Land Rover Defender 90 110 Workshop Book 2 Rover
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DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE GENERAL SPECIFICATION DATA 2.5 Litre Turbo Charged Diesel Engine - Supplement Number of cylinders .............................................. 4 Capacity ............................................................. 2495 cc Compression ratio ................................................ 21:l Valve charger ...................................................... 0. h.v. pushrod operated Turbo charger ..................................................... Garrett T2 Bore .................................................................. Stroke ............................................................... 97,OO mm (3.822 ins) 90,47 mm (3.562 ins) L 19 Crankshaft Main bearing journal diameter ................................ 63,487-63,500 mm (2.4995-2.500 in) Crankpin journal diameter ...................................... 58,725-58,744 mm (2.312-2.31275 in) Regrind dimensions: 63,246 -63,2333 mm (2.490-2.4895 in) .................. Use 0.010 in U/S bearings Regrind dimensions: Crankshaft end thrust ............................................ Taken on thrust washers at centre main bearing 58,48985-58,4708 mm (2.30275-2.30200 in) .......... Use 0.010 in U/S bearings Ciankshaft end-float ............................................. 0,05-0,15 mm (0.002-0.006 in) . . Main bearings Number and type ................................................. 5 halved shells without oil grooves Diametrical clearance ............................................ 0,018-0,061 mm (0.0007-0.0024 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 (0.006-0.014 in) Pistons Type ................................................................. Aluminium alloy ‘V’ shaped valve recess in crown Skirt diametrical clearance (at right angle to gudgeon pin) ................................. 0,025-0,05 mm (0.001-0.002 in) Gudgeon pins Type ................................................................. Floating Fit in piston ......................................................... Hand push fit Diameter ............................................................ 30,1564-30,1625 mm Clearance in connecting rod .................................... 0,0196-0,0036 mm (1.18726-1.18750 in) (0.00077-0. U001 4 in) Piston rings Type : .......................................................... Top Oil control .................................................. Chamfered friction edge, chrome plated Second ...................................................... Taper faced Expander and rails Gap in bore: Top .......................................................... 0,30 to 030 mm (0.011-0.019 in) Second ...................................................... 0,25 to 0,45 mm (0.009-0.017 in) Oil control .................................................. 0,3 to 0,6 mm (o.oii-O.u23 inj Top .......................................................... 0,14Oto0,180 mm (0.002to0.007 in) Oil control .................................................. 0,04 to 0,080 mm (0.001 to 0.003 in) Clearance in piston grooves: Second ...................................................... 0,040 to 0,080 mm (0.001 to 0.003 in) .. continued 41
1191 DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE Camshaft Drive ................................................................. Location ............................................................ End-float ............................................................. Number of bearings .............................................. Material ............................................................. Valves Seat angle: Inlet ............................................................ Exhaust ....................................................... Inlet ............................................................ Exhaust ....................................................... Inlet ............................................................ Exhaust ....................................................... Inlet ............................................................ Exhaust ....................................................... Inlet ............................................................ Exhaust ....................................................... Head diameter: Stem diameter: Valve lift: Cam lift: Valve springs Inner: Type ................................................................. Length, free .................................................. Length, free .................................................. Length, under 21 kg (46 Ib) load ........................ Length, under 8.0 kg (17.7 lb) load .................... Outer: Lubrication System ............................................................... Type ........................................................... End-float of both gears .................................... Radial clearance of gears .................................. Backlash of gears ........................................... Type ................................................................. Full length .................... ,.. ............................. Type ........................................................... System pressure, engine warm at 2000 rpm ................. Oil pump: Drive ........................................................... Oil pressure relief valve: Relief valve spring: Compressed length at 2.58 kg (5.7 lb) load ........... Oil filter: 25,4 mm (0.1 in) wide dry toothed belt Right -hand side (thrust side) 0,l-0,2 mm (0.004-0.008 in) 4 Steel shell, white metal lined 45 45 39,12-39,37 mm (1.540-1.550 in) 33,25-33,50 mm (1.309-1.319 in) 7,912 -7,899 mm (0.3114-0.3109 in) 8,682 -8,694 mm (0.3418-0.3422 in) 9,85 mm (0.388 in) 10,26 mm (0.404 in) 6,81 mm (0.268 in) 7,06 mm (0.278 in) Duplex Interference double coil 42,67 mm (1.680 in) 40,30 mm (1.587 in) 46,28 mm (1.822 in) 40,30 mm (1.587 in) Wet sump, pressure fed 2,5-4,57 kgf cm2 (35-65 Ibf in2) Double gear 10 teeth, sintered iron gears Splined shaft from camshaft skew gear 0,0260,135 mm (0.0009-0.0045 in) 0,025 -0,075 mm (0.0008-0.0025 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 FUEL SYSTEM Inspection pump .................................................. See ENGINE TUNING DATA Fuel lift pump type ............................................... Mechanical with hand primer Pressure range ..................................................... 0,35-0,56 kgf cm2 (5-8 Ibf in2) Fuel filter ........................................................... Paper eiement Air cleaner ......................................................... Paper element type continued a-- F: 42
DIESEL FUEL SYSTEM -TURBO CHARGED ENGINE El ........ ........ a-. COOLING SYSTEM ......:;.... .. ? Type ................................................................. Pressurized spill return system with thermostat control, I. >::.:::: :: ..,. pump and fan assisted Thermostat opening temperature ............................. 82°C Pressure cap ........................................................ 1,0 kgf cm2 (15 Ibf in2) Water pump type ................................................. Centrifugal Fan type ............................................................. 7 blade with viscous coupling Radiator .............................. , .... , ........................ Combined engine coolant and oil cooler CLUTCH Type ................................................................. Verto diaphragm spring Centre plate diameter (friction plate) ........................ 235 mm (9.25 in) Facing material .................................................... Verto 791 Number of damper springs ..................................... 8 Damper spring colour ............................................ 2 off white/green -Suffix C 2 off pigeon blue - Suffix A 4 off ruby red - Suffix B Clutch release bcaring ........................................... Ball journal . TRANSMISSION Type ................................................................. LT230T. Two-speed reduction on main gearbox output. Front and rear drive permanently engaged via a lockable differential Low 3.3198:l Ratios Ninety and One Ten .................................... High 1.4109:l Rear axle Type-Ninety models .............................................. Spiral bevel Type -One Ten models ........................................... Hypoid; full floating shafts, Salisbury 8HA Ratio-All models .................................................. 3.54:l Front axle Front wheel drive ................................................. Ratio ................................................................. 3.54: 1 Overall ratio (including final drive) Ninety and One Ten models .................................... Type-Ninety models .............................................. Spiral bevel Enclosed constant velocity joint In high transfer Fifth (Cruising gear) 4.15:l Fourth 4.991 Third 7.53: 1 Second 1 1.49: 1 First 17.90:l Reverse 18.48:l In low transfer 9.76:l 1 1.75: 1 17.71:l 27.03: 1 42.1 1 : 1 43.47: 1 ELECTRICAL Starter motor ...................................................... Paris Rhone type D9R91 12 volt, with reduction gear .... 43
