Land Rover Defender 1990 User Manual

GED

DEFENDER

90

WORKSHOP MANUAL SUPPLEMENT

Publication

Number

110

SLR

621

130

EN

WS

1

Published by the

Technical Publications Department

@

Copyright Land Rover

1990

of

Land Rover

West Midlands,

Lode Land

Sol

ihul

892

8NW

England

I

.

CONTENTS

...

.....

-

..

;,TI

,::-...$,.

......

........

,..

,.

.....

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.

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Section

Number

01

:

L

04

INTRODUCTION

-

General information

-

Poisonous substances

-

Fuel Handling

-

Sealants

-

Disposal

-

Abbreviations and symbols

-

Special tools

-

Vehicle identification numbers

-

Copyright

G

E

N

-

Tdi engine data

-

Fuel

-

Cooling system

-

Clutch

of

ERAL

system

oil

and fluids

SPECIFICATION

Page

DATA

9-12

9

05

06

109

L

12

E

N

G

I

N

E

T

U

N

I

N

G

DATA

T

O

R

Q

U

E

WRENCH

I

RECOMMENED LUBRICANTS, FLUIDS AND CAPACITIES

-

Tdi engine lubricants

-

Capacities

-

Anti-freeze

SETTING

ENGINE

-

Camshaft - remove and refit - including front cover

-

Power steering pump bracket - remove and

-

Cylinder head - remove and refit

-

Camshaft timing belt - renew

-

Tdi engine - overhaul

refit

oil

seals/timing belt and gears

17

-

18

17

-

ia

17 - 18

30 31

32

34

35

..:r

...

,

_

,.

5..

19

1

FUEL SYSTEM

-

Fuel

injection pump - remove and refit

-

Air cleaner - remove and refit

-

~ur-bo charger- remove and retit

-

Intercooler - remove and refit

:i'

.

,.

-

..

81

84

a5

86

Section

Number

26

I

C

O

L

I

N

G

SYSTEM

Page

e

..

-7

30

157

86

>

-

Engine protection

-

Drain and

-

Fan cowl - remove and refit

-

Fan and coupling - remove and refit

-

Radiator - remove and refit

-

Water pump - remove and refit

I

MANIFOLDS

I

STEERING

ELECTRICAL EQUIPMENT

refill

AND

EXHAUST

87

a8

88

89

90

..

-

a

DEFENDER

INTRODUCTION

01

-

.I

INTRODUCTION

This Workshop Manual Supplement maintenance

Individuals who undertake their own repairs should have some skill and training, and limit repairs to components which could not affect the safety safety critical items such as steering, brakes, or suspension should be carried out by a Land Rover Dealer. Repairs to such items should

WARNINGS and CAUTIONS are given throughout this Supplement

WARNING: Procedures which must

CAUTION: This calls attention to procedures which must be followed to avoid damage

NOTE: This calls attention to methods which make a job easier to perform.

REFERENCES

References to the left

unless otherwise stated. With the engine and gearbox assembly removed, the water pump end

is

referred to as the front.

To

reduce repetition, some operations covered in this Manual do not include reference to testing the vehicle

after repair. It

of

the vehicle is carried out particularly where safety related items are concerned.

of

Land

Rover

vehicles.

or

right hand side in the supplement are made when viewing the vehicle from the rear

is

essential that work is inspected and tested after completion and

is

designed to assist skilled technicians in the efficient repair and

of

the vehicle

NEVER

be

be attempted by untrained individuals.

followed precisely to avoid the possibility

or

its passengers. Any repairs required to

in

the following form:

of

personal injury.

to

components.

if

necessary a road test

of

the engine

DIMENSIONS

to

The dimensions quoted are brackets following the dimensions, have been converted from the original specification.

REPAIRS AND REPLACEMENTS

When replacement parts are required it Attention and accessories: Safety features embodied in the vehicle may be impaired fitted. In certain territories, legislation prohibits the fitting specification. Torque wrench values given in the Workshop Manual supplement must Locking devices, where specified, must be fitted. removal it must specified in the Workshop Manual Supplement.

