Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover

							STEERING 157 I 
I . . ..., ..I,., ,+:::-. :~;..::!;l 26. Lubricate  and fit an 0 ring seal to the piston-rack 
cover. 
27. Fit  the  piston  cover to steering  box.  Align  the 
retaining  ring  hole 
in the  cover  with the cut-out in 
steering box housing  and insei-t hooked end of the 
retaining  ring 
in the hole.  Using  special  tool 
LST123, rotate the cover  anti-clockwise  to feed  the 
ring  into the  groove  until the ring  is  fully  seated, 
This is a reversal of instruction  3 of the dismantling 
procedure. 
., ,. . Li.. I 
ST1956M 
28. Temporarily fit the  drop  arm and secule with  the 
nut 
so that no backlash  is present  between the arm 
and  sector  shaft. 
Set the steering in the straight 
ahead  position. 
29. Fit the preload  setting tool R01016 to the input 
shaft  and  secure  with the  grub  screw. Rotate  the 
input  shaft 
in both directions  clockwise and anti- 
clockwise Y2 to 74 of a turn  to check  the backlash 
distribution. 
30. To check thc drop  arm  angular travel  for  a LHD 
drive  steering  box use the prcload  setting  tool  to 
turn the input  shaft two turns  clockwise  and one 
and  three
-quarter turns anti-clockwise. For RHD 
drive  boxes, the opposite  applies. 
3 1. Remove the  drop arm. 
32.  Return to the  straight ahead position  and screw  the 
rack  adjuster  clockwise  until 
the adjuster pad  just 
contacts  the pad. 
21  
						

							NG 57 STEER 
Fitting input shaft oii seal 
36. Using the three  part tool LST124, lubricate  a new 
seal  and slide  it, lip  side  leading,  over the conical 
seal
-savcr  to the  detachable  lower part of the tool. 
36 
ST1947M 
37,  Withdraw  the conical  seal-saver and place  the 
lower  part 
of the tool  with  the seal,  lip side 
downwards,  over the input  shaft. 
38. Place the seal-driver  part of the tool  on top  of the 
seal  and drive 
it fully  home. 
ST1948M 
39. Fit the  anti-extrustion  washer and secure  the 
assembly  with the wire  circlip. 
/ 
Fitting  sector shaft oil seal 
40. Lubricate  the oil seal  and seal-saver LST12.5, and
						

							STEERING 
/f :*-L,L3 43. Fit the drop  arm,  tab washer  and nut.  Tighten  the 
nut to 170 to 180 Nm (125 to 132 Ibs/ft). Fold one 
side 
of the tab  washer over the drop arm and the 
other  over 
a flat against the nut. 
44 Refit  the steering box to the vehicle  and blecd the 
hydraulic  system. 
1. 
NOTE: Bleeding and test of the power  steering box 
is the same  as that for the Adwest Lightweight box. 
. 
23  
						

							PRINTED IN ENGLAND BY COVENTRY  PRINTERS (2M 5/87 39051) 
ST.. ,r .:- . 
i::: . . -. ..  
						

							Land Rover 
Range  Rover 
Workshop Bulletin 
< . -:.  I 1.3 +, ..a .~ 
 AlTENTlON SERVICE  MANAGER SEPTEMBER 1987 
BULLETIN NUMBER SLR 621 EN WB2 
LAND ROVER 
- TURBO-CHARGER  MAINTENANCE 
2.5 LITRE TURBO-CHARGED DIESEL ENGINE 
Further supplies of this Bulletin  can be obtained,  free of charge, from: 
Land Rover Merchandising Service 
P.O. Box 534, Erdington,  Birmingham  B24 00s 
SERVICE Land Rover Service Division  
						

							z..: -- r. . 1, .. ..”  
						

