length LAND ROVER DEFENDER 1996 Workshop Manual

GENERAL SPECIFICATION DATA
1
INFORMATION REV: 05/99 300Tdi ENGINE
Type Direct injection, turbocharged, intercooled.................................................................................
Number of cylinders 4.........................................................
Bore 90,47 mm.................................................................................
Stroke 97,00 mm...............................................................................
Capacity 2495 cc...........................................................................
Compression ratio 19.5:1±0.5:1 ............................................................
Valve operation O.H.V. pushrod operated................................................................
Crankshaft
Main bearing journal diameter 63,475 - 63,487 mm..........................................
Regrind dimensions 63,233 - 63,246 mm.........................................................
Crankpin journal diameter 58,725 - 58,744 mm................................................
Regrind dimensions 58,471 - 58,490 mm.........................................................
Crankshaft end thrust Taken on thrust washers at centre main bearing.......................................................
Crankshaft end float 0,05 - 0,15 mm.........................................................
Main bearings
Number and type 5 halved shells with oil grooves..............................................................
Diametrical clearance 0,0792 - 0,0307 mm.......................................................
Connecting rods
Length between centres 175,38 - 175,43 mm...................................................
Diametrical clearance (big-end bearings) 0,025 - 0,075 mm........................
End float on crankpin 0,15 - 0,356 mm.......................................................
Pistons
Type Aluminium alloy, combustion chamber in crown..................................................................................
Graphite coating on sidewalls.
Skirt diametrical clearance (at r/angle to gudgeon pin) 0,025 - 0,05 mm....
Maximum height above combustion face 0,8 mm.........................
Gudgeon pins
Type Fully floating.................................................................................
Fit in piston Hand push fit.......................................................................
Diameter 30,156 - 30,163 mm..........................................................................
Clearance in connecting rod 0,003 - 0,016 mm............................................
Piston rings
Type:
- Top Barrel edge, chrome plated........................................................................
- Second Taper faced..................................................................
- Oil control Expander and rails..............................................................
Gap in bore:
- Top 0,40 - 0,60 mm........................................................................
- Second 0,30 - 0,50 mm..................................................................
- Oil control 0,30 - 0,60 mm..............................................................
Clearance in piston grooves:
- Second 0,050 - 0,085 mm..................................................................
- Oil control 0,050 - 0,085 mm..............................................................

04GENERAL SPECIFICATION DATA
2
INFORMATION Camshaft
Drive 30 mm wide dry toothed belt.................................................................................
Location Right hand side (thrust side)...........................................................................
End float 0,1 - 0,2 mm...........................................................................
Number of bearings 4..........................................................
Material Steel shell, white metal lined............................................................................
Valves
Tappet clearance:
- Inlet and exhaust 0,20 mm...................................................
Seat angle:
- Inlet 30° .......................................................................
- Exhaust 45° .................................................................
Head diameter:
- Inlet 38,75 - 39,05 mm.......................................................................
- Exhaust 36,35 - 36,65 mm.................................................................
Stem diameter:
- Inlet 7,960 - 7,975 mm.......................................................................
- Exhaust 7,940 - 7,960 mm.................................................................
Valve lift:
- Inlet 9,67 mm.......................................................................
- Exhaust 9,97 mm.................................................................
Cam lift:
- Inlet 6,81 mm.......................................................................
- Exhaust 7,06 mm.................................................................
Valve head stand down:
- Inlet 0,81 - 1,09 mm.......................................................................
- Exhaust 0,86 - 1,14 mm.................................................................
Valve springs
Type Single coil.................................................................................
Length, free 46,28 mm......................................................................
Length, under 21 kg load 40,30 mm.................................................
Lubrication
System Wet sump, pressure fed.............................................................................
Pressure, engine warm at normal operating speeds 1,76 - 3,87Kgf/cm
2(25 - 55 Ibf/in2) ........
Oil pump:
- Type G-rotor integral with front cover.......................................................................
- Drive off crankshaft nose.....................................................................
Oil pressure relief valve Non-adjustable....................................................
Relief valve spring:
- Full length 51,6mm......................................................................
- Compressed length at 7.71Kg load 31mm................................
Oil filter Screw-on disposable canister.............................................................................
Engine oil cooler Combined with coolant radiator and intercooler...............................................................

