Land Rover Defender Workshop Rover Manual
Have a look at the manual Land Rover Defender Workshop Rover Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 364 Land Rover manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
12ENGINE 24 REPAIR Refit 8. Fitoilpump rotors infront cover. 9. Apply abead ofRTV sealant aroundretaining plate. 10. Fitoilpump retaining platetofront cover, securely tightenscrews. 11. Fitfront cover tocylinder block. SeeFront cover gasket OILPRESSURE RELIEFVALVE Service repairno-12.60.56 Remove 1. Remove engineoilsump. See Engine oil sump 2. Unscrew reliefvalve retaining plugfrom base of front cover. 3. Withdraw valvespring andplunger andcheck for wear. Valve spring freelength, 68.00mm(2.68 in). NOTE: Ifthe valve plunger sleeveisbadly worn, pitted orscored, anew front cover must befitted. See Front cover gasket Always renewvalvespring andplunger asapair. Refit 4. Insert valveplunger andspring intosleeve in front cover andsecure withretaining plug. 5. Fitengine oilsump. See Engine oilsump
ENGINE1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE:Torque wrenches shouldberegularly checkedforaccuracy toensure thatallfixings are tightened tothe correct torque. Nm Engine block Bearing cap 133 ............................................................................................... Blanking plug,oilgallery, rear 37 .................................................................... Oil squirt jetassembly 17 ................................................................................ Drain plug,cylinder block 25 ........................................................................... Oil squirt jet,vacuum pumpcam 7 ................................................................. Connecting rodtocap 59 ................................................................................ Oil pick upassembly tobearing cap 9 ........................................................... Oil pick upassembly tofront cover 25 ............................................................ Camshaft thrustplate 9 .................................................................................. Oil drain pipetoblock (internal) 25 ................................................................. Oil drain pipetoblock (external) 25 ................................................................ Sump tocylinder blockandfront cover 25 ...................................................... Drain plug,oilsump 35 ................................................................................... Tappet guide 14 .............................................................................................. Breather sidecover assembly 25 .................................................................... Baffle platetobreather sidecover 4 .............................................................. Vacuum pump 25 ............................................................................................ Fuel liftpump 25 ............................................................................................. Flywheel housing 45 ....................................................................................... Flywheel housingclutchcoverstud 10 ........................................................... Plug, flywheel housing 12 ............................................................................... Rear oilseal assembly 25 ............................................................................... Oil filter adaptor 45 .......................................................................................... Waxstat adaptortooil filter adaptor 9 ............................................................ Oil pressure switch 17 ..................................................................................... Oil filter, spinon 13 ......................................................................................... Oil cooler unions tofilter adaptor 45 ............................................................... Oil level tube 25 .............................................................................................. Engine mounting foottocylinder block 85 ...................................................... Engine mounting foottoflywheel housing 45 ................................................. Engine mounting footrubber tomounting foot(bolt andnut) 85 ..................... Flywheel tocrankshaft 146 .............................................................................. Clutch coverplatetoflywheel 34 .................................................................... Flex drive platetocrankshaft (auto) 146 .......................................................... Flex drive platetoring gear (auto) 25 ............................................................. Flex drive platetotorque converter (auto) 45 .................................................