							MAINTENANCE 
The following  supplementary maintenance schedule for 
the 2.5 litre  Turbo-Charged  Diesel  engine replaces  the 
schedule  printed  in Workshop  Bulletin 01/86 dated 
October  1986. 
10 
Daily or Weekly  depending on operating conditions, and 
at  every maintenance inspection. 
-Check  engine oil level. 
At 1,600km (1,000 miles), 10,OOkm (6,000 miles)  and 
20,000km (12,000  miles)  then  every 20,000km (12,000 
miles). 
-Check  tappets,  and adjust if required. 
Every 
40,000km (24,000 miles) 
- check  the turbo-charger boost  pressure and if below 
the  bottom  limit 
- 44cm Hg - (8.5 p.s.i.g.), clean the 
turbo
-charger  compressor  housing internally, as 
described  in the  following  pages. 
CHECKING 
BOOST PRESSURE 
Maximum  boost pressure - 50cmHg (9.7 p.s.i.g.) 
Minimum  boost pressure -44cmHg (S.5 p.s.i.g.) 
1. Disconnect,  from the turbo-charger,  the  hose to 
the  actuator  and  insert into the  free 
end a suitable 
T piece. 
2. Connect  a  short  length  of slave  hose  to the  turbo 
charger  and connect  the other  end to the 
T piece. 
3. Connect  a further  slave hose to  the third  leg of the 
T piece and  the  other end to a  pressure  gauge 
capable  of reading 
in excess  of 50cm of Mercury. 
The  pressure  gauge  hose  must be long  enough  to 
reach  into 
the cab of the  vehicle so that  the gauge 
can 
be observed  by the  driver or passenger.  4. 
To  check  the maximum  boost  pressure  drive the 
vehicle  normally  but 
in such a manner  that full 
throttle  can be maintained  whilst  climbing  a 
hill 
with the engine speed  held steady  between  2,500 - 
3,000 r.p.m. Under these circumstances,  the boost 
pressure  should  be 
betwcen 44-50 cmHg (9.7-8.5 
p.s.i.g.). If the pressure  requires  adjustment  carry 
out  the following  instructions. 
5. Taking  care  not to burn the fingers  remove  the 
retaining  clip and disconnect  the  actuator  control 
rod  from 
the waste  gate lever. 
6. Hold  the  rod with  a pair  of grips  and  release  the 
locknut. 
7.  Turn  the rod
-end,  by no more  than one  turn, 
clockwise 
to increase  the  boost pressure or anti- 
clockwise  to decrease  the pressure. 
ST1993M 
8. Rcconncct the actuator  rod to the  waste gate lever, 
&? 9. Road test the vehicle  again  and if neccssary repeat p y.;. . -.    .r 
secure with  the clip  and  tighten the locknut. 
instructions 
5 to  8. 
10. Disconncct the  test  equipment  and  reconnect  the 
hoses. 
11. If the correct  boost  pressure  range is not attained 
after  severai  attempts, 
a generai condition check  of 
the engine  should be 
undcrtaken. Examine  the  air 
intake  system  for 
damagcd pipes or a blocked  air 
filter.  Check  that the inlet  manifold  nuts  and 
bolts 
are tight  and if necessary  retorque. Examine and if 
necessary,  renew the hose  between  the  turbo- 
charger  compressor  housing and the  actuator  and 
the  boost  control  pipe  from the distributor  pump. 
Inspect  the  exhaust  system for general  condition 
and  check  that 
the joints are secure  and not 
leaking.  Check 
also that  the  hose  between  the 
1  
						

							10 
turbo-charger and inlet  manifold is satisfactory  and 
the  clips  are tight.  Check  that the four  nuts 
securing  the turbo
-charger  to the  exhaust  manifold 
are  correctly  torqued to 21
-26 (15-191bC.It). 
12. If any  defects  were found and corrected,  reconnect 
the  test  equipment  and road  test the vehicle  again. 
Should 
the boost  pressure  figure  still be 
unsatisfactory clean  the compressor housing. 
MAINTENANCE 
CLEANING  TURBO-CHARGER COMPRESSOR 
HOUSING 
Removing 
1. Remove the vehicle bonnet panel. 
2. Remove  the heat shield. 
3. Clean  the  exterior of the  turbo-charger  with a 
non
-caustic  solvent. 
4. Disconnect,  at the  turbo-charger, the air inlet  hose 
from  the air cleaner. 
5. Remove  the inlet  manifold  to turbo-charger  hose. 
6. Disconnect  the boost  control  pipe. 
8.Mark the position  of the  compressor housin kg +% li, 
relation  to  the  centre  housing with a scribe 1inc.G 
assist  reassembly. 
9.  The  circlip  retaining  the compressor  housing 
to the 
centre  housing  is tapered, 
in cross  section, on one 
side.  It is necessary  to break  the  taper to  enable 
the  circlip 
to be removed in the  usual  manner. 
Using  a flat  nosed  punch, 
carcfully tap each car of 
the circlip away  from the groove in the compressor 
housing. 
continued 
7. Remove  the clip  and  disconnect  the  actuator  rod 
from  the waste  gate lever  pin.  This  can  be 
more 
easily achieved if a pressure  of 57 to 62cm HgG (12 
to 12 Psi)  is applied  to the  actuator. 
2  
						

