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Land Rover 90 110 Workshop Rover Manual

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Page 637 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 ...........................

Page 638 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...

Page 639 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...

Page 640 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...

Page 641 e DEFENDER ENGINE 11 2 I
... .. I., ;:,:;i 1’ . . - ... , . . . . , ,
ST3121 M
~I .,.. :, ... ... .. . ..._ .. .
19

Page 642 12 ENGINE e DEFENDER
_I
CLUTCH AND FLYWHEEL HOUSING
LAND ROVER Tdi engine
COMPONENTS
ST3066M -
I.
Clutch housing
2. Bell housing stud (9)
3. Starter motor stud (1)
4. Allen bolts (4)
5. Plug (2)
6. Screw housing to block (6)
7. Washer (6)
8. Bolt housing to block (2)
9. Spring washer (2)
10. Bracket (2)
11. Harness clip (2)
12. Oil seal
13. Flywheel
14. Starter ring
15. Reinforcing plate
16.
Bolt flywheel to crank
17. Clutch cover
18. Clutch plate
19. Dowel...

Page 643 .
DEFENDER ENGINE 12
3
ST3066M
21

Page 644 12
SUMP AND OIL PUMP COMPONENTS ST3065M -
LAND ROVER Tdi engine
ENGINE DEFENDER
1. Sump
2. Drain plug
3. Joint washer
4. Flange bolt M8x20 (8)
5. Flange bolt M8x60 (1 2)
6.
Oil pump housing lower
7. Oil pump housing upper
8. Dowel
9. Oil pump gears
10. Spindle
11. Screw
12. Spring washer
13. Support bracket
14. Screw
15. Lock washer
16. Casket
17.
Filter
18. 0 ring
19. Lock washer
20. Screw
21. Spring washer
22. Plain washer
23. Drive shaft
24.
Oil relief...

Page 645 -DEFENDER ENGINE n 12
.-:.:. < ,. . . ,.. ,+ . : ,,.,x2.;:,, ,I. .. ,1: .,~. .._ .. ... .
16
. .,
24
ST3065M

4
4
5
23

Page 646 e DEFENDER
FRONT COVER COMPONENTS ST3064M - LAND
ROVER Tdi engine
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
- 17.
7 8.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Viscous unit
Fan
assemb!y
Bolt (4)
Plain washer (4)
Pulley
Screw
(4)
Spring washer (4)
Water pump assembly
Gasket Flange
bolt M8x85 (2)
Flange bolt M8x75 (1)
Flange screw...

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							e DEFENDER ENGINE 11 2 I 
... .. I., ;:,:;i 1’ . . - ... , . . . . , , 
ST3121 M 
~I .,.. :, ... ... .. . ..._ .. . 
19

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							12 ENGINE e DEFENDER 
_I 
CLUTCH AND FLYWHEEL  HOUSING 
LAND  ROVER  Tdi engine 
COMPONENTS 
ST3066M - 
I. 
Clutch  housing 
2. Bell housing  stud (9) 
3. Starter motor stud (1) 
4. Allen bolts (4) 
5. Plug (2) 
6. Screw housing  to block (6) 
7. Washer (6) 
8. Bolt  housing  to block (2) 
9. Spring  washer (2) 
10. Bracket (2) 
11. Harness  clip (2) 
12. Oil seal 
13.  Flywheel 
14.  Starter  ring 
15. Reinforcing  plate 
16. 
Bolt flywheel  to crank 
17.  Clutch  cover 
18. Clutch  plate 
19.  Dowel 
20.  Screw 
21. Spring  washer 
$! ... .., -->d 
2n

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							. 
DEFENDER ENGINE 12 
3 
ST3066M 
21

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							12 
SUMP AND OIL PUMP COMPONENTS ST3065M - 
LAND ROVER Tdi engine 
ENGINE DEFENDER 
1. Sump 
2. Drain plug 
3. Joint washer 
4. Flange  bolt M8x20 (8) 
5. Flange  bolt M8x60 (1 2) 
6. 
Oil pump  housing  lower 
7. Oil pump housing  upper 
8.  Dowel 
9. Oil pump  gears 
10. Spindle 
11. Screw 
12. Spring  washer 
13. Support  bracket 
14.  Screw 
15. Lock  washer 
16. Casket 
17. 
Filter 
18. 0 ring 
19. Lock  washer 
20.  Screw 
21. Spring  washer 
22.  Plain  washer 
23.  Drive  shaft 
24. 
Oil relief plunger 
25.  Spring 
26.  Joint  washer 
27. Oil relief plug 
22