1191 DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE ENGINE TUNING DATA ENGINE Injection timing ................................................... 13 R.T.D.C. Firing order ........................................................ 1-3-4-2 ... Timing marks: .. Valve timing ....................................................... Slot for peg in flywheel and TDC mark on front pulley Injection timing ................................................... Special tool 18G 1458 inserted in D.P.S. pump Tappet clearances inlet and exhaust .......................... 0,25 mm (0.010 in) Valve timing Inlet opens .......................................................... 16B.T.D.C. Inlet closes .......................................................... 42 A.B.D.C. Inlet peak ........................................................... 103 A.T.D.C. Exhaust opens ..................................................... 51 B.B.D.C. Exhaust closes ..................................................... 13 A.T.D.C. Exhaust peak ...................................................... 109 R.T.D.C. Valve lift Inlet .................................................................. 9,85 mm (0,388 ins) Exhaust ............................................................. 10,26 mm (0.404 ins) Maximum governed speeds Full load ............................................................. 4000 r.p.m. No load (flight speed) ............................................ 4400 k 80 r.p.m. Dic-down time ..................................................... 4 seconds Idle speed ........................................................... 670 * 20 r.p.m. DlSTKlBUTOK PUMP Makehype .......................................................... CAV DPS type with boost control and two speed mechanical governor with auto advance and solenoid electrical shut -off. Tamper proof sealing on flight speed and fuel adjustment screws. Advance box (two stage) ........................................ 7 advance with 3 start retard Back leakage rate 150 -100 Atm: Direction of rotation ............................................. Clockwise, viewed from drive cnd New nozzle ................................................... 7 seconds Original nozzle .............................................. 5 seconds Despatch nozzle ............................................. 8520A290A INJECTORS Makehype .......................................................... CAV Pintaux DES5385001 Nozzle size .......................................................... BDNO/SPC 6209 Opening pressure (working pressure) ........................ 135 to 140 Atmosphercs Injector pipe type ................................................. High pressure multi-bundy size .................................................. 1,94 to 2,06 mm length .............................................. 457,2 mm (18 ins) HEATER PLUGS iviaiteitype .......................................................... rrobe type, Cnampion CE63 i i v~iis 90 waits iicjiiiiiiai Time to reach operating temperature of 850°C ............ 8 seconds ., n TURBO-CHARGER Makehype .......................................................... Garrett T2 Maximum boost pressure ....................................... 48 cm HG (9.3 P.S.I.G.) measured at wastegate actuator T piece 44
DIESEL FUEL SYSTEM - TURBO CHARGED ENGINE I 191 TORQUE WRENCH SETTINGS TURBO -CHARGER FlXINCS Nm Ibf.ft Stud-Turbo charger to exhaust manifold 22-28 16-2 1 Nut-Turbo charger to exhaust manifold 2 1-26 15-19 Adaptor -Oil feed to cylinder block 22-28 16-21 Adaptor -Oil drain to cylinder block 22-28 16-21 Pipc -Oil feed to turbo charger 15-22 11-16 Pipe-Oil drain 32-48 23-35 Stud -Outlet elbow to turbo charger 22-28 16-2 1 Nut-Outlet elbow to turbo charger 2 1-26 15-19 Heat shield support to inlet manifold 22 -28 16-2 1 Stud -Exhaust manifold to cylinder head 30-40 22-30 Nut -Exhaust manifold to cylinder head 28-36 2 1-26 Screw -inlet and exhaust manifold to cylinder head 30-40 22-30 RECOMMENDED ENGINE OILS The following list of recommended engine oils for temperate climates - ambicnt temperaturc range - 10°C to 35°C should be used for oil changes and topping up. They are SHPD (Super High Performance Diesel) oils that allow a maximum of 10,000 km (6,000 miles) between oil and filter changes. BP CASTROL MOBIL SHELL Vanellus C3 Extra 15/40 Deusol Turbomax 15/40 Delvac 1400 Super 15/40 Myrina 15/40 The following list of oils is for emergency use only if the above oils arc not availablc. They can be used for topping-up without detriment, but if used for engine oil changing, they are limited to a maximum of 5,000 km (3,000 miles) between oil and filter changcs. BP Vanellus C3 Multigradc 15/40 CASTROL Dcusol RX Super 15/40 DUCKHAMS Hypergrade 15/50 ESSO Essolube XD-3 15/40 MOBIL Delvac Super 15/40 PETROFINA Fina Dilano HPD 15/40 SHELL Rimula X 15/40 TEXACO URSA Super Plus 15/40 Use only oils to MIL-L-2104C/D or API Service levels CD or SE/CD-ISW/40 SECTION 10 MAINTENANCE SCHEDULE The following additional maintenance is required for the turbo charged engine to that contained in thc main schcdulc for the non-Turbo Charged 2.5 Litre Diesel cngine. Every 500 km (250 miles) - Check engine oil level At 1,600 km (1,000 miles), 10,000 km (6,000 miles) and 20.000 km (12,000 miles) then every 20,000 km (12,000 miles) - Check tappets, and adjust if necessq Every 80.000 km (48,000 miles) - Check maximum turbo-charge boost pressure.