12ENGINE 2 SPECIFICATIONS, TORQUE Nm Cylinder head Cylinder headtocylinder block M10 x117 60°+6 0° ............................................................................................. M12 x100 60°+6 0° ............................................................................................. M12 x140 60°+6 0°+2 0° ........................................................................................ Stub pipeheater feed 22 ................................................................................. Water temperature sensor 14 ......................................................................... Blanking plugcylinder head 14 ....................................................................... Engine liftingbrackets 25 ................................................................................ Electrical harnessclipbracket 25 ................................................................... Exhaust manifold stud 10 ................................................................................ Exhaust manifold nut 45 ................................................................................. Inlet manifold stud 8 ....................................................................................... Inlet manifold nutand bolt 25 .......................................................................... Air temperature sensor,inletmanifold 14 ....................................................... Blanking plug,inletmanifold 14 ...................................................................... Heatshield toinlet manifold 6 ......................................................................... Glow plug 20 ................................................................................................... Glow plugterminal nut 2 ................................................................................ Injector clamp(stud) 8 ................................................................................... Injector clamp(nut) 25 .................................................................................... Thermostat housing 25 ................................................................................... Water outletelbow tothermostat housing 25 .................................................. Water temperature switch,thermostat housing 11 .......................................... Plug thermostat housing 6 ............................................................................. Rocker shaftpedestal bolt 5° +5 0° ..................................................................... Rocker cover(stud) 8 ..................................................................................... Rocker cover(fixing nut) 10 ............................................................................ Breather cyclonetorocker cover 9 ................................................................ Tappet adjusting nut 16 .................................................................................. Front cover tocylinder block 25 ...................................................................... Front cover platetofront cover 25 .................................................................. Static idler-timing belt(stud) 10 ..................................................................... Static idler-timing belt(nut) 45 ...................................................................... Tensioner (timingbelt) 45 ............................................................................... Camshaft hubbolt 80 ...................................................................................... Timing pulleytocamshaft hub 25 ................................................................... Fuel injection pump(stud) 8 ........................................................................... Fuel injection pump(nut) 25 ........................................................................... Abutment brackettoinjection pump 25 ........................................................... Support bracketinjection pumptocylinder block 25 ....................................... Fuel injection pumpaccess platetofront cover plate 25 ................................ Timing pulleytoinjection pumphub 25 ........................................................... TV Damper pulleybolttocrankshaft 80°+9 0° ..................................................... Fan pulley tohub 25 ....................................................................................... Fan andviscous coupling tohub 45 ............................................................... Auto tensioner, auxiliarydrive(stud) 14 .......................................................... Auto tensioner, auxiliarydrive(nut) 45 ........................................................... Auxiliary mounting brackettocylinder block(stud) 8 ..................................... Auxiliary mounting brackettocylinder block(boltandnut) 25 ........................ Water pumptoblock andmounting plate 25 .................................................. Water pumppulley tohub 25 ..........................................................................
ENGINE3 SPECIFICATIONS, TORQUE Nm Turbo charger oildrain adaptor toblock 42 .................................................... Oil drain pipetoturbocharger 25 .................................................................... Turbocharger oildrain pipetoadaptor 38 ....................................................... Turbocharger oilfeed pipeadaptor toblock 25 ............................................... Turbocharger oilfeed pipetoadaptor 25 ........................................................ Oil feed pipetoturbocharger 19 ..................................................................... Turbocharger tocylinder head(stud) 10 ......................................................... Turbocharger tocylinder head(nut) 45 ........................................................... Turbocharger toblanking plate 25 .................................................................. Turbocharger toEGR valve 25 ....................................................................... EGR delivery tubetovalve 25 ........................................................................ EGR delivery tubetomixing tube 25 .............................................................. Fuel liftpump tofilter (union) 15 ..................................................................... Fuel filterfrom liftpump (banjo bolt) 33 ........................................................... Fuel filtertofuel injection pump(banjo bolt) 33 .............................................. Fuel injection pumpfromfuelfilter (banjo bolt) 25 .......................................... Injector pipestoinjectors andfuelinjection pump 29 ..................................... Spill railtoinjectors (banjobolt) 10 ................................................................. Spill railtoinjection pump(banjo bolt) 25 ....................................................... Boost pipeinjection pump(banjo bolt) 10 ....................................................... Plug, rearofinjection pump 29 ....................................................................... PAS pump tomounting plate 25 ..................................................................... PAS pump mounting platetoauxiliaries mountingbracket 25 ........................ PAS pump pulley tohub 25 ............................................................................ Starter motor(boltandnut) 45 ........................................................................ Air conditioning compressor Compressor mountingbrackettofront cover 45 ............................................. Compressor tomounting bracket(stud) 8 ...................................................... Compressor tomounting bracket(nut) 25 ...................................................... Belt tensioner pulleytotensioner arm 45 ........................................................ Belt tensioner assembly tofront cover plate 25 .............................................. Idler pulley tofront cover plate 45 ................................................................... Compressor beltguard (nut) 25 ...................................................................... Sensors towater outletelbow (air/con) 25 ...................................................... Blanking plug,water outletelbow (air/con) 25 ................................................ Generator Generator mountingbrackettofront cover 45 ................................................ Generator tomounting bracket 85 .................................................................. Generator pulleytohub 95 ............................................................................. Generator beltguard 25 .................................................................................. Generator toauxiliaries mountingbracket 25 ................................................. Tachometer electricalconnection 4 ...............................................................