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							-DEFENDER ENGINE n 12 
.-:.:. < ,. . . ,.. ,+  . : ,,.,x2.;:,, ,I. .. ,1: .,~. .._ .. ... . 
16 
. ., 
24 
ST3065M 
 
4 
4 
5 
23

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							e DEFENDER 
FRONT COVER  COMPONENTS ST3064M - LAND 
ROVER Tdi engine 
1. 
2. 
3. 
4. 
5. 
6. 
7. 
8. 
9. 
10. 
11. 
12. 
13. 
14. 
15. 
16. 
- 17. 
7 8. 
19. 
20. 
21. 
22. 
23. 
24. 
25. 
26. 
27. 
28. 
29. 
30. 
31. 
32. 
33. 
34. 
35. 
36. 
37. 
38. 
39. 
40. 
41. 
42. 
43. 
44. 
45. 
46. 
47. 
48. 
49. 
50. 
51. 
Viscous  unit 
Fan 
assemb!y 
Bolt (4) 
Plain  washer (4) 
Pulley 
Screw 
(4) 
Spring  washer (4) 
Water pump assembly 
Gasket  Flange 
bolt M8x85 (2) 
Flange  bolt M8x75 (1) 
Flange screw M8x35 (3) 
Stud M8 
Flange  nut M8 
By pass  hose 
Hose 
clip 
Crank  pulley 
Flange  bolts 
(4) 
Crank pulley bolt 
Washer 
Torsional  vibration damper 
Inspection  plate 
Gasket  Flange  screw 
M6x20 (3) 
Front cover  plate 
Gasket 
Cover  plate seal 
Flange  screw 
M8x25 (3) 
Flange bolt M8x100 (2) 
Flange  bolt M8x70 (2) 
Flange bolt M8x75 (3) 
Flange bolt M8x50 (1) 
Front cover 
Front cover  gasket 
Front 
covedwater inlet  gasket 
Front  cover  dowel 
Flange  screw 
M8x20 (2) 
Flange bolt M8x65 
Crankshaft oil seal 
Camshaft 
oil seal 
Gasket 
- centre  bolt 
Gasket 
- block  front face 
Timing  belt 
Timing  belt tensioner  assembly 
Slotted  washer 
Flange  bolt 
M10x70 
Tensioner  pivot pin 
Crankshaft  gear wheel 
Camshaft  gear wheel 
Bolt 
Plug 
52. Washer 
53. 0 ring 
54. Retaining  plate 
55. 
0 ring 
56. Injection  pump timing  gear 
57. Flange screw (3) 
58. Retaining  plate 
59. Nut 
60. Spring washer (3) 
61. Stud injection  pump to front  cover (3) 
24

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							DEFENDER ENGINE 11 2 
. 
25