PO

Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should be kept away from open wounds. These substances among others include anti-freeze, brake fluid, adhesives.

AS

B

IS

0 N 0

EST0

is

particularly drawn

be

replaced with a new one. Certain fasteners must not be re-used. These fasteners are

US SUBSTANCES

fuel,

S

design engineering specification. Alternative unit equivalents, shown in

is

essential that genuine Land

to

the following points concerning repairs and the fitting

of

parts not to the vehicle manufacturer's

If

the efficiency

windscreen washer additives, air conditioning refrigerant, lubricants and various

Rover

parts are

if

other than Land Rover parts are

of

a locking device

used.

of

replacement parts

be

strictly adhered

is

impaired during

to.

WARNING: Some components on the vehicle, such as gaskets and friction surfaces (brake linings, clutch

discs) may contain asbestos. inhaling asbestos dust

essential precautions must

1.

Work out

2.

Dust found on the vehicle and not by blowing.

3.

Dust waste should

4.

If

any cutting, drilling etc.,

and

of

doors

on1 hand tools

be

observed:

or

in a well ventilated area and wear a protective mask.

or

produced during work on the vehicle should be removed by vacuuming

be

dampened, placed in a sealed container and marked

is

attempted on materials containing asbestos the item should be dampened

or

low speed power tools used.

is

dangerous to your health and the following

to

ensure safe disposal.

1

101

I

INTRODUCTION

FUEL HANDLING PRECAUTIONS

e

DEFENDER

The following information provides basic precautions which must

also outlines the other areas

This

information

of

made

Fuel vapour is highly flammable and in confined spaces When fuel evaporates it produces a readily ignitable mixture. The vapour

be

dangerous.

Always have a

or

WARNING:

the battery terminal could ignite

BEFORE

when fuel systems are being dismantled all forms head

NO HAVING HAD SPECIALIST TRAINING.

HOT

your local fire station.

distributed throughout a workshop by air current, consequently, even a small spillage

when dismantling fuel systems and in areas where fuel containers are stored.

carrying out work on a fuel system. Whenever fuel

-

lamps used must be flameproof and kept clear

ONE

SHOULD BE PERMWrED

FUEL HANDLING

is

issued

fire

extinguisher containing

It

is

imperative that the battery

of

risk which must not

for

basic guidance only, and in any

150

times its own volume in vapour, which when diluted with air becomes

is

heavier than air and will always fall to the lowest level. It can readily

FOAM

fuel vapour in the atmosphere. Always disconnect the vehicle battery

TO

REPAIR COMPONENTS ASSOCIATED

be

CO

is

not disconnected during fuel system repairs as arcing at

ignored.

is

also

GAS,

of

ignition must be extinguished

of

spillage.

be

observed

case

of

doubt, appropriate enquiries should be

very

explosive and toxic.

or

POWDER

is

being handled, transferred

if

close at hand when handling fuel,

WITH

fuel is to be handled safely. It

of

fuel

is very

or

removed, any

FUEL

WITHOUT

stored,

or

FIRST

Before

be adhered to.

i

FUEL TRANSFER

WARNING:

The transfer

transfer tank must including attention

FUEL TANK REMOVAL

A

FUEL TANK REPAIR

Under

commencing any operation requiring fuel drainage from fuel tanks, the following procedures should

1.

Allow sufficient time for the fuel to

2.

Vent system by removing the fuel cap in a drainage.

Fuel

must not be extracted or drained from any vehicle while it is standing over a pit.

of

fuel from the vehicle

be

used according to the transfer tank manufacturef s instructions and local regulations,

to

grounding

fuel vapour label should be attached to the fuel tank upon removal from the vehicle.

no

circumstances should a repair to any tank be attempted.

of

cool,

thus avoiding contact with hot fuels.

well

ventilated area. Replace cap until commencement

fuel

tank must be carried out in a well ventilated area. An approved

tanks.

of

tank

p

i.

