Land Rover 90 110 Workshop Rover Manual
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n e DEFENDER GENERAL SPECIFICATION DATA I04 I Tdi ENGINE Type ........................................................................\ ......... Direct injection, turbocharged, intercooled Number of cylinders ......................................................... 4 Bore ........................................................................\ .......... 90,47 mm (3.562 in) Stroke ........................................................................\ ....... 97,OO mm (3.822 in) Capacity ........................................................................\ .... 2495 cc Compression ratio ............................................................ 19.5:l +- 0.5:l Valve operation ................................................................ O.H.V. pushrod operated Turbo charger ................................................................... Carrett T25 Crankshaft Main journal diameter ...................................................... 63,475 - 63,487 mm (2.499 - 2.4993 in) Regrind dimensions .......................................................... 63,2333 . 63,246 mm (2.4895 - 2.490 in) Regrind dimensions .......................................................... 58,4708 . 58,49985 mm (2.30200 . 2.30275 in) Crankshaft end thrust ....................................................... Taken on thrust washers of centre main bearing Crankshaft end float ......................................................... 0,05 . 0,15 mm (0.002 - 0.006 in) Use 0.010in U/S bearings Crankpin journal diameter ................................................ 58,725 - 58,744 mm (2.312 - 2.31275 in) Use 0.010 in U/S bearings 1 Main bearings Number and type ............................................................. 5 halved shells with oil grooves Diametrical clearance ........................................................ 0,0792 - 0,0307 mm (0.0031 - 0.0012 in) Connecting rods Length between centres ................................................... 175,38 - 175,43 mm (6.905 - 6.907 in) Diametrical clearance (big-end bearings) .......................... 0,025 . 0,075 mm (0.001 . 0.003 in) End float on crankpin ....................................................... 0,15 - 0,356 mm (0.006 . 0.01 4 in) Pistons Type ........................................................................\ ......... Aluminium alloy, combustion chamber in crown Skirt diametrical clearance Maximum height above combustion face ........................ 0,8 mm (0.031 in) Gudgeon pins (at right angle to gudgeon pin ......................................... 0,025 . 0,05 mm (0.001 . 0.002 in) Type ........................................................................\ ......... Floating Fit in piston ...................................................................... Hand push in Diameter ........................................................................\ ... 30,1564 - 30,1625 mm (1.1 8726 - 7.1 8750 in) Clearance in connecting rod ............................................ 0,0036 - 0,0196 mm (0.00014 - 0.00077 in) Pistons rings Type . Top ........................................................................\ ........ Chamfered friction edge, chrome plated . Oil control ..................................................................... Expander ands rails - Second ........................................................................\ ... Taper faced Cap in bore: - Top ........................................................................\ ........ 0,40 . 0,65 mm (0.0157 . 0.0255 in) - Second ........................................................................\ ... 0,30 - 0,50 mm (0.0118 - 0.0196 in) - Oil control ..................................................................... 0,3 - 0,6 mm (0.011 . 0.023 in) Clearance in piston grooves: . Top ........................................................................\ ........ 0,167 . 0,232 mm (0.0065 - 0.0091 in) . Second ........................................................................\ ... 0,05 . 0,08 mm (0.0019 . 0.0031 in) . Oil control ..................................................................... 0,05 . 0,08 mm (0.0019 . 0.0031 in) -:. :.,a: i. I : , 9
04 Camshaft GENERAL SPECIFICATION DATA e DEFENDER Timing Belt ....................................................................... \ Location ........................................................................\ ... End float ........................................................................\ ... Number of bearings ......................................................... Material ........................................................................\ .... Valves Tappet clearance: . Inlet and exhaust ............................................................ Seat angle: . Inlet ........................................................................\ ........ - Exhaust ........................................................................\ ... Head diameter: . Inlet ........................................................................\ ........ . Exhaust ........................................................................