Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual
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INTRODUCTION 9 INFORMATION ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL Across flats (bolt size) AF............................................ After bottom dead centre ABDC................................... After top dead centre ATDC......................................... Alternating current a.c.................................................. Ampere A or amp........................................................ Ampere hour amp hr.................................................... Before bottom dead centre BBDC................................ Before top dead centre BTDC...................................... Bottom dead centre BDC............................................. Brake horse power bhp................................................ British Standards BS.................................................... Carbon monoxide CO.................................................. Centimetre cm............................................................. Centigrade (Celsius) C................................................ Cubic centimetre cm 3................................................... Cubic inch in3............................................................... Degree (angle) deg or° ............................................... Degree (temperature) deg or° ..................................... Diameter dia................................................................ Direct current d.c.......................................................... Electronic Control Unit ECU........................................ Electronic Fuel Injection EFI........................................ Fahrenheit F................................................................. Feet ft........................................................................... Feet per minute ft/min.................................................. Fifth 5th........................................................................ First 1st........................................................................ Fluid ounce fl oz.......................................................... Foot pounds (torque) lbf ft............................................ Fourth 4th..................................................................... Gramme (force) gf........................................................ Gramme (mass) g........................................................ Gallons gal................................................................... Gallons (US) US gal..................................................... High tension (electrical) H.T......................................... Internal diameter I.D.................................................... Inches of mercury in. Hg.............................................. Inches in...................................................................... Kilogramme (force) kgf................................................. Kilogramme (mass.) kg................................................ Kilogramme centimetre (torque) kgf.cm....................... Kilogramme per square millimetre kgf/mm 2................. Kilogramme per square centimetre kgf/cm2................. Kilogramme metres (torque) kgf.m.............................. Kilometres km.............................................................. Kilometres per hour km/h............................................. Kilovolts kV................................................................... Left-hand LH................................................................ Left-hand steering LHStg............................................. Left-hand thread LHThd............................................... Litres l or litre...............................................................Low tension l.t.............................................................. Maximum max............................................................. Metre m........................................................................ Millilitre ml.................................................................... Millimetre mm............................................................... Miles per gallon mpg.................................................... Miles per hour mph...................................................... Minute (angle) ............................................................ Minus (of tolerance) -................................................... Negative (electrical) -................................................... Newton metres (torque) Nm........................................ Number No.................................................................. Ohms ohm................................................................... Ounces (force) ozf....................................................... Ounces (mass) oz........................................................ Ounce inch (torque) ozf.in........................................... Outside diameter O.D.................................................. Part number Part No.................................................... Percentage %............................................................... Pints pt......................................................................... Pints (US) US pt........................................................... Plus (tolerance) +......................................................... Positive (electrical) +.................................................... Pound (force) lbf.......................................................... Pounds inch (torque) in.lbf........................................... Pound (mass) lb........................................................... Pounds per square inch PSI or lbf/in 2.......................... Ratio :........................................................................... Reference ref............................................................... Revolution per minute rev/min..................................... Right-hand RH............................................................. Second (angle) ........................................................... Second (numerical order) 2nd...................................... Specific gravity sp.gr.................................................... Square centimetres cm 2............................................... Square inches in2......................................................... Standard wire gauge s.w.g.......................................... Synchroniser/Synchromesh synchro........................... Third 3rd....................................................................... Top dead centre TDC.................................................. United Kingdom UK...................................................... Vehicle Identification Number VIN............................... Volts V......................................................................... Watts W....................................................................... SCREW THREADS American Standard Taper Pipe NPTF......................... British Standard Pipe BSP........................................... Unified Coarse UNC.................................................... Unified Fine UNF.........................................................