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							12 
CYLINDER BLOCK COMPONENTS ST3063M - 
LAND ROVER Tdi engine 
ENGINE a DEFENDER 
1. 
2. 
3. 
4. 
5. 
6.  7. 
8. 
9. 
10. 
11. 
12. 
13. 
14.  15. 
16. 
. 17. 
18. 19. 
20. 
21. 
22. 
23. 
24. 
25. 
26. 
27. 
28. 
29. 
30. 
31. 
32. 
33. 
34. 
35. 
36. 
37. 
38. 
39. 
40. 
41. 
42. 
43. 
44. 
45. 
46. 
47. 
48. 
49. 
50. 
51. 
Oil filter element 
Oil  filter  adaptor 
Gasket 
Screw 
(2) 
Spring  washer (2) 
Oil cooler adaptor 
Thermostat  bulb 
0 ring 
Spring 
Washer 
Screw 
(2) 
Washer (2) 
Oil  pressure  switch 
Copper  washer 
Blanking  plug 
Skew  gear 
Dowel  pin 
Bush  Locking  screw 
0 ring 
Snap  ring 
- external 
Deep  groove  bearing 
Snap  ring 
- internal 
0 ring - bearinghousifig 
Bearing  housing 
Rear 
side cover 
Casket  Dowel 
- flywheel  housing (2) 
Socket screw (2) 
Washer (2) 
Flange bolts (6) 
Froct side cover  breather 
Gasket  Baffle  plate 
Screw 
No.6 (2) 
Flange  bolt M8x40 (1) 
Flange  screw M8x25 (5) 
Cylinder  block 
Pushrod 
Tappet slide 
Roller follower 
Tappet  guide 
Set  bolt 
Washer 
Camshaft 
Locking  plate 
Screw 
(2) 
Spring  washer (2) 
Camshaft  bearing - front 
Camshaft bearing - interhear (3) 
Camshaft key 
52. Piston 
53. Piston rings 
54. Gudgeon  pin 
55. Circlip (8) 
56. Connecting  rod 
57. Gudgeon pin bush 
58. Connecting  rod bolt 
59. Big end  bearing 
60. Big end  bearing  cap 
61. Connecting  rod nut 
62. Crankshaft 
. 63. Crankshaft main bearing 
64. Main  bearing  cap - rear 
65. Main bearing  cap - centre 
66. Thrust washers 
67. Main bearing  cap (3) 
68. Main bearing  cap bolt 
69. Crankshaft key 
70. Crankshaft  dowel 
71. Crankshaft  bush 
72. Packing strip 
73. let adaptor 
74. joint washer 
75. Dowel 
76. Joint washer 
77. Relief vaive assembly 
78. Drain  plug 
79. joint washer 
80. Dipstick  tube 
81. Dipstick 
82. Oil gallery  plug 
83. cup plug (5) 
84. cup plug 
85. Oil gallery  plug 
86. Camshaft oil feed plug (3) 
87. Ring dowel (2) 
88. Oil feed  adaptor 
89. Oil drain  adaptor 
90. Ladder  frame 
91. Flange bolt M8x125 (3) 
92. Flange bolt M8x60 (4) 
93. Flange screw M8x30 (3) 
-. 
0 I. .. .. . 
26

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							ENGINE e DEFENDER 
ST3063M 
- 
12 
27

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							12 
CYLINDER HEAD COMPONENTS ST3062M - LAND 
ROVER  Tdi 
engine 
ENGINE e DEFENDER 
1. 
3. 
4. 
5. 
6. 
7. 
8. 
9. 
10. 
11. 
12. 
13. 
14. 
15. 
16. 
- 17. 
18. 
19. 
20.  21. 
22. 
23.  24. 
25. 
26. 
27. 
28. 
29.  30. 
31.  32. 
33. 
34. 
35. 
36. 
37. 
38. 
39. 
40. 
41. 
42. 
43. 
44. 
45. 
46. 
47. 
48. 
49. 
50. 
3 -. 
Y 
Oil filler cap 
Rocker cover 
Rocker cover gasket 
Flange  headed  bolt 
Washer  Sealing  washer 
Breather  cyclone 
Flange  headed  screw 
Rocker shaft bolt (3) 
Rocker shaft bolt (2) 
Rocker arm RH 
Rocker  arm LH 
Rocker arm bush 
Tappet  adjuster  screw 
Locknut 
Rocker shaft 
Rocker shaft spacer 
Rocker shaft spring 
Rocker shaft clamp 
Rocker shaft seal 
Exhaust  manifold 
Manifold  stud 
- exhaust 
Self locking nut 
Plair; washer 
Stud  turbocharger  mounting 
Inlet  manifold 
Manifold  stud 
- inlet 
Flarlge nut 
Manifold  gasket 
Engine  lifting brackets 
Cylinder  head 
Cylinder  head gasket 
Head  bolts 
M12 short (4) 
Head  bolts M12 long (10) 
Head bolts M10 (4) 
Adaptor  cooling system 
Ring  dowel 
Valve 
- inlet 
Valve  seat insert 
Valve 
- exhaust 
Valve  seat insert 
Valve  guide 
Valve  stem seal 
Valve  spring  seat 
Valve  spring 
Valve  spring  cup 
Split  cotters 
Injector 
Injector  clamp 
Injector  clamp nut 
51. Injector  clamp stud 
52. Injector  clamp dowel 
53. Injector  sealing washer 
54. Spill return  pipe 
55. Banjo bolt 6mm 
56. Copper  washers 
57. Glow plug 
58. Glow  plug cable 
59. Nut and washer 
60. Thermostat  housing 
61. Casket 
62. Flange screw (3) 
63. Thermostat 
64. Gasket 
65. Thermostat  housing cover 
66. Flange bolt M6x40 (3) 
67. Thermal  transmitter 
68. Joint washer 
69. Flange  bolt 
70. Cup plug (1) 
71. Cup  plug (2) 
28

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