Land Rover Defender 90 110 Workshop Book 1 Rover
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05 DISTRIBUTOR Rotation of rotor ................................................. Dwell angle ........................................................ Makehype. ......................................................... Contact breaker gap ............................................. Condenser capacity .............................................. Centrifugal advance range and capsule.. .................... ENGINE TUNING DATA Vacuum advance capsule range ............................... Vacuum retard capsule range.. ................................ Lucas 35D8 Anti-clockwise 26 - 28 0,35 - 0,40 mm (0.014 - 0.016 in) 0.18 - 0.25 microfarad 12-14at2300rpm 15.03 7-9at 1800rpm 1 ADR 1/20 - 4% at 10 in Hg 2 - 4 at 750 rpm 5 -Tat 20 in Hg 5- 7 at 9 in Hg 5 - 7 at 14 in Hg 1- 3 at 800 rpm Emission 2% - 4W at 10 in Hg Engines 7 - 9 at 20 in Hg 5- 7 at 9 in Hg 5- 7 at 14in Hg 36 Emission Engines I J V8 ENGINE TUNING DATA (Ninety and One Ten V8 with 5-speed gearbox and electronic ignition) - EUROPE ENGINE V8 cylinder Compression ratio.. .............................................. 8.13:l Valve timing Inlet Opens ............................................................ Closes ............................................................ Duration ......................................................... 285 Valve peak ...................................................... 112.5 A.T.D.C. 30 B .T.D. C. 75 A.B. D. C. Exhaust 68 B.B.D.C. 37 A.T.D.C. 285 105.5 B.T.D.C. CARBURETTERS Type ................................................................. Solex specification number.. ................................... 3994 Needle .............................................................. BIFK Idle speed (engine hot).. ........................................ Fast idle speed (engine hot) .................................... Mixture setting- CO at idle .................................. 2 x Solex 175 CDSE 700 to 750 revlmin (run-in engine) 550 to 650 rev/min (new engine) 1050 to 1150 rev/min 1.5 to 3% Pulsair connected IGNITION Distributor makehype.. ......................................... Direction of rotation.. ............................. ..: ........... Centrifugal advance Decelerating check with vacuum retard pipe disconnected Engine rev/min 3600. .............................................................. 2400. .............................................................. 1600. .............................................................. 1000.. ............................................................. No advance below 500 rev/min Ignition timing, dynamic; models with emission control ............................... Lucas 35 DM8 Electronic (Early Models) Lucas 35 DLM8 Electronic (Later Models) Clockwise Crankshaft angle 22 to 28 13 to 21 5 to 9 0 to 3 6 B.T.D.C. with vacuum pipes disconnected using 90-93 octane fuel -2 star rating in UK 2
,::7. , , : - ,;.,< . . . .+.: ..... ENGINE TUNING DATA 05 V8 ENGINE TUNING DATA (Ninety and One Ten V8 with 5-speed gearbox and electronic ignition) L AUSTRALIA ENGINE V8 cylinder Valve timing Inlet Compression ratio.. .............................................. 9.35: 1 Opens ............................................................ 30 B.T.D.C. Closes ............................................................ Duration ......................................................... 285 Valve peak ...................................................... 112.5 A.T.D.C. 75 A.B .D. C. Exhaust 68 B.B.D.C. 37 A.T.D.C. 285 105.5 B.T.D.C. CARBURETTERS Type ................................................................. Needle .............................................................. BIFH 2 x Solex 175 CDSE Solex specification number.. ................................... 4104 Idle speed (engine hot).. ........................................ 700 to 750 rev/min (run-in engine) Mixture setting - CO at idle .................................. ... 550 to 650 rev/min (new engine) 1050 to 1150 rev/min 2% to 3.5% Pulsair connected Fast idle speed (engine hot) .................................... IGNITION Distributor makehype.. ......................................... Direction of rotation. ............................................ Centrifugal advance Decelerating check with vacuum retard pipe disconnected Engine rev/min 2900.. ............................................................. 2400. .............................................................. 