01INTRODUCTION 10 INFORMATION CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY NEW TERM (ACRONYM) Accelerator pedal (AP)................................................. Air cleaner (ACL).......................................................... Air conditioning (AC).................................................... Battery positive voltage (B+)........................................ Closed loop (CL).......................................................... Closed throttle position (CTP)...................................... Canister purge valve (CANPV).................................... Data link connector (DLC)........................................... Diagnostic trouble code (DTC)..................................... Distributor ignition (DI)................................................. Engine control module (ECM)...................................... Engine coolant level (ECL)........................................... Engine coolant temperature (ECT).............................. Engine coolant temperature sensor (ECTS)................ Engine speed (RPM).................................................... Evaporative emission system (EVAP).......................... Engine fuel temperature sensor (EFTS)...................... 4th gear, 3rd gear etc. (4GR, 3GR).............................. Fuel pump (FP)............................................................ Fan control module (FCM)........................................... Generator (GEN).......................................................... Ground (GND).............................................................. Heated oxygen sensor (H02S).................................... Idle air control (IAC)...................................................... Idle air control valve (IACV)......................................... Ignition control module (ICM)....................................... Inertia fuel shutoff (IFS)................................................ Inertia fuel shutoff switch (IFSS).................................. Intake air temperature (IAT)......................................... Malfunction indicator lamp (MIL).................................. Manifold vacuum zone (MVZ)...................................... Mass air flow sensor (MAFS)....................................... Multiport fuel injection (MFI)........................................ On board diagnostic (OBD).......................................... Open loop (OL)............................................................ Park/neutral position (PNP)......................................... Park/neutral position switch (PNPS)............................ Programmable read only memory (PROM).................. Relay module (RM)...................................................... Service reminder indicator (SRI).................................. Solid state relay module (SSRM)................................. Three way catalytic converter (TWC).......................... Throttle body (TB)........................................................ Throttle position sensor (TPS)...................................... Torque converter clutch (TCC).................................... Transmission range (TR).............................................. Transmission range selector (TRS)............................. Vehicle speed sensor (VSS)........................................ Wide open throttle (WOT)............................................OLD TERM (ACRONYM) Throttle pedal (-).......................................................... Air cleaner (-)............................................................... Air conditioning (AC).................................................... Battery plus, bat +, bat feed (B+)................................. Closed loop (-)............................................................. Closed throttle, idle position (-).................................... Charcoal canister purge valve (-)................................. Serial link (-)................................................................ Fault code (-)............................................................... Electronic ignition (-).................................................... Electronic control unit (ECU)........................................ Coolant level (-)........................................................... Coolant temperature (temp)......................................... Coolant temperature thermistor (-).............................. Engine speed (rev/min)................................................ Evaporative loss system (ELC)................................... Fuel temperature thermistor (-).................................... Fourth gear, 3rd gear (-).............................................. Fuel pump (-)............................................................... Condenser fan timer (-)................................................ Alternator (-)................................................................ Ground, earth (B-)........................................................ Lambda (02) sensor (-)................................................ Idle speed control (ISC)................................................ Stepper motor (-)......................................................... Ignition module (-)........................................................ Inertia switch (-)........................................................... Inertia switch (-)........................................................... Intake temperature/ambient temperature (-)................ EFI warning lamp (-).................................................... Manifold depression, vacuum (-)................................. Air flow meter (-).......................................................... Electronic fuel injection (EFI)....................................... Fault code display unit (-)............................................ Open loop (-)............................................................... Park or neutral (-)......................................................... Start inhibit switch (-)................................................... Chip, PROM (PROM)................................................... Relay (-)....................................................................... Check engine light (-)................................................... Control unit (-).............................................................. Catalyst, catalytic converter (CAT).............................. Throttle housing (-)...................................................... Throttle potentiometer (-)............................................. Direct drive clutch (DDC).............................................. Transmission gear (-)................................................... Shift lever, shifter (-).................................................... Road speed transducer (-)........................................... Full throttle, wide open throttle (WOT).........................
INTRODUCTION 11 INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) An adhesive label containing the Vehicle Identification Number, date of manufacture and gross axle weight ratings is positioned in a recess on the LH side of the drivers footwell. The information also includes wheel and tyre sizes and tyre pressures at gross axle weight ratings. Key to vehicle identification label A.Month and year of manufacture B.Gross vehicle weight rating C.Gross axle weight rating for front axle D.Gross axle weight rating for rear axle E.Vehicle identification number (17 digits) F.Vehicle identification number - bar code The VIN is also stamped on a plate visible through the LH side of the windscreen. The number is also stamped on the RH side of the chassis to the rear of the front lashing eye.
01INTRODUCTION 12 INFORMATION LOCATION OF IDENTIFICATION NUMBERS Engine serial number - V8i engine Stamped on a cast pad on the cylinder block, between numbers 3 and 5 cylinders. NOTE: The appropriate engine compression ratio is stamped above the serial number. Automatic gearbox serial number The serial number is stamped on a plate attached to the LH side of the casing. Transfer gearbox serial number The serial number is stamped on the LH side of the gearbox casing below the mainshaft rear bearing housing adjacent to the bottom cover, see J6092 Front axle serial number Serial number is stamped on the front of LH axle tube. Rear axle serial number Serial number is stamped on rear of LH axle tube.