							MAINTENANCE 
9 
ST1988M  I  
10. Remove the circlip  using  a strong  pair of circlip 
pliers  with  well  fitting 
90 dcgrcc angle tips. 
. 11. Remove  any burrs made on the  back  plate 
clearance  diameter of 
the compressor  housing 
before removing 
it from  the  centre housing. 
_I .. . .. .. ., .!’ 
12. Withdraw  the  compressor  housing complete with 
the actuator. To avoid  damaging  the compressor 
wheel  withdraw 
the housing  squarely  without 
tilting  the housing. 
14 
ST1991M 
Hefitting 
16. Fit a ncw ‘0’ ring seal  to the back  plate. 
17. Place  the circlip in position  over the  centre housing 
with  the  tapered  side  towards  the 
rear of the 
ve  hide. 
18. Offer-up the compressor  housing,  taking  care not 
to  damage  the  compressor  wheel and back 
platc, 
and line up the  scribe marks  made before removal. 
19. Secure  the housing  with the circlip  and carefully 
tap the  ears and inner diameter  of 
the circlip with a 
flat nosed  punch to ensure  that it is fully seated in 
the groove. 
Cleaning 
13. Remove the ‘0’ ring seal  from the back plate. 
14. Clean  the intcrnal surfaces of the  compressor 
housing, 
thc compressor  wheel and back  plate  with 
;I soft brush  and a non-caustic solvent. Do not use 
compressed  air to dry  the 
comprcssor wheel  and ST1992M 
back  plate. 
damage  caused during removal. 
1c 12. PI--- LIG;tt~~ the ciiclip, ieiiiove burn, and  repair any 30. Connect  the  actuator  rod to the wastegate  lever 
and  secure  with the clip. 
continued 
3  
						

							MAINTENANCE 
-_ l 21. Connect  the boost control pipe. 
22. Fit the  inlet  manifold  to turbo  charger  hose and 
secure  with the clips. 
23. Connect the air  intake  hose and secure  with the 
clip. 
24. 
Fit the  heat  shield. 
25. Fit the  bonnet. 
26. Re-check  the boost  pressure. 
27.  If the  boost  pressure  is still  not satisfactory,  change 
1  
the actuator.  CAUTION: 
Use 
only the threaded  rod-end to make 
adjustments.  Forcing the complete  rod  in 
or out will 
change  the calibration  with the possibility 
of damaging 
engine 
boost. 
8. Screw the  rod  end  in either  direction until the rod 
end  eye 
will locate  easily over the wastegate  lever 
pin  and  secure 
with the retaining  clip. 
9. Rclcase the pressure and tighten the rod  end  luck 
nut. 
STATIC  CALIBRATION 
OF ACTUATOR 
1. Mount a dial test indicator so that  the stylus  rests 
2. Pressurise  the actuator  until the lever  moves 
RENEW  TURBO
-CHARGER  ACTUATOR 0.38 (0.015ins). At this point the pressure 
on 
the  end  of the  actuator  rod. 
should  be 
11.5 p.s.i.g. 10.5 p.s.i.g. 
3. If the pressure is higher,  slacken  the lock  nut and 
lengthen  the actuator 
rod. Should  the pressure  be 
lower,  shorten 
the rod. 
4. When the correct  pressure is achieved,  tighten the 
rod  end  lock  nut. 
1. Remove  the heat  shield. 
2. Remove  the actuator  hose. 
3.  Remove  the two  screws  securing 
thc actuator 
bracket  to the  turbo
-charger. 
4. Remove  the clip  retaining  the actuator  rod to the 
wastegate  lever pin and  withdraw  the actuator  from 
- 
the engine. 
ST2065M 
5. Fit the  replacement  actuator with the two bolts  and 
single  nut and  bolt.  Tighten  the bolts  to 12.5  to 
14.0 
Nm (111 to 124  ins Ibs.) 
6. Push the wastegate  lever as far as possible  towards 
the actuator  and apply  pressure  to keep  the lever  in 
this  position. 
7. Pressurise  the actuator  to 57 to 62cm HgG (11 to 12 
p.s.i.g.) and  hold  this pressure. 
5. Fit heat shield, 
6. Check  the boost  pressure  on the  road as previously 
described. 
PRINTFD IN FNGI ANI) HY COVFNTRY PRINWRS I1 6M9/8730658)