12ENGINE 4 SPECIFICATIONS, TORQUE METRIC Nm M5 6 ...................................................................................................... M6 9 ...................................................................................................... M8 25 ..................................................................................................... M10 45 ................................................................................................... M12 90 ................................................................................................... M14 105 .................................................................................................. M16 180 .................................................................................................. UNC /UNF 1/4 9 ...................................................................................................... 5/16 24 ................................................................................................... 3/8 39 ..................................................................................................... 7/16 78 ................................................................................................... 1/2 90 ..................................................................................................... 5/8 136 .................................................................................................... NOTE: Torque valuesabovearetobe used asaguide where notorque isspecified.
FUELSYSTEM 1 DESCRIPTION ANDOPERATION DESCRIPTION Fuel system The fuelsystem incorporates asupply andspill return line onallmodels asillustrated below. On 90models, seeJ6191, thefuel tank ismounted at the RH side ofthe vehicle chassis underthefront seat. On standard 110and130models thefuel tank is located atthe rear ofthe vehicle between thechassis longitudenal sections,asshown inJ6192. As anoption, atwin tank system fittedwitha combined change-over tapand 3way fuelsupply and return system, canbeinstalled onboth 110and130 models, seeJ6193. The tank/s onallvehicles isvented by a 2 way valve in the filler cap. FUEL SYSTEM LAYOUT 1. Fuel tank 2. Fuel sedimentor, iffitted 3. Fuel liftpump 4. Fuel filter 5. Fuel injection pump 6. Spill return line 7. Fuel injectors
19FUEL SYSTEM 2 DESCRIPTION ANDOPERATION A mechanical liftpump, withahand priming facility,is driven bythe camshaft, andismounted onthe RH side ofthe engine. A fuel filter, withareplaceable elementand incorporating awater separator, ismounted onthe front RHside ofthe engine compartment. A fuel sedimentor maybefitted when thevehicle is operating inmore arduous conditions, andisused to minimise waterdeposits inthe fuel system before reaching thefuel pump andfilter. Fuel injection iscarried outbyaBosch directinjection pump, incorporating acold start advance unitand a high idlesetting. Thepump ismounted onthe RH side of the engine andisdriven directly bygears inthe front cover fromthecrankshaft. Thepump meters and distributes fuelto4pintle typeinjectors locatedin pre-combustion chambersinthe cylinder head.Four heater plugs,located inthe cylinder headdirectly below eachinjector, arefitted toimprove coldstarting. An optional handthrottle, foruse with acentre power take off,islocated onthe fascia tothe LHside ofthe fuse box,andislinked independently tothe fuel injection pumpthrottle lever. Air intake The aircleaner ismounted onthe RH side ofthe engine andisconnected byhoses tothe cold air intake ductandturbocharger inlet.Fitted between the air cleaner andturbocharger isthe crankcase breather hose which connects toabreather filteronthe rocker cover. A single stageturbocharger, fittedbetween the exhaust manifold andexhaust downpipe,is connected byhoses tothe aircleaner andan intercooler whichismounted onthe LHside ofthe radiator. Theintercooler isconnected byahose tothe inlet manifold. WhenanEGR valve isfitted tothe turbocharger, additionalpipes/hoses areused to connect thecomponents. Exhaust gasrecirculation (EGR),whenfitted. Exhaust gasrecirculation iscontrolled byan ECU mounted underthefront centre seatorcubby boxand receives thefollowing inputs: Enginetemperature fromcoolant temperature sender unitonLH side ofcylinder head. Throttleposition frompotentiometer oninjection pump. Engine speedfromspeedometer. When allcorrect signals arereceived, theEGR solenoid allowsvacuum toopen EGRvalve and recirculate aportion ofthe exhaust gas.SeeJ6196 for the EGR system component locationandOperation for full system function.