INTRODUCTION 13 INFORMATION FAULT DIAGNOSTIC EQUIPMENT TestBook Land Rover Vehicles are equipped with substantial electronics to provide the best performance from the vehicles systems. Diagnostic equipment named TestBook is available to expand the diagnostic abilities of the dealer workshop. This repair manual is produced with TestBook in mind. Features of TestBook include :- ·Fully upgradable support for the technician. ·Structured diagnostics to accommodate all skill levels. ·Touch screen operation. ·Direct print out of screen information and test results. ELECTRICAL REFERENCE LIBRARY The Electrical Reference Library is a separate publication intended for use by trained Land Rover technicians as an aid to diagnosing electrical faults.READING THIS MANUAL This manual 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. Fault diagnosis. Adjustment. Repair. Overhaul. Specifications, Torque. 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 auxiliary drive belt. A cross reference sites this information in: Section: Electrical - Sub-section: Repairs - Heading: Auxiliary drive belt American terminology. A few words used in this manual differ to words used in America. Where this occurs the American word is placed inside square brackets. For example: bonnet [hood], wing [fender], ramp [hoist].
GENERAL SPECIFICATION DATA 1 INFORMATION ENGINE 4.0 V8i Type V8i................................................................................. Number of cylinders Eight, two banks of four......................................................... Bore 94,00 mm................................................................................. 3.70 in Stroke 71,12 mm............................................................................... 2.80 in Capacity 3950 cm 3........................................................................... 241 in3 Compression ratio 9.35:1............................................................ Valve operation Overhead by push-rod................................................................ Maximum power 140kW at 4750 rev/min............................................................... Crankshaft Main journal diameter 63,500-63,487 mm....................................................... 2.500-2.4995 in Minimum regrind diameter 62,471-62,484 mm............................................ 2.459-2.260 in Maximum out of round 0,040 mm.................................................. 0.0016 in Crankpin journal diameter 55,513-55,500 mm................................................ 2.1855-2.1850 in Minimum regrind diameter 54,484-54,497 mm............................................... 2.1450-2.1455 in Crankshaft end thrust - end float Taken on thrust washers of centre main bearing 0,10-0,20 mm.......... 0.004-0.008 in Maximum run-out 0,08 mm............................................................. 0.003 in Main bearings Number and material 5, Lead-indium overlay........................................................ Diametrical clearance 0,015-0,060 mm....................................................... 0.0006-0.0024 in Undersize bearing shells 0,254 mm, 0,508 mm.................................................. 0.010 in, 0.020 in Connecting rods Type Horizontally split big-end, plain small-end................................................................................. Length between centres 155,12-155,22 mm................................................... 6.107-6.111 in Big-end bearings Type and material Lead-indium overlay............................................................ Diametrical clearance 0,015-0,060 mm....................................................... 0.0006-0.0024 in End-float crankpin 0,15-0,36mm............................................................ 0.006-0.014 in Undersize bearing shells 0,25 mm, 0,50 mm.................................................. 0.010, 0.020 in Piston/gudgeon pins Length 60.00-60,50 mm.............................................................................. 2.362-2.382 in Diameter 23,995-24,000 mm.......................................................................... 0.9447-0.9449 in Fit-in connecting rod Press fit......................................................... Clearance in piston 0,006-0,015 mm.......................................................... 0.0002-0.0006 in
04GENERAL SPECIFICATION DATA 2 INFORMATION Pistons Clearance in bore, measured at bottom of skirt at right angles to piston pin 0,020-0,050 mm................................... 0.0008-0.0020 in Piston rings Number of compression rings 2.......................................... Number of control rings 1.................................................... No 1 compression ring Molybdenum barrel faced..................................................... No 2 compression ring Tapered and marked T or TOP..................................................... Width of compression rings 1,48-1.49 mm.............................................. 0.058-0.059 in Top 1,21-1,23 mm.......................................................................... 0.047-0.048 in Compression ring gap 0,40-0,65 mm...................................................... 0.016-0.26 in Top 0.3-0.5 mm.......................................................................... 0.012-0.020 in Oil control ring type Aclonoform.......................................................... Oil control ring width 3,0 mm......................................................... 0.118 in Oil control ring rail gap 0,38-1,40 mm..................................................... 0.015-0.055 in Camshaft Location Central........................................................................... Number of bearings 5.......................................................... Bearing type Tin-aluminium - Non serviceable..................................................................... Camshaft end-float 0............................................................ Drive Chain 9,52 mm pitch x 54 pitches.................................................................................. Tappets Type Hydraulic-self-adjusting................................................................................. Valves Length: Inlet 116,59-117,35 mm.................................. 4.590-4.620 in Exhaust 116,59-117,35 mm........................... 4.590-4.62 in Seat angle: Inlet 45°to 45°25 .................................. Exhaust 45°to 45°25 ........................... Head diameter: Inlet 39,75-40,00 mm.................................. 1.565-1.575 in Exhaust 34,23-34,48 mm........................... 1.347-1.357 in Stem diameter: Inlet 8,664-8,679 mm.................................. 0.341-0.342 in Exhaust 8,651-8,666 mm........................... 0.340-0.341 in Stem to guide clearance: Inlet 0,025-0,066 mm.................................. 0.001-.0026 in Exhaust 0,038-0,078 mm........................... 0.0015-0.003 in Valve lift (Inlet and Exhaust) 9,94 mm............................................ 0.391 in Valve spring fitted length at pressure of 29,5 kg, 65 lb 40,4 mm.... 1.590 in Lubrication System type Wet sump, pressure fed..................................................................... Oil pump type Eccentric rotor................................................................... Oil pressure at 2400 rev/min with engine at running temperature 2.1 - 2.8 bar..................................................... 30 - 40 lb/in 2 Oil filter - internal Wire screen, pump intake filter............................................................... Oil filter - external Full flow, self-contained cartridge.............................................................
