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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
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01INTRODUCTION 14 INFORMATION READING THIS SUPPLEMENT This Supplement is divided into sections shown on the contents page, alongside a range of icons, familiar to service technicians. Relevant information is contained within each of these sections. These are further divided into the following sub-sections which appear at the foot of each page :- Description and operation. Adjustment. Repair. Overhaul. To avoid repeating information through the sections, where part of the repair operation impacts on another section, a cross reference is given to direct the reader to where the information is sited. For example: The maintenance section states the need to renew drive belt. A cross reference sites this information in: Section 12 Engine - Sub-section: Repair
04 - GENERAL SPECIFICATION DATA CONTENTS Page INFORMATION ENGINE - Td5 1...................................................................................................... FUEL SYSTEM - Td5 3........................................................................................... COOLING SYSTEM - Td5 3.................................................................................... CLUTCH - Td5 3..................................................................................................... TRANSMISSION - Td5 4......................................................................................... STEERING 5........................................................................................................... SUSPENSION 6...................................................................................................... ROAD SPRING DATA 6.......................................................................................... SHOCK ABSORBERS 7......................................................................................... BRAKES 7............................................................................................................... AIR CONDITIONING 8............................................................................................ WIPER MOTORS 8................................................................................................. ELECTRICAL 8....................................................................................................... BULBS9 ................................................................................................................. VEHICLE WEIGHTS AND PAYLOAD 10................................................................ TOWING WEIGHTS 11........................................................................................... OFF-ROAD PERFORMANCE 11............................................................................ TYRE SIZE AND PRESSURES 12......................................................................... WHEELS 12............................................................................................................ VEHICLE DIMENSIONS 13....................................................................................
GENERAL SPECIFICATION DATA 1 INFORMATION ENGINE - Td5 Type 2.5 litre in-line direct injection Diesel, turbocharged................................................................................. and intercooled Number of cylinders 5 in-line, No. 1 cylinder at front of engine......................................................... Bore 84.450 mm (3.3248 in)................................................................................. Stroke 88.950 mm (3.5020 in)............................................................................... Capacity 2498 cm 3(152.5 in3) ........................................................................... Firing order 1 - 2 - 4 - 5 - 3....................................................................... Compression ratio 19.5:1............................................................ Direction of rotation Clockwise viewed from the front of the engine........................................................... Dimensions Length 766 mm (30.1 in)..................................................................... Width 708 mm (27.8 in)....................................................................... Height 788 mm (31.0 in)...................................................................... Emissions standard :- Engine Serial No. Prefixes 10P to 14P - EU2 Model ECD 2........ Engine Serial No. Prefixes 15P to 19P - EU3 Model ECD 3........ Lubrication Type Wet sump, pressure fed................................................................................. Pump type Eccentric rotor, crankshaft driven integral with stiffener........................................................................ plate. Filter type: Primary Centrifuge filter.................................................................... Secondary Disposable canister with full flow by-pass............................................................... Pressure at idle (cold) 3.0 bar (43.5 lbf.in 2) ...................................................... Pressure at 3500 rev/min (hot) 1.5 - 3.0 bar (21.75 - 43.5 lbf.in2) ......................................... Relief valve opening pressure 4.0 bar (58 lbf.in2) .......................................... Low oil pressure switch opening pressure 0.2 - 0.6 bar (3.0 - 8.8 lbf.in2) ....................... Crankshaft Main bearing journal diameter 61.9875 - 62.0125 mm.......................................... Crankpin journal diameter 53.99 - 54.01 mm................................................ Crankshaft end float 0.020 - 0.250 mm......................................................... Main bearings Number and type 6 half shells (5 main, 1 thrust).............................................................. Pistons Type Graphite compound skirt with combustion chamber in................................................................................. crown. Clearance in cylinder bore 0.172 - 0.206 mm (measured at bottom of skirt, 90°to ............................................... gudgeon pin) Diameter 84.270 - 85.254 mm (measured 90°to gudgeon pin, .......................................................................... and 40.00 mm from bottom of skirt.)