1600. .............................................................. No advance below 800 rev/min Ignition timing .................................................... Lucas 35 DM8 Electronic (Early Models) Lucas 35 DLM8 Electronic (Later Models) Clockwise Crankshaft angle 12 to 16 8 to 12 2 to 6 6 B.T.D.C. with vacuum pipes disconnected using 96 octane fuel V8 ENGINE TUNING DATA (Ninety and One Ten V8 with 5-speed gearbox and electronic ignition) SAUDI ARABIA ENGINE V8 cylinder Compression ratio.. .............................................. 8.13: 1 Valve timing (low lift camshaft) Inlet 64 A.B .D. C. Opens ............................................................ 36 B.T.D.C. Closes ............................................................ Duratien ......................................................... 280 Valve peak ...................................................... 99 A.T.D.C. Exhaust 74 B.B.D.C. 26 A.T.D.C. 119 B.T.D.C. *-\on0 LDV 3
05 ENGINE TUNING DATA 1 CARBURETTERS Type ................................................................. Solex specification number.. ................................... Needle .............................................................. Idle speed (engine hot).. ........................................ Fast idle speed (engine hot) .................................... Mixture setting -CO at idle .................................. IGNITION Distributor makehype.. ......................................... Direction of rotation.. ........................................... Centrifugal advance Decelerating check with vacuum retard pipe disconnected Engine rev/min 4600. .............................................................. 3600. .............................................................. 3000.. ............................................................. 2400., ............................................................. 1600.. ............................................................. No advance below 900 rev/min Ignition timing, dynamic; models with emission control ............................... 2 x Solex 175 CDSE 3999 BIFC 700 to 750 rev/min (run-in engine) 550 to 650 rev/min (new engine) 1050 to 1150 rev/min 1.5% to 3% Pulsair connected Lucas 35 DM8 Electronic (Early Models) Lucas 35 DLM8 Electronic (Later Models) Clockwise Crankshaft angle 21 to 25 16 to 20 12 to 16 7 to 11 1 to 3 6 B.T.D.C. with vacuum pipes disconnected using 90-93 octane fuel V8 ENGINE TUNING DATA (Ninety and One Ten V8 with 5-speed gearbox and electronic ignition) ALL COUNTRIES EXCEPT EUROPE, SAUDI ARABIA AND AUSTRALIA ENGINE V8 cylinder Valve timing (low lift camshaft) Compression ratio,. .............................................. 8.13: 1 Inlet Opens ............................................................ 36 B.T.D. C. Valve peak ...................................................... 99 A.T.D.C. Closes ............................................................ 64 A.B.D.C. Duration ......................................................... 280 Exhaust 74 B.B.D.C. 26 A.T.D.C. 280 119 B.T.D.C. CARBURETTERS Solex specification number.. ................................... 4000 Needle .............................................................. BIFQ Type ................................................................. Idle speed (engine hot).. ........................................ 700 to 750 rev/min (run-in engine) Fast idle speed (engine hot) .................................... 2 x Solex 175 CDSE 550 to 650 rev/min (new engine) 1050 to 1150 rev/min 4
ENGINE TUNING DATA SPARKING PLUGS 8.0:l compression ratio ......................................... Gap .................................................................. 0,75-0,80mm (0.029-0.032in) Champion N12Y or Unipart GSP 131 IGNITION COIL Makehype.. ........................................................ AC Delco 7992188 Primary resistance at 20°C (68°F) ............................. Consumption - ignition on at engine idle speed ......... 3.0 - 3.5 ohms 2.0 amps approx. CARBURETTER Makeltype.. ........................................................ Weber 32/34 DMTL Venturi ............................................................. Auxiliary Venturi ................................................ Main jet ............................................................. Air correction jet ................................................. Emulsion tube.. ................................................... Idle jet .............................................................. Idle CO% .......................................................... Idle speed - hot.. ................................................ Primary 24 4 110 160 €30 55 1% - 2.5% 600 - 700 rpm 2.5 LITRE PETROL ENGINE TUNING DATA ENGINE Firing order ........................................................ Compression pressure (approximately): .................... Ignition timing dynamic @ 2000 rpm ........................ Static, if no dynamic equipment available .................. Timing marks. ..................................................... Valve clearance, inlet and exhaust ........................... Valve timing: Inlet opens ...................................................... Inlet closes ...................................................... Inlet peak ....................................................... Exhaust opens.. ................................................ Exhaust closes.. ................................................ Exhaust peak ................................................... DISTRIBUTOR - LUCAS Type ................................................................. Rotation of rotor ................................................. Contact breaker gap ............................................. Dwell angle ........................................................ Centrifugal advance range ..................................... ., vacuum advance capsuie range ............................... Secondary 25 4 115 160 F30 60 1-3-4-2 11,2 kgf cm2 (160 Ibf in2) @ 300 rpm cranking speed T.D.C. disconnected On crankshaft pulley 0,25 mm (0.010 in) Engine hot 16 B.T.D.C. using 90 octane fuel with vacuum pipe 11 B.T.D.C. 47A.B.D.C. 108 A.T.D.C. 46 B.B.D.C. 18 A.T.D.C. 104 B.T.D.C. With a 0,38 mm (0.015 in) valve clearance. Nominal setting for checking only. Lucas 45D4 Anti-clockwise 0,35 - 0,40 mm (0.014 - 0.016 in) 49 - 59 0 - 1 at 500 Distributor rpm 18 - 20 at 2250 Distributor rpm 0 - M at 3.5 Hg 11 - 13 at 25 Hg U_.. , c 1. c: J 6
ENGINE TUNING DATA 105 I SPARKING PLUGS Gap .................................................................. . -, . . i .. ?::., ,..*-.I. :%;...~ ::i ..is,::-:/ 8.0: 1 compression ratio ......................................... Champion N9YC .. 0,72 - 038 mm (0.028 - 0.035 in) IGNITION COIL Makehype .......................................................... Primary resistance at 20°C (68°F) ............................. Consumption - ignition on at engine idle speed ......... 2.0 amps approx. Bosch 0221 119 368 2.9 ohms CARBURETTER Makehype. ......................................................... Weber 32/34 DMTL Needle valve.. ..................................................... 175 Venturi ............................................................. Auxiliary Venturi ................................................ Main jet ............................................................. -.: .:: Air correction jet ................................................. :. Emulsion tube.. ................................................... Idle jet .............................................................. Idle CO% .......................................................... Idle speed - hot - Non Air Conditioning.. ............... Idle speed - hot - Air Conditioning.. ..................... Float level .......................................................... ..... Primary 24 4 112 160 F30 52 1.5% k 1% 700 rpm 800 rpm k 50 rpm 7 k 0,5 mm (0.275 iz 0.019 in) Secondary 25 4 112 190 F39 60 2.25 and 2.5 LITRE DIESEL ENGINE TUNING DATA ENGINE Firing order ........................................................ Injection timing.. ................................................. Injection timing. ............................................... Inlet opens ...................................................... .. Timing marks: Valve timing .................................................... Valve clearance inlet and exhaust ......................... Valve timing: Inlet closes ...................................................... Inlet peak ....................................................... Exhaust opens.. ................................................ Exhaust closes.. ................................................ Exhaust peak ................................................... Low idle speed ................................................. High idle speed ................................................ 1-3--4---2 13 B.T.D.C. (2.25 litre Diesel) On engine flywheel and damper on 2.5 Diesel On engine flywheel and pump flange 0,25 mm (0.010 in) 16 B.T.D.C. 42 A.B.D.C. 103 A.T.D.C. 5lB.B.D.C. 13 A.T.D.C. 109 B.T.D.C. 650 5 20 rpm 4200 +- 20 rpm INJECTORS Nozzle size ......................................................... Makehype.. ........................................................ CAV Pintaux Opening pressure.. ............................................... 135 Atm BDNO/SPC 6209 or BDNO/SP 6209 ... .: . ......, ~ ,. : .... 7