GENERAL SPECIFICATION DATA 3 INFORMATION ENGINE MANAGEMENT SYSTEM (GEMS) Fuel system type Sagam-Lucas Gems hot wire system electronically.............................................................. controlled Fuel pump-make/type High pressure electrical, immersed in the fuel tank...................................................... Fuel pump delivery pressure 2.4-2.6 bar............................................ 34-37 lbf/in 2 Fuel filter In-line filter canister type.......................................................................... Mass air flow sensor (MAF) Make and type Lucas Hot Wire 20AM................................................................. Injectors Make and type Lucas D1000................................................................. Engine Control Module (ECM) Make and type Lucas GEMS 8.2................................................................. Fuel pressure regulator Make and type Lucas 8RV................................................................. Fuel temperature sensor Make and type Lucas 6TT................................................................. Coolant temperature sensor Make and type Lucas 8TT................................................................. Bypass air valve (Stepper motor) Make and type Lucas 3ACM................................................................. Throttle position sensor Make and type Lucas 3TP................................................................. Heated oxygen sensor Make and type Lucas 4LS - heated................................................................. Camshaft position sensor Make and Land Rover part no. Honeywell ERR2261......................................... Crankshaft position sensor Make and type Lucas 4CS................................................................. Knock sensor Make and type Lucas 2KS.................................................................
04GENERAL SPECIFICATION DATA 4 INFORMATION Intake air temperature sensor Make and type Lucas 10TT................................................................. Ignition coils Make and type Lucas 2DIS2................................................................. COOLING SYSTEM Type Pressurized system with cross-flow radiator and................................................................................. remote header tank, thermostat control, pump and fan assisted. Water and antifreeze mixture as coolant. Type of pump Centrifugal impellor, belt driven................................................................... Thermostat 88 0C ....................................................................... 1900F Expansion tank cap pressure - system pressure 1.0 bar............. 15 lbf/in2 Fan and viscous coupling assembly 11 blade axial flow 433mm, 17 in diameter.................................
GENERAL SPECIFICATION DATA 5 INFORMATION AUTOMATIC TRANSMISSION Automatic gearbox Model ZF4HP22............................................................................... Type Four speed and reverse epicylic gears with fluid................................................................................. torque converter and lock-up Transfer gearbox LT230Q Two speed reduction on main gearbox output, front............................................................................ and rear drive permanently engaged. Transfer gearbox ratios: High 1.211:1......................................................................... Low 3.269:1......................................................................... Automatic gearbox ratios 4th 0.728:1........................................................................... 3rd 1.000:1........................................................................... 2nd 1.480:1.......................................................................... 1st 2.480:1........................................................................... Reverse 2.086:1................................................................... Overall ratios - final drive High transfer.............................................. Low transfer 4th 3.46:1........................................................................... 9.34:1 3rd 4.75:1........................................................................... 12.83:1 2nd 7.03:1.......................................................................... 18.98:1 1st 11.78:1........................................................................... 31.80:1 Reverse 9.91:1................................................................... 26.75:1 Propeller shafts Type Front Solid bar 28.6mm, 1.125 in diameter................................................................................. Rear Tubular 51mm, 2.00 in diameter................................................................................. Universal joints Open type Hookes O3EHD................................................................. Rear axle Type Spiral bevel, fully floating shafts................................................................................. Ratio 3.54:1................................................................................. Front axle Type Spiral bevel, enclosed constant velocity joints, fully................................................................................. floating shafts Angularity of universal joint on full lock 32° ............................ Ratio 3.54:1.................................................................................