\ ... Stem diameter: - . Inlet ........................................................................\ ........ - Exhaust ........................................................................\ ... Valve lift: . Inlet ........................................................................\ ........ . Exhaust ........................................................................\ ... Cam lift . Inlet ........................................................................\ ........ . Exhaust ........................................................................\ ... Valve head stand down - Inlet and exhaust ............................................................ Valve spring length fitted ................................................. lubrication System ........................................................................\ ...... Pressure, engine warm at normal operating speeds .................................................. Oil pump: - Type ........................................................................\ ....... - Drive ........................................................................\ ...... - End float of both gears .................................................. - Radial clearance of gears ................................................ - Backlash or gears ........................................................... Oil pressure relief valve .................................................... Relief valve spring: - Full length ...................................................................... - Compressed length at 2.58 kg (5.7 Ib) load .................. Oil filter ........................................................................\ .... Engine oil cooler .............................................................. 30 mm (1.2 in dry toothed belt Right hand side (thrust side) 0,l - 0,2 mm (0.004 - 0.008 in) 4 Steel shell, white metal lined 0,20 mm (0.008 in) 30 45 O 39,35 - 39,65 mm (1.549 - 1.560 in) 36,35 - 36,65 mm (1.431 - 1.443 in) 7,960 - 7,975 mm (0.313 - 0.314 in) 7,940 - 7,960 mm (0.212 - 0.313 in) 9,93 mm (0.401 in) 10,26 mm (0.404 in) 6,81 mm (0.268 in) 7,06 mm (0,278 in) 0,9 - 1,l mm (0.035 - 0.040 in) 40,4 mm (1.590 in) at pressure of 29.5 kg (65 Ib) . Wet sump, pressure fed 25 - 55 p.s.i. (1.76 - 3.86 kgf/cm2) Double gear 10 teeth, sintered iron gears Splined shaft from camshaft skew gear 0,026 - 0,135 mm (0.0009 - 0.0045 in) 0,025 - 0,075 mm (0,0034 - 0.0067 in) 0,l - 0,2 mm (0.0034 - 0,0067 in) Non-adjustable 67,82 mm (2.670 in) 61,23 mm (2.450 in) Screw -on disposable canister Combined with coolant radiator and intercooler ...... (-?$ ........ .. .- . .- 10
e DEFENDER ENGINE TUNING DATA 105 Tdi ENGINE TUNING DATA . i-. 3 1.. ENGINE Firing order ....................................................................... \ 1-3-4-2 injection pump timing ...................................................... 1,54 mm lift at T.D.C. Timing marks: Valve timing ...................................................................... Slot for peg in flywheel and TDC mark on front injection timing ................................................................ Statically timed with special tool inserted in Bosch Tappet clearances inlet and exhaust ................................. 0,20 mm (0.008 in) cold Valve timing: inlet Exhaust . Opens ........................................................................\ .... 16 B.T.D.C. . Closes ........................................................................\ .... 42 A.B.D.C. . Peak ........................................................................\ ....... 103 A.T.D.C. 109 B.T.D.C. . Lift ........................................................................\ .......... 9,93 mm (0.401 in) Maximum governed speeds: pulley pump hub 51 B.B.D.C. 13 A.T.D.C. 10,26 mm (0.404 in) . Full load (speed cut-off starts) ....................................... 3800 r.p.m. . No load (flight speed) .................................................... 4100 . 4260 r.p.m. .. Idle speed ...................................................................... 780 . 800 rpm . .... INJECTION PUMP Makeltype ........................................................................\ . Bosch rotary VE 411 1 F 1900R 347-1 Type with boost control and negative mechanical torque control. Two speed mechanical governor with speed advance and solenoid electrical shut -off. Tamper proof sealing on flight speed and fuel adjustment screws Direction of rotation ........................................................ Clockwise, viewed from drive end Advance box (single stage) .............................................. 9 advance (7.38 mm) Peak pumping pressure .................................................... 650 bar INJECTORS Makeltype ........................................................................\ . Bosch two spring (04321 93879 assembly number) Nozzle sizeltype ............................................................... DSLA 145P208 Nozzle holder ................................................................... KBEL 98 P52 Opening pressure (working pressure) .............................. initial pressure 200 atmospheres Secondary 280 atmospheres injector pipe type ............................................................. Guido high pressure cold drawn steel Injector pipe size .............................................................. 1,8 mm dia. Length 490 mm . ... ,. I. . .. , . , HEATER PLUGS Makeltype ........................................................................\ . Probe type, Beru 11 volts Time to reach operating temperature of 850°C ............... 8 seconds TURBOCHARGER Makeltype ........................................................................\ . Carrett T25 Maximum boost pressure ................................................. 0.82 bar (12 P.S.I.C.) measured at wastegate Fuel specification .............................................................. Diesel 852869 (certain levels down to 45 with actuator T piece adjustment 13