04GENERAL SPECIFICATION DATA 2 INFORMATION Gudgeon pins Type Fully floating, offset towards piston thrust side.................................................................................. Piston rings Type Upper compression Barrel edge, chrome plated................................................. Lower compression Taper faced................................................. Oil control Bevelled ring with spring................................................................ New ring to groove clearance Upper compression Not measured................................................. Lower compression 0.050 - 0.082 mm (0.002 - 0.003 in)................................................. Oil control 0.050 - 0.082 mm (0.002 - 0.003 in)................................................................ Piston ring fitted gap in cylinder bore Upper compression 0.30 - 0.45 mm (0.0118 - 0.0177 in)................................................. Lower compression 0.40 - 0.60 mm (0.0157 - 0.0236 in)................................................. Oil control 0.25 - 0.40 mm (0.0098 - 0.0157 in)................................................................ Camshaft Drive Duplex chain................................................................................. End float 0.6 - 0.16 mm........................................................................... Number of bearings 6.......................................................... Tappets Type Hydraulic lash adjusters with followers................................................................................. Valves Stem diameter Exhaust 6.905±0.008 mm (0.271±0.0003 in) ................................................................... Inlet 6.915±0.008 mm (0.272±0.0003 in) ......................................................................... Head diameter Exhaust 31.7 mm (1.25 in)................................................................... Inlet 34.7 mm (1.37 in)......................................................................... Seat face angle Exhaust 45° ................................................................... Inlet 30° ......................................................................... Valve face angle Exhaust 44°48’±12’ ................................................................... Inlet 29°48’±12’ ......................................................................... Valve springs Type Parallel, single coil.................................................................................
GENERAL SPECIFICATION DATA 3 INFORMATION FUEL SYSTEM - Td5 Type Direct injection from pressure regulated supply with................................................................................. cooled return flow Pressure regulator setting 4 bar (58 lbf.in 2) ................................................ Pump Electric two stage submersible................................................................................ Pump output Low pressure 30 l/h (6.6 gal/h) at 0.5 bar (7.25 lbf.in 2) .......................................................... High pressure 180 l/h (39.6 gal/h) at 4 bar (58 lbf.in2) .......................................................... Max consumption 30 l/h (6.6 gal/h)............................................................. Injectors Electronic unit injectors........................................................................... Injector normal operating pressure 1500 bar (21750 lbf.in 2) .................................. Filter In-line canister filter/water separator with water................................................................................. detection COOLING SYSTEM - Td5 Type Pressurised spill return partial flow, thermostatically................................................................................. controlled Cooling fans 11 blade axial flow on viscous coupling and 11 blade..................................................................... axial flow electric Electric cooling fan switching points On Vehicle speeds of 50 mph (80 km/h) and below while........................................................................... ambient temperature is 28°C (82°F) or above Off Vehicle speeds of 62.5 mph (100 km/h) and above or........................................................................... ambient temperatures of 25°C (77°F) and below Coolant pump Centrifugal impeller, belt driven from crankshaft................................................................... Thermostat Waxstat with pressure relief valve....................................................................... Thermostat opening temperature Initial opening 82°C (179°F) .......................................................... Fully open 96°C (204°F) ............................................................... Expansion tank cap relief valve operating pressure 1.4 bar (20.3 lbf.in 2) ......... CLUTCH - Td5 Type Diaphragm spring, hydraulically operated with................................................................................. self-centering pre-loaded release bearing Drive plate diameter 267 mm......................................................... Pressure plate diameter 270 mm...................................................
04GENERAL SPECIFICATION DATA 4 INFORMATION TRANSMISSION - Td5 Main gearbox Type R380 Single helical constant mesh....................................................................... Speeds 5 forward, 1 reverse, all synchromesh............................................................................. Transfer box Type LT230TE Two speed reduction on main gearbox output. Front................................................................. and rear drive permanently engaged via a lockable differential Rear axle Type Spiral bevel, fully floating shafts................................................................................. Ratio 3.54:1................................................................................. Front axle Type Spiral bevel, enclosed constant velocity joints, fully................................................................................. floating shafts, 32°angularity of universal joint on full lock Ratio 3.54:1................................................................................. Propeller shafts Type, front and rear Tubular 51 mm dia........................................................... Universal joints Open type Hookes O3EHD.................................................................
GENERAL SPECIFICATION DATA 5 INFORMATION STEERING Power steering box Make/type Adwest Varamatic - worm and roller box........................................................................ Ratio Variable: straight ahead 19.3:1 on lock 14.3:1................................................................................. Steering wheel turns, lock-to-lock 3.375.................................... Steering pump Make/type Hobourn-Eaton series 500........................................................................ Steering geometry Steering wheel diameter 412 mm (16.22 in).................................................. Toe-out measurement 0 to 2 mm toe out...................................................... Toe-out included angle 0°to 0°20’ ..................................................... Camber angle 0°* .................................................................. Castor angle 3°* ..................................................................... Swivel pin inclination static 7°* ............................................... * Check with vehicle on level ground, in unladen condition and five gallons of fuel. Rock the front of the vehicle up and down to allow it to take up a normal static position. Turning circle between kerbs 90 models: 265/75 x 16 tyres 12,65 m (41.5 ft).............................................................. All other tyres 11,70 m (38.4 ft)................................................................... 110 models: 750 x 16 tyres 13,41 m (44 ft).................................................................. 130 models: 750 x 16 tyres 15,24 m (50 ft)..................................................................
