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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd 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. 
    						
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