This 1995 Land Rover Defender 90 came to us with a familiar but serious complaint—overheating. A blown head gasket had compromised the engine, and with that failure came the need for a full rebuild of the cylinder heads and a complete cooling system overhaul.

The Cylinder Head and Cooling System

We tore into the top end, removing the heads, resurfacing them, and restoring every sealing surface to factory spec. A fresh top-end gasket set was installed, valves inspected, and compression brought back where it belonged. To protect that work, we renewed the entire cooling system: a new water pump, thermostat and housing, and a viscous fan clutch were fitted to ensure steady temperatures no matter the terrain.

More Than Just the Engine

While the Defender was in our hands, we addressed the rest of the mechanicals that time had worn down. The air conditioning system, long neglected and no longer blowing cold, was repaired and recharged. Electrical gremlins—lights, relays, and grounding issues—were sorted out to restore reliability. Even the rolling stock got attention, with new all-terrain tires mounted, balanced, and torqued down properly.

Back to Full Strength

After weeks of meticulous work, this Defender 90 is back on the road with confidence. The engine now runs cool, the AC blows cold, the electrics function as they should, and the truck rides on fresh rubber. What began as a single overheating complaint became a comprehensive rejuvenation—one that ensures this Rover is ready for many more years of service, adventure, and the occasional trail.

At Legacy Motorworks, every repair is an opportunity to return an icon to its prime.