Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover
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GENERAL SPECIFICATION DATA 104 I - ......... Lubrication (continued) ,&&gTz 4.gy;,$! Oil pump: Latest type ..... Type ........................................................... Drive .......................................................... End-float of both gears ....................................... Radial clearance of gears ................................. Backlash of gears.. ......................................... 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 (0.0008 - 0.0025 in) 0,l - 0,2 mm (0.0034 - 0.0067 in) Oil pressure relief valve Type .............................................................. Non-adjustable Relief valve spring: Full length.. .................................................. Compressed length at 2,58 kg (5.7 Ib) load ........... 67,82 mm (2.670 in) 61,23 mm (2.450 in) 2.5 LITRE PETROL ENGINE - q,. ENGINE Type ................................................................. Bore ................................................................. Stroke ............................................................... Capacity ............................................................ Valve operation.. ................................................. Compression ratio.. .............................................. Maximum power @ 4000 rpm ................................. Maximum torque @ 2000 rpm. ................................ Commencing serial no. .......................................... 4 cylinder 90,47 mm (3.562 in) 97 mm (3.82 in) 2495 cm3 (152.25 in3) Overhead by push-rod 8.0: 1 59.5 Kw (80 bhp) 175 Nm (129 lbf ft) 17H00011C Crankshaft Main journal diameter ....................................... Minimum regrind diameter .............................. Crankpin journal diameter. ................................. Minimum regrind diameter .............................. 58,48985 - 58,47080 mm (2.30275 - 2.30200 in) Crankshaft end thrust ........................................ Taken on thrust washers at centre main bearing Crankshaft end -float.. ........................................ 0,05 - 0,15 mm (0.002 - 0.006 in) 63,487 - 63,500 mm (2.4995 - 2.500 in) 63,246 - 63,2333 mm (2.4900 - 2.4895 in) 58,725 - 58,744 mm (2.312 - 2.31275 in) Main bearings Number and type .............................................. Diametrical clearance ........................................ Undersizes ...................................................... 5 halved shells Material ......................................................... Copper-lead lined 0,018 - 0,06 mm (0.0007 - 0.0026 in) 0,25 mm (0.010 in) Connecting rods Type. ............................................................. Horizontally split big end, plain small end Length between centres ...................................... 175,36 - 175,46 mm (6.904 - 6.908 in) Connecting rod bearings Type and material ............................................. Steel shell, copper-lead lined 0,025 - 0,075 mm (0.001 - 0.003 in) End -float on crankpin ........................................ 0,20 - 0,30 mm (0.007 - 0.012 in) Diametrical clearance ........................................ Undersizes ...................................................... .... . . r. ._. 0,25 mm (0.010 in) ..... ..... 5
104 I GENERAL SPECIFICATION DATA Gudgeon pins Type .............................................................. Floating Fit in piston ..................................................... Push fit by hand Clearance in connecting rod ................................ 0,007 - 0,015 mm (0.0003 - 0.0006 in) Pistons Type 8 .O: 1 compression ratio ............................... Aluminium alloy. Recessed crown. Standard and oversize pistons ........................... 0,043 - 0,067 mm (0.0017.- 0.0026 in) Clearance in bore measured @ 17 mm from bottom of skirt at right angles to gudgeon pin: Piston rings Compression ................................................... 2 Gap in bore .................................................. 0,40 - 0,65 mm (0.016 - 0.026 in) Clearance in groove.. ...................................... 0,046 - 0,097 mm (0.0018 - 0.0038 in) Oil control ...................................................... 1 Gap in bore .................................................. 0,30 - 035 mm (0.012 - 0.022 in) Clearancc in groove. ....................................... 0,026 - 0,076 mm (0.0012 - 0.003 in) Camshaft Location ......................................................... End-float ........................................................ Number of bearings.. ......................................... 4 Material ......................................................... Drive ............................................................. 