..

:’”

3

e

DEFENDER

INTRODUCTION

101

-

<,,

.

RECOMMENDED

A

number

work. These items include:

COMPOUND.

obtaining supplies, contact one

Marston Lubricants Limited

Hylo

Cale Lane, New Springs

Wigan, WN2

Tel: 0942 824242

Fax: 0942 826653

Telex: 67230

USED ENGINE

Prolonged and repeated contact with engine

-skin, leading to dryness, irritation and dermatitis. In addition,

contaminants which may cause skin cancer. Adequate means be provided.

Health Protection Precautions

of

House

SEALANTS

branded products are recommended in this Supplement

HYLOMAR GASKET AND JOINTING COMPOUND

They should be available locally from garage equipment suppliers.

of

the following companies

IJR

OIL

HANDLING PRECAUTIONS

or

motor

for

Northern Adhesives Limited

Prudhoe Northumberland NE42 6NP

Tel:

0661

Fax:

0661 35839

oil

will result in the removal

used

of

for

use during maintenance and repair

advice and the address

32014

engine

skin protection and washing facilities should

oil

and

HYLOSIL

If

there

of

natural fats from the

contains potentially harmful

RN

SILICON

is

any problem

the nearest stockist.

1. Avoid prolonged and repeated contact with

2. Wear protective clothing, including impervious gloves where applicable.

3. Do not put oily rags in pockets.

4. Avoid contaminating clothes, particularly

5.

Overalls must be cleaned regularly. Discard unwashable clothing and

6.

First aid treatment must be obtained immediately for open cuts and wounds.

7.

Use barrier creams, before each work period, to help the removal

8.

Wash with soap and water

Preparations containing lanolin replace the natural skin

D

O

9.

10.

11.

12. Where there is a

DISPOSING

Environmental protection precaution

It

is

Dispose

S

P E CI FICATIO N

not use petrol, kerosene, diesel fuel,

If

skin disorders develop, obtain medical advice.

Where practicable, degrease components prior to handling.

risk

shields; in addition an

OF

USED

OILS

illegal to pour used

of

used

oil

through authorised waste disposal contractors.

to

ensure all

of

eye

contact,

eye

wash facility should be provided.

AND FLUIDS

and other fluids onto the ground, down sewers or drains,

eye

oils,

particularly used engine

underwear, with

oil

is

removed (skin cleansers and nail brushes

gas

oil,

thinners

oil.

oils

which have been removed.

or

solvents

.

protection should be worn, for example, goggles

oils.

oil

impregnated footwear.

of

oil

from the skin.

for

washing the skin.

or

will

help).

or

face

into waterways.

..

Purchasers are advised that the specification details set out in this Supplement apply to a range and not The Manufacturers in such manner Manufacturer's policy

While every Manufacturer any inaccuracy

to

any one.

effort

For

the specification

resetve the right to vary their specifications with

as

they think fit. Major

of

constant product improvement.

is

made to ensure the accuracy

or

Dealer, by whom this Supplement is supplied, shall in any circumstances be held liable for

or

the consequences thereof.

of

a particular vehicle, purchasers should contact their Dealer.

or

without notice, and at such times and

as

well

as

minor changes may be involved in accordance with the

of

the particulars contained in this Supplement, neither

of

vehicles

the

3

INTRODUCTION

01

COPYRIGHT

Q

Rover Group Ltd

All

rights reserved.

any form, electronic, mechanical, photocopying, recording

Rover

Group Ltd.

1990

No

part

of

this publication may be produced, stored

in

a

or

other means without

e

retrieval system or transmitted

prior

DEFENDER

written permission

in

of

SPECIAL

The use carried out efficiently, and safely. Where the be used to avoid the possibility

ACCESSORIES AND CONVERSIONS

Land should be carried out to any vehicle produced by Land Rover which could affect the safety its passengers.

T

Land Before fitting any accessory accessory

WARNING:

vehicle. Land Rover

may occur as conversions to Land

SERVICE

of

approved special service tools is important.