ENGINE TUNING DATA HEATER PLUGS Makelt ype .......................................................... DISTRIBUTOR PUMP Makehype. ......................................................... Direction of rotation.. ........................................... Maximum speed setting (sealed) 2.25 engine .............. Maximum speed setting (sealed) 2.50 engine .............. Back leakage rate 150 - 100 Atm: New nozzle ...................................................... Original nozzle.. ............................................... Probe type, Champion CH 63 12 volt CAV DPA-2.25 DPS-2.50 type with mechanical governor and auto advance and solenoid electrical shut-off Clockwise, viewed from drive end 4200 engine rpm 4400 k 8 rpm 7 seconds 5 seconds 8
. .1. .. TORQUE WRENCH SETTINGS fi :I ......... ..... ENGINE . 2.25 litre Petrol and Diesel Nm 7 . 10 7 . 10 22 . 28 22 . 28 40 . 50 30 . 38 37 . 41 22 . 28 130 . 143 20 . 28 22 . 28 22 . 28 22 . 28 7 . 10 20 . 28 20 . 27 22 . 28 40 . 50 30 . 40 13 . 19 7 . 10 260 . 280 14 . 18 14 . 19 22 . 28 7 . 10 27 . 40 22 . 28 8 . 11 22 . 28 22 . 28 7 . 10 7 . 10 115 . 130 91 . 113 22 . 28 22 . 28 10 . 17 80 . 95 40 . 50 22 . 28 130 . 136 130 . 136 20 . 25 40 . 50 22 . 28 30 . 40 30 . 40 22 . 28 22 . 28 15 . 20 22 . 28 22 . 28 Bearing in water pump casing ................................. Breather filter to top cover ..................................... By-pass housing to thermostat housing ...................... Carburetter to inlet manifold .................................. Chainwheel pulley to camshaft ................................ Clutch cover plate to flywheel ................................. Connecting rod to cap ........................................... Fan assembly to water pump hub ............................. Fly wheel to crankshaft ......................................... Fuel pump to side cover ......................................... Heat shield bracket to manifold ............................... Heat shield to bracket ........................................... Oil strainer to mounting bracket .............................. P . clip to lifting bracket ......................................... Plug to immersion heater tapping ............................ . Oil pump cover to pump body 20 . 28 Rocker shaft to pedestal ........................................ Solenoid heat shield to manifold heat shield ............... Starter motor to housing ........................................ Sump plug to sump ............................................... Distributor clamp ................................................ Distributor to adaptor ........................................... Pulley to crankshaft .............................................. Water temperature to cylinder head adaptor .............. Spark plug .......................................................... cylinder head ................................................... Cover thermostat housing to cylinder head ................ Rocker pedestal to cylinder head ............................. Top cover to cylinder head ..................................... Alternator adjusting link to cylinder block ................. Alternator mounting bracket to cylinder block ............ Camshaft thrust plate to cylinder block ..................... Chain damper to cylinder block ............................... Cylinder head (Diesel) to cylinder block .................... Cylinder head (Petrol) to cylinder block .................... DPA injector pump (Diesel) to cylinder block ............ Distributor housing (Petrol) to cylinder block ............. ................................. Adaptor for water temperature transmitter to Lifting bracket to cylinder head ............................... Drive shafdgear to cylinder block ............................ Engine mounting foot to cylinder block ..................... Flywheel housing to cylinder block ........................... Front cover to cylinder block .................................. Main bearing cap (Diesel) to cylinder block ............... Oil feed pipe to cylinder block ................................ Main bearing cap (Petrol) to cylinder block ................ Oil filter to cylinder block ...................................... Oil pump to cylinder block ..................................... Plug oil gallery front to cylinder block ....................... Plug oil gallery rear to cylinder block ........................ Side cover to cylinder block .................................... Side cover FP mounting to cylinder block .................. Sump to cylinder block (bolts and nuts) ..................... Water pump to cylinder block ................................. Dipstick tube assembly to cylinder block ................... Ibf ft 5 . 7.3 5 . 7.3 16 . 20.6 16 . 20.6 30 . 36.8 22 . 28 27 . 30 16 . 20.6 96 . 105 14.7 . 20.6 16 . 20.6 16 . 20.6 16 . 20.6 5 . 7.3 14.7 . 20.6 14.7 . 20.6 14.7 . 20 16 . 20.6 30 . 36.8 22 . 29.5 9.5 . 14 5 . 7.3 192 . 206 10.3 . 13.2 10.3 . 14 16 . 20.6 5 . 7.3 20 . 29.5 16 . 20.6 6-8 16 . 20.6 16 . 20.6 5 . 7.3 5 . 7.3 84.8 . 95.8 67 . 83 16 . 20.6 16 . 20.6 7.4 . 12.5 59 . 70 30 . 36.8 16 . 20.6 96 . 100 96 . 100 14.7 . 18.4 30 . 36.8 16 . 20.6 22 . 30 22 . 30 16 . 20.6 16 . 20.6 11 . 14.7 16 . 20.6 16 . 20.6 1
