Land Rover 90 110 Workshop Rover Manual

							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  
						

							48B DEFENDER GENERAL SPECIFICATION DATA n 04 

						

							p. .-.. : .!:. .d . ..I  
						

							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