19 TURBO-CHARGER DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE Removing 1. Remove thc bonnct. 2. Remove the hose connecting the air clcancr to the turbo -charger. 3. Remove the turbo-charger heat shield fixings and remove the heat shield. 4. Release the clamp securing the turbo-charger elbow to the exhaust downpipe. 5. Remove the inlet manifold to the turbo-charger hose. 6. Disconnect the boost control hose from the turbo- charger. 7. Disconnect from the turbo-charger the lubrication inlet pipe. 8. Disconnect, at the flexiblc hose, the lubrication drain pipe from the turbo -charger. \\ \ \\ \ 9. Remove the five nuts to release the exhaust elbow and gasket from the turbo -charger. +- . 10. Release the lock tabs and removc the four nuts securing the turbo -charger to the exhaust manifold and remove the turbo -charger and gasket. : *-=- Fitting 11. Fit the raised bead side of a new gasket uppermost to the exhaust manifold and fit and secure the turbo-charger with the four nuts, tightening evenly to the correct torque and secure with lock tabs. 12. Fit the exhaust elbow, using a new gasket, to thc turbo-charger and retain with the five nuts tightening evcnly to the correct torque. 46
DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE 119 ST1863M 13. Fit the exhaust downpipe to the turbo-charger 14. Connect the lubrication inlet pipe to the turbo- 15. Fit the oil drain pipe to the flexible connection. 16. Connect the boost control pipe to the turbo- 17. Fit the hose connecting the inlet manifold to turbo- 18. Fit the heat shield. 19. Fit the air cleaner to turbo-charger hose. 20. Immediately prior to starting the engine release the oil inlet pipe to the turbo-charger and fill the centre housing with a recommended makc and grade of engine oil and re-fit the pipe. elbow and tighten the clamp bolt. charger. charger. charger. CHECKING TURBO-CHARGER BOOST PRESSURE 1. Disconnect, from the turbo-charger, the hose to the actuator and insert, into the free end a suitable ‘T’ piece. 2. Connect a short length of slave hose to the turbo- charger and connect the other end to the ‘T’ piece. 3. Connect a further slave hose to the third leg of the ‘T’ piece and the other end to a pressure gauge capable of reading in excess of 50 cm of Mercury. The pressure gauge hose must be long enough to reach into the cab of the vehicle so that the gauge can be observed by the driver or passenger. 4. Drive the vehicle in the normal manner (2,500- 3,000 r.p.m. full load) and observe the maximum pressure obtained and compare with the figure in Data Section 05. RENEW TURBO-CHARGER ACTUATOR 1. Remove the two screws securing actuator bracket to the turbo -charger. 2. Remove the nut and bolt securing actuator to the heat shield bracket and disconnect the hose. 3. Remove clip retaining actuator arm to the wastegate lever pin and withdraw the actuator from the engine. 4. Fit the replacement actuator with the two bolts and single nut and bolt. Tighten bolts to 12.5 to 14.0 Nm (111 to 124 in Ibs). 5. Push the wastegate lever as far as possible towards the actuator and apply pressure to keep lever in this position. 6. Pressurizc the replacement actuator to 57-62 cm HgG (11-12 p.s.i.g) and hold this pressure. CAUTION: Use only the threaded rod-end to make adjustments. Forcing the entire rod in or out will change the calibration with the possibility of damaging engine over -boost . 7. Screw the rod-end in either direction until the rod end eye will locate easily over the wastegate pin and secure with retaining clip. 8. Release the calibration pressure and tighten the rod end locknut. Reconnect the hose. 9. Check the boost pressure, on the road, as described earlier. The pressure should not fall below 44 or exceed 50 cm HgG (8.5 - 9.7 p.s.i.g.) 47
11911 DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE TURBO-CHARGER FAULT TRACING It is important to be aware that when tracing a suspected fault in a turbo-charger that a turbo-charger cannot compensate for incorrect engine operation deficiencies in the air, or fuel intake systems, exhaust emission components or for damaged and worn engine internal parts such as valves and pistons. Before suspecting the turbo -charger, the engine should be checked against the tuning data in Section 05. Replacing a sound turbo-charger with another will not correct engine deficiencies. Systematic fault tracing of a suspected turbo-charger failure is important for two reasons. First, it must be found what, if anything, is wrong with the turbo- charger so that it can be cxchanged. Second, it must be decided what action is necessary to prevent a repeat failure. In many cases, evidence pointing to the cause of a failure is destroyed while removing the turbo-charger from the engine. For example, if a turbo-charger failed because of a faulty installation, such as loose connections that allowed dirt to enter the compressor, this would not be evident once the turbo -charger was removed from the engine. Failure to correct the installation, such as reinstalling defective manifold flange Connections, could cause an identical failure of the replacement unit. The hose connecting the air cleaner to the compressor, which could contain dirt or harmful particles, should bc cleaned or renewed if necessary. In general, the fault tracing procedures that can be done with the least effort and in the least amount of time should be done first. Do not remove and renew the turbo -charger until the following visual checks and repairs that can be made with the turbo -charger installed, have been done. DO NOT, UNDER ANY CHARGER. CIRCUMSTANCES, DISMANTLE THE TUKBO- VISUAL INSPECTION 1. 