06 ENGINE . 2.5 litre Diesel DPS pump studs to front cover ................................ DPS pump to front cover ....................................... DPS pump to support bracket ................................. Distributor pipe banjo bolts ................................... Pulley to DPS pump ............................................. Tensioner assembly .............................................. Vacuum pump .................................................... Throttle bracket to DPS pump ................................ Oil squirt to cylinder block ..................................... Throttle linkage to DPS pump ................................ Front cover to cylinder block .................................. Front cover plate to cylinder block ........................... Cover plate to front cover plate ............................... Cowl mounting bracket to front cover ....................... TORQUE WRENCH SETTINGS . Timing pointer to front cover Drain plate to front cover .... ENGINE . VS Petrol engine Alternator mounting bracket . Air intake adaptor to carbs ... ................................. ................................. ................................. o cylinder head ............ Alternator to mounting bracket ............................... Alternator to adjusting link .................................... Chainwheel to camshaft ........................................ Connecting rod bolt .............................................. Clutch attachment to flywheel ................................. Cylinder head: Outer row ....................................................... Centre row ...................................................... Inner row ........................................................ Distributor clamp bolt ........................................... Exhaust manifold to cylinder heads .......................... Fan attachment ................................................... Flywheel to crankshaft .......................................... Inlet manifold to cylinder heads .............................. Lifting eye to cylinder heads., ................................. Main bearing cap bolts .......................................... Main bearing cap rear bolts .................................... Manifold gasket clamp bolt .................................... Oil pump cover to timing cover ............................... Oil plug ............................................................. Oil relief valve cap ............................................... Oil sump drain plug .............................................. Oil sump to cylinder block ..................................... Oil sump rear to cylinder block ............................... Rocker cover to cylinder head ................................. Rocker shaft bracket to cylinder head ....................... Spark plug .......................................................... Starter motor attachment ....................................... Damper to crankshaft ........................................... Timing cover to cylinder block ................................ Tempatrol unit to water pump ................................ Water pump pulley to water pump hub ..................... X$Im+ --- ..__ ---.-- *- --.l:-A--.L- -.I v aLGi puiiip LIIIIIII~ LUVCI IU c;yllIlUCl UlOLK ................ CLUTCH . V8 Petrol engine Clutch cover bolts ................................................ Slave cylinder bolts .............................................. Nm 6-10 22 . 28 22 . 28 42 . 48 14 . 20 22 . 28 22 . 28 14 . 20 5 -7 5 -7 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 7 - 10 24 34 24 24 54 . 61 47 . 54 24 . 30 54 . 61 88 . 95 88 . 95 19 . 22 19 . 22 11, 5 74 . 81 47 . 54 24 68 . 75 88 . 95 13, 5 . 20 11 . 14 25 . 30 40 40, 6 . 47 8 -11 17, 6 . 20. 3 7 34 . 40 13, 8 . 16. 2 40, 6 . 47, 4 257 . 285 24 . 30 36 . 40 23 24 . 30 Nm 27. 5 27. 5 lbf ft 4.5 . 7.3 16 . 20.6 16 . 20.6 31 . 35.4 10.3 . 15 16 . 20.6 16 . 20.6 10.3 . 15 4 -5 4 -5 16 . 20.6 16 . 20.6 16 . 20.6 16 . 20.6 16 . 20.6 5 . 7.3 17 25 17 17 40 . 45 35 . 40 18 . 22 40 . 45 65 . 70 65 . 70 14 - 16 14 - 16 9 55 . 60 35 . 40 17 50 . 55 65 . 70 10 . 15 8.10 18 . 22 30 30 . 35 5 -8 13 . 15 5 25 . 30 10 - 12 30 . 35 190 . 210 18 . 22 27 . 30 17 18 . 22 lbf ft 20 20 .... ... g .... U ..... C 2