Rover

vehicles are designed and constructed for a

Rover

has

or

TOOLS

of

personal injury

tested and approved a large number

or

commencing any conversion work to any Land Rover vehicle,

conversion

DO

NOT

a

direct result

is

approved by Land

FIT

unapproved accessories

will

not accept any liability

of

fitment

Rover

vehicles.

of

They

are essential

use

of

special service tools i specified, only these tools should

or

damage

of

Rover.

or

conversions, as

for

death, personal

non-approved accessories

to

components.

variety

accessories and conversions, suitable for this vehicle.

of uses but no alterations

if

service operations are to be

they

could affect the safety

injury

or

damage to property which

or

the carrying out

or

conversions

of

the vehicle or

CHECK

of

non-approved

that

of

the

4

DEFENDER

INTRODUCTION

n

01

,-

'

..

.

.-

.

a:.;

,;.:

.:..,*-:.

'

I:

.I

%

1.

.

..

.:,

,I

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..

...

.....

..

ABBREVIATIONS AND SYMBOLS

Across flats (bolt size)

After bottom dead centre After top dead centre Alternating current

Ampere Ampere hour

Before Before

Bottom dead centre Brake horse power bhP

British Standards Carbon monoxide Centimetre Centigrade (Celsuis) Cubic centimetre Cubic inch Degree (angle)

.

Degree (temperature) Diameter Direct current Electronic Control Unit

Electronic Fuel Injection Fahrenheit Feet Feet Fifth First Fluid ounce Foot pounds (torque) Fourth

Gramme Gramme (mass) Gallons gal

Gallons (US) High tension (electrical) Internal diameter

Inches

Inches Kilogramme

Kilogramme (mass.) kg Kilogramme centimetre (torque)

Kilogramme per square millimetre Kilogramme per square centimetre Kilogramme metres (torque) Kilometres Kilometres per hour

Kilovolts Left-hand steering Left-hand thread Litres

..............................................................

.................................................

bottom dead centre

top dead centre

..........................................................

............................................................

...........................................

.............................................................

.....................................................

...............................................................

.......................................................................

per

minute

...............................................

.....................................................................

......................................................................

.......................................................

..................................................................

(force)

.....................................................

......................................................

................................................................

..................................................

of

mercury

....................................................................

(force)

...........................................................

................................................................

...................................................................

..........................................

..............................

.....................................

..............................................

............................

...................................

.........................................

............................................

...................................................

..............................................

................................................

.................................

...................................

........................................

....................................

................................................

..........................................

..............................................

...................

...............

..............

...........................

.........................................

..........................................

............................................

ABDC ATDC

a.c.

amp

amp hr

BBDC

BTDC

BDC

CO

cm3

deg or deg

or

dia.

d.c.

E.C.U.

E.F.I.

ft/min

5th

fl

ft

4th

US gal

H.T.

I.D.

in. Hg

kg

kgf.cm

kgf/mm2

kgf/cm2

kgf.m

km

km/h

LHStg

LHThd

litre

AF

BS

cm

C

in3

O

F

ft

1st

oz

Ib

g

f

g

in

f

kV

Low tension Maximum Metre Millilitre Millimetre

Miles per gallon

Miles per hour Minute (angle)

Minus Negative (electrical) Newton meters (torque)

Number Ohms Ounces Ounces Ounce inch (torque) Outside diameter Part number Percentage

.....................................................................

Pints Pt Pints (US)

Plus (tolerance)

Positive (electrical)

Pound

Pounds inch (torque) Pound Pounds per square inch Ratio

........................................................................

Reference Revolution per minute Right-hand Second (angle) Second (numerical order) Specific gravity Square centimetres Square inches Standard wire gauge

Synchroniser/Synchromesh

Third

...................................................................

Top dead centre

United Kingdom Vehicle Identification Number Volts

......................................................................

Watts

....................................................................

SCREW TH READS

American Standard Taper Pipe British Standard Pipe Unified Coarse

Unified Fine

..........................................................

