Land Rover Defender 90 110 Workshop Book 6 Supplement Rover

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DEFENDER LOCATION OF VEHICLE IDENTIFICATION & UNIT  NUMBERS 101 
VEHICLE  IDENTIFICATION  NUMBER (VIN) 
The Vehicle  Identification  Number and the 
recommended  maximum vehicle weights  are 
stamped  on a plate  riveted  to the  top 
of the  pedal 
box behind  the brake  servo 
The  number 
is also  stamped  on the  right-hand side 
of the  chassis forward of the spring  mounting  turret. 
Always  quote this number  when writing  to Land 
Rover. 
Key to Veh  iicle ldentiiication Number  Plate 
A. Type approval 
B. VIN (minimum of 17 digits) 
C.  Maximum  permitted laden weight 
for vehicle 
D. Maximum  vehicle and trailer  weight 
E. Maximum  road weight - front  axle 
F. Maximum  road weight - rear axle 
E 
F PAINT 0 TRIM 
ST3067M 
The  Vehicle  Identification  Number identifies  the 
manufacturer,  model range, wheel 
base, body type, 
engine,  steering,  transmission,  model name and 
place 
of manufacture.  The following  example shows 
the  coding  process. 
SAL  World  manufacturer  identifier 
LD  Land  Rover 
C Class 100 inch 
V Class 90 inch 
H Class 110 inch 
A Basic 
B 2door 
M 4door 
H High  Capacity 
F Tdi or 
8 5 speed  LHD or 
7 5 speed  RHD 
H 
1991 MY 
A Solihull  site 
ENGINE  SERIAL NUMBER - Tdi ENGINE 
The engine  number is stamped  on the  cylinder 
block  on the  right  hand  side 
of the engine  above 
the  camshaft  front cover  plate. Commencing  Serial 
Number 
IIL 00001. 
.. 
7  
						

							L 
01 LOCATION OF VEHICLE IDENTIFICATION & UNIT NUMBERS e DEFENDER 
MAIN  GEARBOX LT77 - 5 SPEED 
The serial  number is stamped  on a cast pad  on the 
bottom  right hand  side 
of the gearbox. 
RR1513M 1 . 
TRANSFER  GEARBOX LT230 
------- 
The serial  number is stamped  on the left hand  side 
of the gearbox  casing below the mainshaft  rear 
bearing  housing  adjacent 
to the bottom  cover. 
FRONT  AND REAR  AXLES 
Serial number is stamped  on top of the left hand 
axle tube.  
						

							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) 
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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 

						

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							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