TORQUE WRENCH SETTINGS ... r; CLUTCH - 4-cylinder Petrol and Diesel engine Nm ; .. .. Clutch cover bolts ................................................ 30 . 38 MAIN GEARBOX (FIVE-SPEED) LT 77 mm . 4-cylinder Petrol and Diesel engine Oil pump body to extension case ............................. Clip to clutch release lever ..................................... Attachment plate to gearcase .................................. Attachment plate to remote housing ......................... Extension case to gearcase ..................................... Pivot plate .......................................................... Remote selector housing to extension case ................. Gear lever housing to remote housing ....................... Guide clutch release sleeve .................................... Slave cylinder to clutch housing ............................... Front cover to gearcase ......................................... 5th support bracket .............................................. Plunger housing to remote housing .......................... Blanking plug extension case .................................. Gear lever retainer ............................................... Yoke to selector shaft ........................................... Fixing gear lever assembly nut ................................ Reverse pin to centre plate nut ................................ Clutch housing to gearbox bolt. ............................... Plug - detent spring ............................................ Oil filter plug ...................................................... Plug oil filler - remote housing .............................. Breather ............................................................ Oil level plug ...................................................... Blanking plug - reverse switch hole ........................ Fifth gear layshaft nut ........................................... v . :: . .. Oil drain plug ....................................................... MAIN GEARBOX (FIVE-SPEED) LT85 . V8 engine Stop . 4th speed adjustment .................................. Clip to clutch releasc lever ..................................... Spring housing to top cover .................................... .. .. Plate . lower (retained with Loctite 270) .................. Slave cylinder to clutch housing .I. .... . ............................... 5th fork bracket ................................................... Front cover to bearing plate ................................... Plate - Lower (upper fixings) ................................ Selector fork to shaft and reverse beam to shaft ........... Top cover to gearbox ............................................ lst/2nd selector fork to shaft ................................... Extension case to gearbox ...................................... Extension case to gearbox ...................................... Extension case to gearbox ...................................... Extension case to gearbox ...................................... Clutch housinghearing plate/gearbox ....................... Reverse lever pivot .............................................. Gross hole/gearbox casing ...................................... Oil leveygear case ................................................ Filter plug .......................................................... Reverse light switch hole-blanking plug ..................... Switch reverse light (optional) ................................ Layshaft ............................................................ Filler/top cover .................................................... ... Drain plug .......................................................... .... .. .... .. .. 7 . 10 7- 10 7- 10 7 . 10 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 7- 10 7- 10 22 . 28 40 . 47 47 . 54 65 . 80 22 . 28 25 . 35 25 . 35 25 . 35 7- 11 25 . 35 20 . 27 204 . 231 7- 10 7- 10 7- 10 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 30 . 40 47 . 54 47 . 54 47 . 54 47 . 54 65 . 80 204 . 231 65 . 80 13, 5 . 20 25 . 35 25 . 35 65 . 80 25 . 35 133 . 20 13, 5 . 20 Ibf ft 22 . 28 5 -7 5-7 5-7 5 -7 16 .21 16 .21 16 .21 16 .21 16 .21 16 .21 16 .21 16 .21 16 .21 5 -7 5-7 16 .21 30 .35 35 .40 48 .59 16 .21 19 .26 19 .26 19 .26 5-8 19 .26 15 .20 130 .170 5-7 5 -7 5 -7 16- 21 16 .21 16 .21 16 . 21 16 . 21 16 . 21 16 . 21 22 . 30 35 . 40 35 . 40 35 . 40 35 . 40 48 . 59 150 .170 48 . 59 I0 . 15 19 . 26 19 . 26 48 . 59 19 . 26 10- 15 10- 15 3