.........................................................

.....................................................................

................................................................

...........................................................

.................................................

...................................................

.........................................................

(of

tolerance)

...............................................

................................................

....................................

..............................................................

...............................................................

(force) (mass)

....................................................

......................................................

......................................

.............................................

.................................................

............................................................

........................................................

.....................................................

................................................

(force)

.......................................................

......................................

(mass)

.........................................................

....................................

...........................................................

.....................................

...........................................................

.......................................................

...................................

................................................

.............................................

.......................................................

.......................................

.........................

................................................

..................................................

............................

..........................

...........................................

.................................................

.......................................................

1.t.

ma.

mi

mm

mpg mPh

Nm

No.

ohm

ozf

oz

ozf.in.

O.D.

Part

No.

US pt

Ibf

in.lbf.

P.S.I.

ref.

r.p.m

RH

2nd

sp.gr.

cm2

in2

s.w.~.

synchro.

3rd

TDC

UK

VIN

W

NPTF

BSP

UNC

UNF

m

'

-

%

+ +

Ib

:

I'

v

5

loll

INTRODUCTION

e

DEFENDER

Special

The use carried out efficiently, and safely. Where special tools are specificed,

avoid the possibility

they save can

Every special

which has not been tested and approved by us. New tools are only introduced where an operation cannot

satisfactorily carried out using existing tools or standard equipment. The user

is

necessary and that it wilt perform accurately, efficiently and safely.

Special tools bulletins

All

should be placed with the local distributor may order direct from

The tools recommended in this Workshop Manual Supplement are listed in a multi-language illustrated

catalogue obtainable from Messers. V. L. Churchill at the above address under publication number VLC

23721187

Erdington, Birmingham, 624

of

approved special service tools

of

personal injury

be

considerable.

tool

is

designed with the

will

be

issued periodically giving details

orders and enquiries from the United Kingdom should be sent direct to

V.

L. Churchill distributor, where one exists. Countries where there

V.

or

from Land

Rover

Merchandising Service, quoting publication number SMR

OQ5.

is

or

close

L.

Churchill Limited,

Service

important. They are essential

damage to the components.

co-operation

PO

Tools

only these

of

Land Rover, and

of

new tools

Box

3,

Daventry, Northants, England,

if

service

Also

as

V.

operations are to

tools

should be used to

the amount

no

tools

is

therefore assured that the

they are introduced.

L.

Churchill. Overseas orders

of

is

put into production

681

MI,

be

time which

is

no

NNI

1

4NF.

PO

Box

534,

be

tool

6

DEFENDER

LOCATION

OF

VEHICLE IDENTIFICATION & UNIT NUMBERS

101

..

~.,..

..

.I

).

.

b: : ..,

..

...

,.

...

..

.

..

.

VEHICLE IDENTIFICATION NUMBER (VIN)

The Vehicle Identification Number and the recommended maximum vehicle weights are

of

stamped on a plate riveted to the top

box

behind the brake servo

The number

of

the chassis forward

is

also stamped on the right-hand

of

the spring mounting turret.

the pedal

Always quote this number when writing to Land Rover.

side

E

F

ST3067M

The Vehicle Identification Number identifies the manufacturer, model range, wheel engine, steering, transmission, model name and place

of

the coding process.

SAL World manufacturer identifier

LD Land Rover

C

Class

V

Class

H

Class

A

Basic

B

2door

M 4door

H High Capacity

F

Tdi or

8

5

speed LHD or

7

5

speed RHD

H

1991

A

Solihull site

PAINT

0

TRIM

base,

body type,

manufacture. The following example shows

100

inch

90

inch

110

inch

MY

..

Key

to

Veh

iicle

ldentiiication Number Plate

A.

Type approval

B.

VIN

(minimum

of

17

digits) C. Maximum permitted laden weight

D. Maximum vehicle and trailer weight

E.

Maximum road weight - front axle

F.