GENERAL SPECIFICATION DATA
7
INFORMATION AIR CONDITIONING
System CFC free expansion valve system.............................................................................
Compressor Sanden TRS105N.....................................................................
Refrigerant R134a CFC free.......................................................................
Charge quantity 1.1 Kg................................................................
WIPER MOTORS
Tailgate wiper motor
Make/type IMOS (non-serviceable)........................................................................
Running current, wet screen at 20°C ambient 1.0 to 2.8 amps.................
Wiper speed, wet screen at 20°C ambient 37 to 43 cycles per minute.......................
Windscreen wiper motor
Make/type Lucas 14W uprated two speed........................................................................
Armature end float 0,1 to 0,2 mm............................................................
Brush length, minimum 4,8 mm....................................................
Brush spring tension 140 to 200 g........................................................
Resistance of armature winding
at 16ÊC (69ÊF) measured between adjacent
commutatator segments 0.23 to 0.35 ohms...................................................
Light running, rack disconnected: current at 13.5 V 2.0 amps.........
Wiper speed, wet screen, 60 seconds from cold Low speed - 45±3 rev/min, High speed - 65±5 ..............
rev/min
ELECTRICAL
System 12 volt, negative ground.............................................................................
Battery
Make/type - standard Land Rover Parts and Equipment/Lucas maintenance.......................................................
free 9-plate 072
Make/type - heavy duty Land Rover Parts and Equipment/Lucas maintenance....................................................
free 14-plate 663
Generator
Manufacturer Magnetti Marelli....................................................................
Type A127 - 100amp.................................................................................
Polarity Negative ground.............................................................................
Brush length:
New 17 mm.........................................................................
Worn, minimum free protrusion from moulding 5 mm........
Brush spring pressure flush with moulding 1.3N to 2.7N......................
Regulator voltage 13.6 to 14.4 volts.............................................................
Nominal output
Generator speed 6000 rev/min.....................................................
Control voltage 14 volt........................................................
Amp 65 amp.........................................................................

04GENERAL SPECIFICATION DATA
12
INFORMATION VEHICLE DIMENSIONS
90 models
Overall length:
Soft top and Pick-up 3722 mm (146.5 in)................................................
Hard top and Station wagon 3883 mm (152.9 in)....................................
Overall width: 1790 mm (70.5 in)...................................................................
Overall height:
Soft top 1965 mm (77.4 in)....................................................................
Pick-up and Station wagon 1963 mm (77.3 in)......................................
Hard top 1972 mm (77.6 in)...................................................................
Wheelbase 2360 mm (92.9 in).......................................................................
Track front/rear 1486 mm (58.5 in).................................................................
Width between wheel boxes 925 mm (36.4 in)............................................
110 models
Overall length:
Soft top and Pick-up 4438 mm (175 in)................................................
High capacity pick-up 4631 mm (182 in)..............................................
Hard top/Station and County 4599 mm (181 in)...................................
Overall width: 1790 mm (70.5 in)...................................................................
Overall height: 2035 mm (80.1 in)..................................................................
Wheelbase 2794 mm (110 in).......................................................................
Track front/rear 1486 mm (58.5 in).................................................................
Width between wheel boxes:
High capacity pick-up 1090 mm (43 in)..............................................
all other models 925 mm (36.4 in).......................................................
130 models
Overall length 5132 mm (202 in)...................................................................
Overall width 1790 mm (70.5 in)....................................................................
Overall height 2035 mm (80.1 in)...................................................................
Wheelbase 3226 mm (127 in).......................................................................
Track front/rear 1486 mm (58.5 in).................................................................
Width between wheel boxes 1090 mm (43 in)............................................

GENERAL FITTING REMINDERS
7
INFORMATION COTTER PINS
1.Fit new cotter pins throughout when replacing
any unit.
2.Always fit cotter pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a cotter pin.
3.All cotter pins should be fitted as shown unless
otherwise stated.
NUTS
1.When tightening a slotted or castellated nut
never loosen it to insert cotter pin or locking wire
except in those recommended cases where this
forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should
be selected, or washer thickness reduced.
2.Where self-locking nuts have been removed it is
advisable to replace them with new ones of the
same type.
NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.
LOCKING WIRE
1.Fit new locking wire of the correct type for all
assemblies incorporating it.
2.Arrange wire so that its tension tends to tighten
the bolt heads, or nuts, to which it is fitted.SCREW THREADS
1.Both UNF and Metric threads to ISO standards
are used. See below for thread identification.
2.Damaged threads must always be discarded.
Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and
is not recommended.
3.Always ensure that replacement bolts are at
least equal in strength to those replaced.
4.Do not allow oil, grease or jointing compound to
enter blind threaded holes. The hydraulic action
on screwing in the bolt or stud could split the
housing.
5.Always tighten a nut or bolt to the recommended
torque value. Damaged or corroded threads can
affect the torque reading.
6.To check or re-tighten a bolt or screw to a
specified torque value first loosen a quarter of a
turn, then re-tighten to the correct value.
7.Oil thread lightly before tightening to ensure a
free running thread, except in the case of
threads treated with sealant/lubricant, and
self-locking nuts.
UNIFIED THREAD IDENTIFICATION
1. Bolts
A circular recess is stamped in the upper surface
of the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter
for a short length at its extremity.