04GENERAL SPECIFICATION DATA 6 INFORMATION SUSPENSION Type Coil springs controlled by telescopic dampers front................................................................................. and rear. Front Transverse location of axle by Panhard rod, and fore................................................................................. and aft location by two radius arms. Anti-roll bar fitted as standard on 90 models with 265/75 tyres and 130 models. Rear Fore and aft movement inhibited by two tubular trailing................................................................................. links. Lateral location of axle by a centrally positioned ’A’frame, upperlink assembly, bolted at the apex to a ball joint mounting. Anti-roll bar fitted as standard on 90 models with 265/75 tyres, 110 models with self levelling unit, and 130 models. ROAD SPRING DATA 90 (2400 Kg) Part No. Colour Code Front - Driver’s side NRC 9446 Blue/green Front - Passenger side NRC 9447 Blue/yellow Rear - Driver’s side NRC 9448 Blue/red Rear - Passenger side NRC 9449 Yellow/white 90 (2550 Kg) Front - Driver’s side NRC 9446 Blue/green Front - passenger side NRC 9447 Blue/yellow Rear - Driver’s side NRC 9462 Green/yellow/red Rear - Passenger side NRC 9463 Green/yellow/white 110 (3050 Kg) Front - both sides NRC 8045 Yellow/yellow Rear - both sides NRC 6904 Red/green 110 Levelled (2950 Kg) Front - both sides NRC 8045 Yellow/yellow Rear - both sides NRC 7000 Green/white 110 (3400 Kg) Front - both sides NRC 8045 Yellow/yellow Rear - both sides NRC 6904 Red/green Rear helper springs - both sides RRC 3266 No colour code 110 (3600 Kg) Front - Driver’s side NRC 9448 Blue/red Front - passenger side NRC 9449 Yellow/white Rear - both sides NRC 6904 Red/green Rear helper springs - both sides RRC 3226 No colour code 130 (3500 Kg) Front - driver’s side NRC 9448 Blue/red Front - passenger side NRC 9449 Yellow/white Rear - driver’s side NRC 6389 Red/red Rear - passenger side NRC 6904 Red/green Front/rear helper springs - both sides RRC 3266 No colour code
GENERAL SPECIFICATION DATA 7 INFORMATION SHOCK ABSORBERS Type Telescopic, double-acting non-adjustable................................................................................. Bore diameter 35.47mm................................................................... BRAKES Front brake Caliper AP Lockheed, four opposed pistons.............................................................................. Operation Hydraulic, self adjusting......................................................................... Disc 90 - Solid, outboard, 110/130 - Ventilated, outboard.................................................................................. Disc diameter 298 mm (11.73 in)................................................................... Disc thickness 90 - 14,1 mm (0.56in), 110/130 - 24mm (0.95 in).................................................................. Wear limit 1 mm (0.04in) per side of disc......................................................................... Disc run-out maximum 0,15mm (0.006 in)..................................................... Pad area 58 cm 2(9.0 in2) .......................................................................... Total swept area 801,3 cm2(124.2 in2) ............................................................... Pad material Ferodo 3440 non asbestos..................................................................... Pad minimum thickness 3 mm (0.12in)................................................... Rear brake Caliper AP Lockheed opposed piston.............................................................................. Operation Hydraulic, self adjusting......................................................................... Disc Solid, outboard.................................................................................. Disc diameter 90 - 290 mm (11.42 in), 110/130 - 298 mm (11.73)................................................................... Disc thickness 90 - 12,5 mm (0.49 in), 110/130 - 14,1 mm (0.56 in).................................................................. Wear limit 90 - 0,38 mm (0.015 in), 110/130 - 1,0 mm (0.04 in)......................................................................... per side of disc Disc run-out maximum 0,15 mm (0.006 in)..................................................... Pad area 90 - 30,5 cm 2(4.37 in2), 110/130 - 36,2 cm2(5.61 in2) .......................................................................... Total swept area 90 - 694 cm2(106.98 in2) ............................................................... Pad material Ferodo 3440 non asbestos..................................................................... Pad minimum thickness UP TO 02MY - 3 mm (0.12 in)................................................... Pad minimum thickness From 02MY - 2 mm (0.08 in)................................................... Parking brake Type Mechanical, cable operated drum brake on the rear of................................................................................. the transfer gearbox output shaft Drum internal diameter 254 mm (10.0 in)..................................................... Width 70 mm (2.75 in)................................................................................ Pad material Ferodo 3611 non asbestos..................................................................... Servo/master cylinder Manufacturer Lucas.................................................................... Servo type LSC 80........................................................................ Master cylinder type 25,4 mm (1.0 in) diameter, tandem......................................................... Pressure reducing valve, failure conscious Cut-in pressure, 90 - 24 bar (360 Ibf/in 2) ratio 4.0:1, ...................... 110 - 43 bar (645 Ibf/in2) ratio 2.9:1* NOTE: * Pressure reducing valves are not fitted to all 110 specifications.