76 link chain Right-hand side (thrust side) of engine 0,06 - 0,13 mm (0.0025 - 0.0055 in) Steel shell, white metal lined Valves Length: Inlet ........................................................... Exhaust ....................................................... Inlet ........................................................... Exhaust.. ..................................................... Inlet ........................................................... Exhaust ....................................................... Inlet ........................................................... Exhaust.. ..................................................... Inlet ........................................................... Exhaust.. ..................................................... Inlet ........................................................... Exhaust ....................................................... External diameter.. ........................................ Internal diameter. .......................................... Width ......................................................... Seat angle: Head diameter: Stem diameter: Stem to guide clearance: Valve lift: Exhaust valve seat insert: Seat angle and depth ....................................... 111,20- 111,66mm(4.377-4.396in) 111,12 - 11139 mm (4.374 - 4.393 in) 30 45 44,32 - 44,58 mm (1.744 - 1.755 in) 34,43 - 34,18 mm (1.355 - 1.345 in) 7,899 - 7,912 mm (0.3109 - 0.31 15 in) 8,697 - 8,679 mm (0.3424 - 0.3416 in) 0,033 - 0,048 mm (0.0013 - 0.0019 in) 0,035 - 0,076 mm (0.0014 - 0.0022 in) 10,236 mm (0.403 in) 9,85 mm (0.388 in) 36,576 - 36,601 (1.440 - 1.441 in) 28,448-28,702mm (1.120- 1.130in) 5,055 - 5,105 mm (0.199 - 0.201 in) 45. 0,635 - 0,889 mm (0.025 - 0.035 in) .. ..... ... t, . 6
GENERAL SPECIFICATION DATA Valve springs Type .............................................................. Duplex interference coil Inner: Length, free ................................................. 42,67 mm (1.680 in) Length, free ................................................. 46,28 mm (1.822 in) Length, under 21 kg (46 Ib) load ........................ 40,30 mm (1.587 in) Length, under 8,O kg (17.7 Ib) load .................... 37,13 mm (1.462 in) Outer: 04 Lubrication System ........................................................... System pressure, engine warm at 2000 rpm ............. Oil pump: Type .......................................... Drive .......................................................... Radial clearance of gears ................................. Backlash of gears.. ......................................... End-float of both gears.. ..................................... Oil pressure relief valve Relief valve spring: Type .............................................................. Full length .......... ....................... Compressed length at 2,58 kg (5.7 Ib) load ........... Wet sump, pressure fed 2,45 - 4,50 kgf cm2 (35 - 65 lbf in2) 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 (0.0008 - 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) 2.25 LITRE DIESEL ENGINE ENGINE Type ................................................................. Bore ................................................................. ....................................................... ....................................................... Valve operation.. ................................................. Compression ratio.. .............................................. Maximum power ........................ Maximum torque.. ...................... 4 cylinder 90,47 mm (3.562 in) 88,9 mm (3.500 in) 2286 cm3 (139 in3) Overhead by push-rod 33: 1 44Kw (59 bhp) at 4000 rpm 136 Nm (100 Ibf ft) at 1800 rpm Crankshaft Main bearing journal diameter ............................. 63,487 - 63,500 mm (2.4995 - 2.500 in) 63,246 - 63,2333 mm (2.490 - 2.4895 in) ............... Use 0.010 in U/S bearings Regrind dimensions: Crankpin journal diameter .................................. Regrind dimensions: 58,48985 - 58,4708 mm (2.30275 - 2.30200 in) ........ Crankshaft cnd thrust ........................................ 58,725 - 58,744 mm (2.312 - 2.31275 in) Use 0.010 in U/S bearings Taken on thrust washers at centre main bearing Crankshaft end -float .......................................... 0,OS - 0,15 mm (0.002 - 0.006 Main bearings Number and tVDe .............................................. 5 halved shells ,I Material ......................................................... Diametrical clearance Steel shell, copper-lead lined 0,020 - 0,063 mm (0.0008 - 0.0025 in) t ........................................ n) tin plated 7