ENGINE
13
REPAIR FRONT COVER GASKET
Service repair no - 12.65.10
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.Remove crankshaft gear.See Crankshaft gear
3.Remove camshaft gear.See Camshaft gear
4.Remove injection pump gear.See Injection
pump gear
5.Remove fuel injection pump.See FUEL
SYSTEM, Repair, Fuel injection pump
6.Remove engine oil sump.See Engine oil
sump
7.Remove oil pick up strainer.See Oil pick-up
strainer
8.Remove 10 bolts securing timing gear housing to
block.
9.Withdraw timing gear housing complete with
gasket.
10.Clean all gasket material from mating faces.
Refit
11.Fit slave guide studs to locate gasket.
12.Fit new gasket to cylinder block.
13.Align flats on oil pump with flats on crankshaft.
14.Fit front cover to block taking care not to damage
oil seal.15.Secure with bolts of correct length in locations
where slave studs are not fitted, see J6149.
16.Remove slave studs and fit correct length bolts.
17.Tighten all bolts to
25 Nm (18 lbf/ft).
1- 25 mm,2- 35 mm,3- 80 mm.
18.Fit oil pick-up strainer.
See Oil pick-up
strainer
19.Fit oil sump.See Engine oil sump
20.Fit fuel injection pump.See FUEL SYSTEM,
Repair, Fuel injection pump
21.Fit injection pump gear.See Injection pump
gear
22.Fit camshaft gear.See Camshaft gear
23.Fit crankshaft gear.See Crankshaft gear
24.Fit camshaft drive belt.See Camshaft drive
belt

ENGINE
17
REPAIR 11.Refit clutch.
See CLUTCH, Repair, Clutch
assembly
12.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 gearbox
13.Reconnect battery.
CRANKSHAFT BEARING BUSH
Service repair no - 12.21.45
Remove
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Remove flywheel.See Flywheel
5.Remove bearing bush.
NOTE: The bearing bush can be removed
by using one of the following methods.
Method 1.
Obtain a short length of steel rod of a diameter having
a good slide fit in the bore of the bush. Pack the bore
with grease and insert the steel rod into the end of the
bore, give a sharp blow with a hammer and the
grease should drive out the bush. It is recommended
that the bush and rod be covered by a suitable cloth
or rag to prevent grease from splashing.Method 2.
Thread the bore of the existing bush and using a
suitable bolt extract the bush. Thoroughly clean bush
location ensuring all swarf is removed.
Refit
1.Fit new bush using a suitable shouldered drift,
inserting bush flush with end of crankshaft.
2.Refit flywheel.
See Flywheel
3.Refit clutch.See CLUTCH, Repair, Clutch
assembly
4.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 gearbox
5.Reconnect battery.

12ENGINE
24
REPAIR Refit
8.Fit oil pump rotors in front cover.
9.Apply a bead of RTV sealant around retaining
plate.
10.Fit oil pump retaining plate to front cover,
securely tighten screws.
11.Fit front cover to cylinder block.
See Front
cover gasket
OIL PRESSURE RELIEF VALVE
Service repair no - 12.60.56
Remove
1.Remove engine oil sump.
See Engine oil
sump
2.Unscrew relief valve retaining plug from base of
front cover.
3.Withdraw valve spring and plunger and check for
wear.
Valve spring free length, 68.00 mm (2.68 in).
NOTE: If the valve plunger sleeve is badly
worn, pitted or scored, a new front cover
must be fitted.
See Front cover gasket
Always renew valve spring and plunger as a pair.
Refit
4.Insert valve plunger and spring into sleeve in
front cover and secure with retaining plug.
5.Fit engine oil sump.
See Engine oil sump

