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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  
    						
    							48B DEFENDER GENERAL SPECIFICATION DATA n 04 
    
    						
    							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  
    						
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