7 -. 3. 4 5. Inspect all connections within the intake system. Tighten loose connections as required. Replace damaged air intake components. Check the connection between the compressor and the engine intake manifold. Tighten loose bolts as required. Check exhaust system connections at turbine housing inlet and outlet flanges for oil leakage and loose connections. Tighten loose connections as required. If oil leakage exists, check the general condition of the engine. Check the oil line connections at the centre housing oil inlet and outlet ports for leakage. Tighten loose connections as required. Start engine and recheck connections. 48
COOLING SYSTEM 1261 I -. ENGINE PROTECTION DRAIN AND FILL VS ENGINE COOLING SYSTEM .. .. ”.! .. To prevent corrosion of the aluminium alloy engine parts it is imperative that the cooling system is filled with a solution of clean water and the correct type of anti -freeze, winter and summcr, or water and inhibitor if frost precautions are not required. Never fill or top-up with water only, always add an inhibitor (Marstons SQ36) if anti-freeze is not used. NEVER USC salt water with an inhibitor otherwise corrosion will occur. In certain territories where the only available water supply may have some salt content, use only clean rainwater or distilled water. Recommended solutions Anti -freeze Unipart Universal Anti-freeze or permanent type ethylene base, without methanol, with a suitable inhibitor for aluminium engines and engine Use one part of anti -freeze to one part water. Inhibitor Marston Lubricants SQ36 inhibitor concentrate. Use 100 cc of inhibitor per litre of water. Anti -freeze can remain in the cooling system and will provide adcquatc protection for two years provided that the specific gravity of the coolant is checked before the onset ofthe second winter and topped-up with new anti -freeze as required. Land Rovers leaving the factory have the cooling system filled with 50% of anti-freeze mixture. This gives protection against frost down to minus 47°C (minus 53°F). Vehicles so filled can be identified by a label affixed to the windscreen and radiator. After the second winter the system should be drained and thoroughly flushed. Before adding new anti-freeze examine all joints and renew defective hoses to make sure that the system is leakproof. Inhibitor solution ., should be drained and flushed out and new inhibitor solution introduced every two years, or sooner where the purity of the water is qucstionablc. See the ‘General specification data’ section for protection quantities. ” parts. ., .. WARNING: Do not remove the radiator filler cap when the engine is hot because the cooling system is pressurized and personal scalding could result. 1. Remove the radiator filler plug. 2. Remove the radiator drain plug and allow thc coolant to drain, if neccssary, into a suitable container. Refit thc drain plug and ncw washer. The drain plug is situated on the left-hand side of thc radiator towards the bottom facing the engine compartment. NOTE: Disconnect bottom hose to drain on radiators without a drain plug. Connect hose after draining. 3. Remove the engine drain plugs, one each side of the cylinder block, beneath the exhaust manifolds. Allow the coolant to drain and refit plugs and washers. 1
1261 COOLING SYSTEM 4. To drain the expansion tank remove it from the vehicle, empty, flush -out and refit. If necessary renew the expansion tank hose. 5. Make up a solution of anti-freeze and water in a scparatc container in the concentration required. The cooling system capacity is quoted in the data scction. Therefore to allow for topping up and the DRAIN AND FILL 2.25 LITRE PETROL AND DIESEL AND 2.5 DIESEL SYSTEMS WARNING: Do not remove the radiator or expansion tank filler caps when the engine is hot because the cooling system is pressurized and personal scalding could result. 1. Remove the expansion tanks and radiator filler Plug. expansion tank make up a quantity in excess of this quantity. 6. If anti-freeze is not required use Marstons SQ36 in the concentration recommended as described under ‘Engine protection’. Make up a quantity in excess of capacity for topping up and expansion tank. 7. Make sure all drain plugs are tight and fill the system through the radiator filler plug until the coolant is just below the filler neck. Fit the plug but do not over tighten. 8. Half fill the expansion tank with coolant and secure the cap correctly. 2. Remove the radiator drain plug and allow the coolant to drain, if necessary into a suitable container. Refit the drain plug with a new washer. The plug is located on the left-hand side of the radiator facing the engine compartment. 9. Start and run the engine until normal operating temperature is reached. Allow the engine to cool and check the levels in the radiator and expansion tank and top up if necessary. Finally check all hose connections for leaks. 2 ST1146M