FUEL SYSTEM
9
DESCRIPTION AND OPERATION OPERATION
Diesel engines operate by compression ignition. The
rapid compression of air in the cylinder during the
compression cycle heats the air and when fuel is
injected into the heated air, it ignites instantaneously.
During cold tarting, automatically controlled heater
plugs assist in raising the temperature of the
compressed air to ignition point.
A cold start advance unit advances the injection timing
to further assist starting. Idle quality is improved by
the high idle setting.
The engine is supplied with pre-compressed air by a
single stage turbocharger.
Exhaust gases passing over a turbine cause it to
rotate, driving a compressor mounted on the turbine
shaft. Air drawn from the cold air intake passes, via
the air cleaner, to the turbocharger where it is
compressed. Compression in the turbocharger warms
up the air considerably, so that it expands. As a result
the air mass per cylinder is reduced, having a
negative effect on power output. By fitting a charge-air
intercooler, located on the LH side of the radiator, the
air is cooled before reaching the cylinders. This
increases power output through increased mass of
oxygen in the combustion process, as well as
maximising engine durability, through maintaining
lower piston and head temperatures.
Fuel is drawn from the tank by a mechanical lift pump
and passes to the injection pump via a filter. In
addition to removing particle contamination from the
fuel, the filter incorporates a water separator, which
removes and stores water.
The sedimentor/s, when fitted, is located adjacent to
the fuel tank/s and separates contamination and water
particles in the fuel before reaching the fuel lift pump.
The injection pump meters a precisely timed, exact
quantity of fuel to the injectors in response to throttle
variations, injection timing varying with engine speed.
Any excess fuel delivered to the injection pump is
passed back to the tank via the spill return line.
Fuel is injected in a finely atomised form into the main
combustion chamber, the burning fuel expands
rapidly, creating extreme turbulence which mixes the
burning fuel thoroughly with the compressed air,
providing complete combustion.Cold Starting is assisted by heater plugs, a cold start
advance unit and a high idle setting.
Heater plugs
Heater plug operation is controlled by a timer unit,
start relay and resistor. When the ignition is turned on
the timer unit is energised, the heater plugs start to
operate and a warning light on the dashboard
illuminates, remaining on until the heater plugs are
automatically switched off.
The length of time the heater plugs will operate is
dependent on under bonnet temperature, which is
monitored by a sensor located in the timer unit.
Starting the engine results in the power supply to the
heater plugs passing through the resistor, which
reduces their operating temperature. The heater plugs
are cut out either by the temperature sensor in the
timer, or by a microswitch on the injection pump which
operates when the throttle is depressed.
Cold start advance
The cold start advance unit is connected to the engine
cooling system via hoses. It contains a temperature
sensitive element which is retracted when cold and
pulls the advance lever, via cable, towards the rear of
the pump against spring pressure. As coolant
temperature rises, the cold start element expands
releasing tension on the cable and allowing spring
pressure to move the advance lever forwards.
Exhaust gas recirculation (EGR), when fitted
Operation of the EGR system is dependent on the
following:
·Engine temperature - must be between 20°C and
100°C approx.
·Engine speed - must be between 630 and 2850
rev/min.
·Engine load - calculated by throttle position
sensor.
·EGR valve lift position.
·Duration of engine idling.

19FUEL SYSTEM
4
ADJUSTMENT TURBOCHARGER BOOST PRESSURE - CHECK
Service repair no - 19.42.06
1.Disconnect actuator hose from turbocharger and
insert a suitable 'T' piece connector.
2.Connect a short length of suitable hose to
turbocharger and 'T'piece.
3.Connect further hose to 'T' piece and pressure
gaugeLRT-12-011. The pressure gauge hose
must be long enough to reach into the vehicle
cab so that the gauge can be observed by driver
or passenger.
4.To check maximum boost pressure, drive
vehicle normally, but in such a manner that full
throttle can be maintained whilst climbing a hill
with engine speed held steady between 2,500
and 3,000 rev/min. Under these circumstances
boost pressure should read 0,95 - 1,09 Kgf/cm
2
(13.5 - 15.5 lb/in2).PRIMING THE FUEL SYSTEM
Service repair no - 19.50.01
NOTE: If the fuel system has been
completely drained carry out the
procedures for priming both the
sedimentor, if fitted, and fuel filter and injection
pump.
Sedimentor and fuel filter
If the sedimentor or fuel filter have been dismantled
and air has entered the fuel system carry out the
following procedure:
1.Slacken fuel filter bleed screw.
2.Operate hand priming lever on fuel lift pump until
fuel, free from air, emerges from filter.
NOTE: Ensure that the fuel pump lever is
on the bottom of operating cam when
priming, otherwise maximum movement of
the lever cannot be achieved.
3.Tighten filter bleed screw whilst fuel is still
emerging.