FUELSYSTEM 3 DESCRIPTION ANDOPERATION 90FUEL SYSTEM 110FUEL SYSTEM 1. Fuel filter 2. Supply pipe,liftpump tofilter 3. Supply pipe,fuelfilter toinjection pump 4. Fuel injection pump 5. Fuel liftpump 6. Spill return pipe,injection pumptotank 7. Supply pipe,sedimentor tofuel pump 8. Fuel tank 9. Supply pipe,fueltank tosedimentor 10. Fuel fillerpipe 11. Breather pipe 12. Sedimentor, iffitted NOTE: Ifasedimentor isnot fitted, thefuel supply pipefrom thetank willconnect directly tothe fuel liftpump.
19FUEL SYSTEM 4 DESCRIPTION ANDOPERATION 110/130 TWINTANK FUELSYSTEM -5 DOOR VEHICLES 1. Fuel filter 2. Supply pipe,liftpump tofilter 3. Supply pipe,filtertoinjection pump 4. Fuel injection pump 5. Fuel liftpump 6. Spill return pipe,injection pumptochange-over tap 7. Supply pipe,fueltank change-over taptolift pump 8. Spill return pipe,change-over taptoside tank 9. Change-over tap,spill return 10. Fuel fillercap 11. Side fueltank 12. Supply pipe,sidetank tosedimentor 13. Sedimentor, iffitted, sidetank 14. Supply pipe,sedimentor tofuel tank change-over tap 15. Change-over tap,side andrear tanks 16. Supply pipe,rearsedimentor tofuel tank change-over tap 17. Spill return pipe,change-over taptorear tank 18. Rear fueltank 19. Fuel fillerpipe 20. Breather pipe 21. Supply pipe,reartank tosedimentor 22. Sedimentor, iffitted, reartank NOTE: Ifsedimentors arenot fitted, the fuel supply pipefrom theside andrear tanks connects directlytothe fuel tank change-over tap.
FUELSYSTEM 5 DESCRIPTION ANDOPERATION 110/130 TWINTANK FUELSYSTEM -2 DOOR VEHICLES 1. Fuel filter 2. Supply pipe,fuelliftpump tofilter 3. Supply pipe,filtertoinjection pump 4. Injection pump 5. Fuel liftpump 6. Spill return pipe,injection pumptochange-over tap 7. Supply pipe,fueltank change-over taptolift pump 8. Side fueltank 9. Spill return pipe,change-over taptoside tank 10. Change-over tap,spill return 11. Supply pipe,sidetank tosedimentor 12. Fuel fillerpipe 13. Breather pipe 14. Sedimentor, iffitted, sidetank 15. Supply pipe,sedimentor tofuel tank change-over tap 16. Change-over tap,fueltanks 17. Supply pipe,rearsedimentor tofuel tank change-over tap 18. Spill return pipe,change-over taptorear tank 19. Rear fueltank 20. Fuel fillerpipe 21. Breather pipe 22. Supply pipe,reartank tosedimentor 23. Rear sedimentor, iffitted NOTE: Ifsedimentors arenot fitted, the fuel supply pipefrom theside andrear tanks connects directlytothe fuel tank change-over tap.