104 I GENERAL SPECIFICATION DATA Connecting rods Type .............................................................. Horizontally split big end, plain small end Length between centres ...................................... 175,38 - 175,43 mm (6.905 - 6.907 in) Big end bearings Type and material ............................................. Steel shell, copper-lead lined Diametrical clearance ........................................ 0,020 - 0,0635 mm (0.0008 - 0.0025 in) End -float on crankpin ........................................ 0,15 - 0,356 mm (0.006 - 0.014 in) Gudgeon pins Type .............................................................. Floating Fit in piston ..................................................... Push fit by hand Clearance in connecting rod ................................ 0,0196 - G,0036 mm (0.0007 - 0.00014 in) 30,1564 - 30,1625 mm (1 3726 - 1 A875 in) Diameter ........................................................ Pistons Type .............................................................. Aluminium alloy, with V shape recess in crown Standard size pistons ...................................... 0,111 - 0,134 mm (0.0044 - 0.0053 in) Oversize pistons ............................................ 0,111 - 0,157 mm (0.0044 -0.0062 in) Clearance in bore, measured at bottom of skirt at right angles to gudgeon pin: Piston rings Compression No. 1 (top): Type ........................................................... Gap in bore .......... .................................. Type ............................ ........................ Gap in bore .................................................. Type ........................................................... Gap in bore .................................................. Clearance in groove ................... Compression Nos. 2 and 3: Clearance in groove.. ...................................... Oil control No. 4: Clearance in groove ........................................ Valves Length: Inlet ........................................................... Exhaust ....................................................... Inlet ....................... ............................... Exhaust ....................................................... Inlet ........................................................... Exhaust ....................................................... Inlet ........................................................... Exhaust ...................................................... Inlet ........................................................... Exhaust ....................................................... Inlet ........................................................... Exhaust ....................................................... Seat angle: Head diameter: Stem diameter: Stem to guide clearance: Valve lift: Square friction edge, chrome plated 0,35 - 0,50 mm (0.014 - 0.019 in) 0,06 - 0,11 mm (0.0025 - 0.0045 in) Bevelled friction edge. Marked T or TOP on upper side 0,25 - 0,38 mm (0.010 - 0.015 in) 0,06 - 0,11 mm (0.0025 - 0.0045 in) Ring and spring 0,279 - 0,406 mm (0.011 - 0.016 in) 0,038 - 0,064 mm (0.0015 - 0.0025 in) 116,26 - 116,5i mm (4.377 - 4.587 in) 116,79 - 117,25 mm (4.598 - 4.616.h) 45 45 39,12 - 39,37 mm (1.540 - 1.550 in) 33,25 - 33,50 mm (1.309 - 1.318 in) 7,912 - 7,899 mm (0.3114 - 0.3109 in) 8,682 - 8,694 mm (0.3418 - 0.3422 in) 0,033 - 0,048 mm (0.0013 - 0.0019 in) 0,058 - 0,073 mm (0.0023 - 0.0029 in) 935 mm (0.388 in) 10,26 mm (0.404 in) 8
GENERAL SPECIFICATION DATA 104 I Camshaft Location .............................................. Right-hand side (thrust side) of engine End -float ........................................................ Material ............ ..................................... Stee! shell, white metal lined Drive ........................................... Chain 0,l - 0,2 mm (0.004 - 0.008 in) Number of bcarings .......................... ..... 4 Valve springs Type .............................................................. Duplex Interference double coil Inner: Length, free ................................................. Length, under 8,0 kg (17.7 Ib) load .................... Length, free ................................................. Length, under 21 kg (46 Ib) load ........................ 42,67 mm (1.680 in) 40,30 mm (1.587 in) 46,28 mm (1.822 in) 40,30 mm (1.587 in) Outer: Lubrication . System ..................................................... System pressure, engine warm at 2000 rpm ............. Oil pump: Type ........................................................... Drive ................................... ................. End-float of gcars: Steel gear ......................... ....................... Aluminium gear ............................................ Backlash of gcars. ................... .......... Radial clearance of gears ................................. Wet sump, pressure fed 2,5 - 437 kgf cm2 (35 - 65 lbf in2) Double gcar Splined shaft from camshaft skew gear 0,05 - 0,12 mm (0.002 - 0.005 in) 0,07 - 0,15 mm (0.003 - 0.006 in) 0,02 - 0,10 mm (0.001 - 0.004 in) 0,151 - 0,28 mm (0.006 - 0.012 in) Oil pressure relief valve Type .............................................................. Non-adjustable Relief valve spring: Full length .................................................... 67,82 mm (2.670 in) Compressed length at 2,58 kg (5.7 Ib) load ........... 61,23 mm (2.450 in) 2.5 LITRE DIESEL ENGINE ENGINE Number of cylinders ............................................. Bore ..................................... ...................... Strokc ................................................... ............................ ................................... Piston area (total) .......... ...................... Maximum powcr at4000 rpm .................................. Maximum torque at 1800 rpm ................................. 4 90,47 mm (3.562 in) 97,OO mm (3.810 in) 2495 cc 21:l 257,l cm3 (39.86 in) 65.5 bhp 113 lbf ft Crankshaft Main bearing journal diameter.. ........................... 63,487 - 63,500 mm (2.4995 - 2.5000 in) Regrind dimensions: 63,246 - 63,2333 mm (2.490 - 2.4895 in) ............... Crankpin journal diameter .................................. Regrind dimensions: 58,48985 - 58,4708 mm (2.30275 - 2.30200 in). ....... Crankshaft end thrust ........................................ Crankshaft end-float .......................................... Use 0.010 in U/S bearings 58,725 - 58,744 mm (2.312 - 2.31275 in) Use 0.010 in U/S bearings 0,05 - 0,15 mm (0.002 -0.006 in) Taken on thrust washers at centre main bearing 9
104 I GENERAL SPECIFICATION DATA Main bearings Number and type .............................................. Diametrical clearance ........................................ Connecting rods Length between centres.. .................................... Diametrical clearance (big-end bearings). ............... End-float on crankpin ........................................ Pistons Type .............................................................. angle to gudgeon pin) ........................................ Skirt diametrical clearance (at right Gudgeon pins Type .............................................................. Fit in piston ..................................................... Diameter ........................................................ Clearance in connecting rod ................................ Piston rings Type: Top ................................................... Second ............................................... Oil control .......................................... Camshaft Drive ............................................................. Location ......................................................... End-float ........................................................ Number of bearings.. ......................................... Material ......................................................... Valves Seat angle: Inlet ........................................................... Exhaust ....................................................... Inlet ........................................................... Exhaust ....................................................... Inlet ........................................................... Exhaust ....................................................... Inlet ........................................................... Exhaust ....................................................... Head diameter: Valve lift: Cam lift: Stem diameter: Tnlpt .......... _...-- .............................. Exhaust ....................................................... 5 halved shells 0,018 - 0,061 mm (0.0007 - 0.0024 in) 175,38 - 175,43 mm (6.905 - 6.907 in) 0,025 - 0,075 mm (0.001 - 0.003 in) 0,15 - 0,356 mm (0.006 - 0.014 in) Aluminium alloy V shaped valve recess in crown 0,025 - 0,05 mm (0.001 - 0.002 in) F1 oat i n g Hand push fit 30,1564 - 30,1625 mm (1.18726 - 1.18750 in) 0,0196 - 0,0036 mm (0.00077 - 0.00014 in) Square friction edge, chrome plated Taper faced Expander and rails 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) 9,85 mm (0.388 in) 10,26 mm (0.404 in) 6,81 mm (0.268 in) 7,06 mm (0.278 in) 7,912 - 7,899 mm (0.3114 - 0.3109 in) 8,682 - 8,694 mm (0.3418 - 0.3422 in) 10
