides every primary component required for a modern V8 Defender.