n e DEFENDER TORQUE WRENCH SE~TINGS 106 I Tdi ENGINE Bearing cap to cylinder block ................................... Camshaft thrust plate to cylinder block .................... Clutch cover plate to flywheel ................................. Connecting rod to cap ............................................. Dipstick tube assembly to cylinder block ................. Dipstick mounting bracket to inlet manifold ............ Earthing strap stud to cylinder block ........................ Engine mounting foot to cylinder block ................... Housing flywheel to cylinder block .......................... Flywheel to crankshaft .............................................. Oil filter adaptor to cylinder block ........................... Oil pressure switch ................................................... Oil pump cover to pump body ................................ Oil pump relief valve plug ........................................ Oil pump to cylinder block ...................................... Oil pump strainer to oil pump ................................. Oil squirt jet assembly to cylinder block .................. Plug - blanking oil gallery ......................................... Plug - drain oil sump ................................................ Plug . drain cylinder block ........................................ Plug - drain flywheel housing ................................... Plug . inlet manifold (boost take-off) ....................... Side cover to cylinder block ..................................... Sump to ladderframe ................................................ Ladderframe to cylinder block .................................. * Oil strainer to mounting bracket .............................. Starter motor to flywheel housing ............................ Sump to ladderframekylinder block ......................... Sump to cylinder blocUfront cover .......................... Support brackets - exhaust manifold to cylinder block ........................ Vacuum pump to cylinder block .............................. Vertical drive shaft gear to cylinder block ................ Alternator and heat shield to mounting bracket ....... Cylinder head to cylinder block ............................... Adjusting link to alternator ....................................... Adjusting link to pas pump plate .............................. Breather cylcone to rocker cover ............................. Engine lifting bracket to cylinder head ..................... Electrical hamess clip to cylinder head ..................... Exhaust manifold to cylinder head ........................... Glow plug terminal nut ............................................ Glow plug to cylinder head ...................................... Heater stud (water) to cylinder head ........................ Injector clamp stud to cylinder head ........................ Injector clamp to injector nut ................................... Inlet manifold to cylinder head ................................ Rocker cover to cylinder head .................................. Rocker shaft to cylinder head ................................... Tappet adjusting nut ................................................. Thermostat housing to cylinder head ....................... Water outlet to thermostat housing ......................... Cowl mounting bracket to front cover ..................... Fan assembly to water pump hub ............................ Front cover plate to cylinder block .......................... Front cover plate to front cover ............................... Front cover to cylinder block ................................... Injector pump stud to front cover ............................ water temperature switch to thermestat heusing .... injector pump to front cover ................................... Nm 130 .136 7-10 30 .38 56 .62 22 .28 7-10 21 .30 80 .90 40 .50 139 .153 22 .28 40 .50 15 .19 20 .28 27 .33 22 .28 40 .50 14 .20 22 .28 32 .42 40 .50 25 10 .14 23 .27 23 .30 40 .50 22 .28 22 .28 20 .24 22 .28 22 .28 22 .28 22 .28 22 .28 22 .28 See section 12 7-10 22 .28 22 .28 20 .26 3-5 15 .30 15 .30 6-10 20 .25 20 .26 3, 5 . 4, 5 28 .32 22 .26 22 .28 7 .10 75 .73 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 22 . 28 6 -10 15