1041 GENERAL SPECIFICATION DATA FUEL SYSTEM - V8 engine Carburetter ........................................................ Air cleaner.. ....................................................... See ‘ENGINE TUNING DATA’ Fuel pump - Make, type ...................................... Facet, electric mounted vertically on R.H. side of chassis Cyclone, replaceable element COOLING SYSTEM - 2.25 Petrol, 2.25 and 2.5 Diesel Type ................................................................. Pressurized spill return system with thermostat control, Pressure cap ....................................................... 0,6 kgf cm2 (9 Ibf in2) Type of pump ..................................................... Centrifugal pump and fan assisted Thermostat ........................................................ 82°C COOLING SYSTEM - V8 engine Type.. ............................................................... Pressurized spill return system with thermostat control, Emission and non -emission 82”C, Australia 88°C Type of pump ..................................................... Centrifugal pump and fan assisted Thermostat ........................................................ -- CLUTCH - 2.25 Petrol Type ................................................................. Borg and Beck diaphragm spring Centre plate diameter ........................................... 242,l mm (9.500 in) Facing material ................................................... Raybestos 1488-05 Facing material identification colour ........................ Whitdviolct on periphary Number of damper springs ..................................... Damper spring colour ........................................... Dark grey/light green Clutch release bearing.. ......................................... Ball journal 6 CLUTCH - 2.25 and 2.5 Diesel engine - Early type Type ................................................................. Verto diaphragm spring Centre plate diameter ........................................... 242,l mm (9.500 in) Facing material ................................................... Raybestos 1488-05 Number of damper springs ..................................... Damper spring colour ........................................... 2 off whitelgreen Clutch release bearing.. ......................................... Ball journal 8 2 off pigeon blue 4 off ruby red CLUTCH -Later type Type ................................................................. Vcrto diaphragm spring Centre plate diameter (friction plate) ....................... 235 mm (9.25 in) Facing material ................................................... Verto 791 Number of damper springs ..................................... Damper spring colour ........................................... 2 off whitcigreen - suffix ‘C’ Clutch release bearing.. ......................................... Ball journal 8 2 off pigeon blue -suffix ‘A’ 4 off ruby red -suffix ‘B’ CLUTCH - V8 engine Type ................................................................. Borg and Beck diaphragm spring Centre plate diameter ........................................... 267 mm (10.5 in) Facing material ................................................... Raybestos 1488-05. Grooved. Whitehidet Damper spring colour ........................................... Light blue/dark blue Release bearing.. ................................................. Ball journal Number of damper springs ..................................... 6 12
GENERAL SPECIFICATION DATA TRANSMISSION - Ninety and One Ten VS with 5-speed gearbox Main gearbox Type - Manual.. .............................................. Main gearbox ratios.. ......................................... LT85 5-speed helical constant mesh, with synchromesh on all forward gears Fifth (Cruising gear) 0.7951 Fourth 1.0000 Third 1.4362 Second 2.1804 First 3.6497 Reverse 3.8242 Transfer gearbox Type .............................................................. - Ninety models ........................................... . - One Ten models ........................................ Overall ratio (including final drive) -Ninety models * Overall ratio (including final drive) - One Ten models REAR AXLE - One Ten only Type ................................................................. Ratio ................................................................ Track ................................................................ FRONT AXLE - All models and Ninety rear Type ................................................................. Ratio ................................................................ PROPELLER SHAFTS - All Models Type: Front and rear ............................................ LT230T. Two-speed reduction on main gearbox output. Front and rear drive permanently engaged via a lockable differential. High Low High Low Fifth (Cruising Fourth Third Second First Reverse gear) Fifth (Cruising Fourth Third Second First Reverse gear) 1. 1923 3.3198 1.410 3.3198 In high transfer 3.3544 4.2189 6.0592 9.1989 15.3977 16.1339 In high transfer 3.9695 4.9925 7.1702 10.8856 18.2210 19.0922 In low transfer 0.3401 11.7471 16.8712 25.6134 42.8734 44.9233 In low transfer 9.3401 11.7471 16.87 12 25.6134 42.8734 44.9233 Salisbury 8HA 3.538 1485,90 mm (58.50 in) Spiral bevel, enclosed constant velocity joints 3.538 Single Hookes universal needle roller joints. Sliding portion on front shaft gaitered, rear shaft open 14