Maximum road weight - rear axle

for

\

vehicle

ENGINE SERIAL NUMBER - Tdi ENGINE

The engine number

block on the right hand side

is

stamped on the cylinder

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

The serial number bottom right hand side

RR1513M

.

TRANSFER GEARBOX

The serial number

of

the gearbox casing

bearing housing adjacent

LT77

is

1'

is

-

5

SPEED

stamped on a cast pad on the

of

the gearbox.

-------

LT230

stamped on the

below

the mainshaft rear

to

the bottom cover.

left

hand side

FRONT AND REAR AXLES

Serial number

axle tube.

is

stamped on top

of

the

left

hand

e

Tdi

Type Number

Bore

Stroke Capacity

Compression ratio Valve operation Turbo charger

Crankshaft

DEFENDER

ENGINE

.................................................................................

of

cylinders

..................................................................................

...............................................................................

............................................................................

...................................................................

.........................................................

............................................................

................................................................

G

ENE

RA

L

S

P

E

C

IFI

C

A

T

ION

D

A

Direct injection, turbocharged, intercooled 4

90,47 mm (3.562 in)

97,OO mm (3.822 in)

2495 cc

19.5:l

O.H.V. pushrod operated Carrett T25

+

-

0.5:l

T

A

n

I04

I

Main journal diameter

Regrind dimensions

Crankpin journal diameter

Regrind dimensions

1

Crankshaft end thrust Crankshaft end float

Main bearings

Number and type Diametrical clearance

Connecting rods

Length between centres Diametrical clearance (big-end bearings) End float on crankpin

Pistons

Type

.................................................................................

Skirt

diametrical clearance (at right angle to gudgeon pin Maximum height above combustion face

......................................................

..........................................................

................................................

..........................................................

.......................................................

.........................................................

.............................................................

........................................................

...................................................

..........................

.......................................................

.........................................

........................

63,475 - 63,487 mm (2.499 - 2.4993 in) 63,2333 . 63,246 mm (2.4895 - 2.490 in)

0.010'in U/S bearings

Use

58,725 - 58,744

58,4708 . 58,49985 mm (2.30200 . 2.30275

Use

0.010

Taken on thrust washers

0,05 . 0,15 mm (0.002 - 0.006 in)

5 halved shells with 0,0792 - 0,0307

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

Aluminium alloy, combustion chamber in crown

0,025 . 0,05

0,8 mm (0.031 in)

mm

(2.312 - 2.31275 in)

in U/S bearings

of

oil

grooves

mm

(0.0031 - 0.0012 in)

.

mm

(0.001 . 0.002 in)

centre main bearing

0.01

4 in)

in)

Gudgeon pins

.................................................................................

Type

Fit

in piston Diameter Clearance in connecting rod

Pistons rings

Type

.

Top

-

Second

.

Oil

control

Cap in

-

Top

-

Second

-

Oil

control

-:.

:.,a:

i.

I

:

,

'

Clearance in piston grooves:

.

Top

.

Second

.

Oil

control

......................................................................

...........................................................................

............................................

................................................................................

...........................................................................

.....................................................................

bore:

................................................................................

...........................................................................

.....................................................................

................................................................................

...........................................................................

.....................................................................

Floating

Hand push in 30,1564 - 30,1625 mm 0,0036 - 0,0196 mm (0.00014 - 0.00077 in)

Chamfered friction edge, chrome plated

Taper faced

Expander ands rails

0,40 . 0,65 0,30 0,3 - 0,6 mm (0.011

0,167 . 0,232 mm (0.0065 - 0.0091 in)

0,05 . 0,08 mm (0.0019 . 0.0031 in)

0,05

mm

(0.0157 . 0.0255 in)

-

0,50

mm (0.0118 - 0.0196 in)

.

0,08

mm

(0.0019 . 0.0031 in)

.

0.023

(1.1

8726

in)

-

7.1

8750 in)

9

04

GENERAL

SPECIFICATION

DATA

e

DEFENDER

Camshaft

Timing Belt

Location End float Number

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

.......................................................................

...........................................................................

of

bearings