Tdi ENGINE (continued) Injector pump to support bracket ............................ Tensioner (timing belt) to cylinder block ................. Timing pulley to camshaft ........................................ Timing pulley to injector pump hub ......................... lV damper pulley to crankshaft ................................ Water pump to cylinder block .................................. Water pump to cylinder block - stud ....................... Water pump to front cover ...................................... Oil drain adaptor to cylinder block - Turbo .............. Oil drain pump to turbo ........................................... Oil feed pipe to turbo .............................................. Outlet elbow to turbo - nut ..................................... Outlet elbow to turbo - stud ................................... Turbocharger to exhaust manifold ........................... Belt tensioner assembly to front cover plate compressor ............................... Compressor to mounting bracket ............................ to front cover and plate ........................................... Banjo bolt - fuel pump ............................................. Banjo bolt - boost pipe ............................................ Banjo bolt - spill rail ................................................. Banjo bolt - fuel filter ............................................... Banjo bolt - injector spill rail .................................... Fuel lift pump to fuel filer unions ............................. Fuel lift pump to cylinder block ............................... P.A.S. pump to mounting plate ................................ P.A.S. pump mounting plate to front cover ............. P.A.S. pump pulley to hub ....................................... Tappet guide retaining screw ................................... Oil feed pipe adaptor to cylinder block . Turbo ...... - Compressor mounting bracket Injector pipes to injectors and injector pump .......... Nm 22 .28 40 .50 40 .50 22 .28 333 .350 23 .30 23 .30 22 .28 22 .28 32 .48 22 .28 15 .22 21 .26 22 .28 21 .26 14 .16 40 .50 40 .50 10 .14 8 . 12 20 .30 14 .20 2 10 .14 22 .28 22 .25 14 .16 22 .28 14 .16 13 .15 (!?: .... ..... :: . Y ..... &.~ ...% i 16
e DEFENDER Oils must meet BLS.22.OL. 09 or RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES 109 I -30 -20 -10 0 10 20 30 40 50 5Wf30 I 5Wi40 ) 5Wt50 1 .;:. CCMC PD1 or CCMC D3 The engine oil and filter must be changed every 10,000 km (6000 miles) and it is important that only oils listed below, or clearly marked as meeting the required specification, should be used. Superior engine protection can be obtained by the use of Super High Performance Diesel (SHPD) oils to specification CCMC D3. Some of the oils meeting the above specifications are listed below:- 1 Owl30 10Wi40 ) 10W150 ) 15Wl40 ) 15Wt50 ) 20Wf40 ) -+- Oils to BLS 22.OL.09tCCMC PD1 Agip Superdiesel or Sint Turbo Diesel BP Vanellus C3 or Visco Diesel Caltex RPM Delo 400* Castrol Syntron X, TXT, Dynamax or GTX Century Superb Duckhams QXR or Hypergrade Esso Superlube EX 2, Superlube +, Ultra Oil or Super Oil Gulf Super Diesel or Engine Oil T Mobil Delvac Super, Mobil 1 Rally Formula or Mobil 1 Formula 15Wl50 Kuwait Q8 Auto-4 or Q8 Auto-7 Shell Rimula X or Rotella MTX Texaco Dieseltex SHPD oils to CCMC D3 Agip Sigma Turbo BP Vanellus C3 Extra Castrol Turbomax Century Centurion Caltex RPM Delo 450 Duckhams Fleetmaster SHPD or Fleetmaster Extra Elf Multiperformance 4D Esso Super Diesel Oil TD or Special Diesel Oil Fina Kappa LDO Gulf Superfleet Special Mobil Delvac 1400 Super Texaco Ursa Super TD Shell Myrina Total Rubia TIR or Total Diesel Silkolene Turbolene D In markets where oils to the above specifications are not available use products to MIL-L-2104D or API CD. Under severe operating conditions, eg. off road in mud, airborne sand, dust, operating at high speeds in high ambient temperatures above 40°C or continual stoptstart operation, the oil and filter change period should not exceed 5000 km (3000 miles). Continuous off road operation in mud, dust and wading conditions requires a monthly oil and filter change. Failure to adhere to the recommended service and operating instructions may result in premature engine wear or damage. Oil Viscosity - Ambient Temperatures Applications Chart I AMBIENT TEMPERATURE C I !jAE vscosTy I SPECIFICATION 17
CAPACITIES The following capacity figures are approximate and are provided as a guide only. All oil levels must be set using the dipstick or level plugs as applicable. Engine sump oil ................................................................ 6,OO litres (10.56 pints) Transfer box oil ................................................................ 2,30 litres (4 pints) Cooling system ................................................................ 11,lO litres (20 pints) Extra when filling following new filter .............................. 0,85 litres (1.50 pints) Anti-freeze Ethylene Glycol based anti-freeze (containing no methanol) with non-phosphate corrosion inhibitors only are suitable for use in Tdi engines to ensure protection of the cooling system against frost and corrosion. No inhibitors should be used. Only anti-freeze, summer and winter even in climates where anti-freeze is not necessary. One part anti -freeze, one part water, i.e. 50% anti-freeze in coolant. Complete protection below -36°C. ~ See cooling system section 26 for engine protection information. 18