01INTRODUCTION
4
INFORMATION ACCESSORIES AND CONVERSIONS
DO NOT FITunapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitting of non-approved conversions
to the vehicle.
WHEELS AND TYRES
WARNING: DO NOT replace the road
wheels with any type other than genuine
Land Rover wheels which are designed for
multi-purpose on and off road use and have very
important relationships with the proper operation
of the suspension system and vehicle handling.
Replacement tyres must be of the make and sizes
recommended for the vehicle, and all tyres must
be the same make, ply rating and tread pattern.
STEAM CLEANING
To prevent consequential rusting, any steam cleaning
within the engine bayMUSTbe followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine water pipes, hose clips and ignition
coil clamp.
SPECIFICATION
The specification details and instructions set out in
this Manual apply only to a range of vehicles and not
to any one. For the specification of a particular vehicle
purchasers should consult their Dealer
The Manufacturer reserve the right to vary their
specifications with or without notice, and at such times
and in such manner as they think fit. Major as well as
minor changes may be involved in accordance with
the Manufacturer's policy of constant product
improvement.
Whilst every effort is made to ensure the accuracy of
the particulars contained in this Manual, neither the
Manufacturer or Dealer, by whom this Manual is
supplied, shall in any circumstances be held liable for
any inaccuracy or the consequences thereof.SPECIAL SERVICE TOOLS
The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified,only these tools should be used
to avoid the possibility of personal injury or
damage to the components.Also the amount of time
which they save can be considerable.
Every special tool is designed with the close
co-operation of Land Rover, and no tool is put into
production which has not been tested and approved
by us. New tools are only introduced where an
operation cannot be satisfactorily carried out using
existing tools or standard equipment. The user is
therefore assured that the tool is necessary and that it
will perform accurately, efficiently and safely.
Special tools bulletins will be issued periodically giving
details of new tools as they are introduced.
All orders and enquiries from the United Kingdom
should be sent direct to V. L. Churchill. Overseas
orders should be placed with the local V. L. Churchill
distributor, where one exists. Countries where there is
no distributor may order direct from:
V. L. Churchill Limited,
PO Box 3,
Daventry, Northants,
England, NN11 4NF.
The tools recommended in this Workshop Manual are
listed in a multi-language illustrated catalogue,
obtainable from:
Messers. V. L. Churchill at the above address,
or from:
Land Rover Merchandising Service,
PO Box 534,
Erdington,
Birmingham, B24 0Q5,
COPYRIGHT
ÓLand Rover 1996
All rights reserved. No part of this publication may be
produced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, recording or other
means without prior written permission of Land Rover.
04GENERAL SPECIFICATION DATA
2
INFORMATION Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin 0,018-0,041 mm...................................
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 1,478-1,49 mm..............................................
Compression ring gap 0,40-0,65 mm......................................................
Oil control ring width 3,0 mm.........................................................
Oil control ring rail gap 0,38-1,40 mm.....................................................
Camshaft
Location Central...........................................................................
Bearings Tin - aluminium...........................................................................
Number of bearings 5..........................................................
Drive Chain 9,52 mm pitch x 54 pitches..................................................................................
TappetsHydraulic-self-adjusting ...........................................................................
Valves
Length: Inlet 116,59-117,35 mm..................................
Exhaust 116,59-117,35 mm...........................
Seat angle: Inlet 45°to 45 1/2° ..................................
Exhaust 45°to 45 1/2° ...........................
Head diameter: Inlet 39,75-40,00 mm..................................
Exhaust 34,226-34,480 mm...........................
Stem diameter: Inlet 8,664-8,679 mm..................................
Exhaust 8,651-8,666 mm...........................
Stem to guide clearance: Inlet 0,025-0,066 mm..................................
Exhaust 0,038-0,078 mm...........................
Valve lift (Inlet and Exhaust) 9,49 mm............................................
Valve spring length fitted 40,4 mm at pressure of 29,5 kg..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Eccentric rotor...................................................................
Oil pressure 2.75 bar (40 lb/in
2) at 2500 rev/min with engine at ......................................................................
running temperature
Oil filter-internal Wire screen, pump intake filter.................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................
04GENERAL SPECIFICATION DATA
4
INFORMATION Piston rings
Number of compression rings 2..........................................
Number of control rings 1....................................................
No 1 compression ring Nitrided steel barrel faced.....................................................
No 2 compression ring Tapered spherical barrel marked 'TOP'.....................................................
Width of compression rings 1.478 - 1.49 mm.............................................. 0.0582 - 0.0587 in
(Top) 1.21 - 1.23 mm................................ 0.0476 - 0.0484 in
Compression ring gap 0.40-0.65 mm...................................................... 0.0157 - 0.0256 in
(Top) 0.3 - 0.5 mm................................ 0.0118 - 0.0197 in
Oil control ring type Aclonoform..........................................................
Oil control ring width 3.0 mm......................................................... 0.1181 in
Oil control ring rail gap 0.38-1.40 mm..................................................... 0.0150 - 0.0551 in
Camshaft
Location Central...........................................................................
Bearings Non serviceable...........................................................................
Number of bearings 5..........................................................
Drive Chain 9.52 mm pitch x 54 pitches..................................................................................
Camshaft End Float 0.076 - 0.355 mm......................................................... 0.003 - 0.014 in
TappetsHydraulic self-adjusting ...........................................................................
Valves
Length: Inlet 116.59 - 117.35 mm.................................. 4.590 - 4.620 in
Exhaust 116.59 - 117.35 mm........................... 4.590 - 4.620 in
Seat angle: Inlet 46°-46°25' ..................................
Exhaust 46°-46°25' ...........................
Head diameter: Inlet 39.75 - 40.00 mm.................................. 1.565 - 1.575 in
Exhaust 34.227 - 34.48 mm........................... 1.3475 - 1.3575 in
Stem diameter: Inlet 8.664 - 8.679 mm.................................. 0.3411 - 0.3417 in
Exhaust 8.651 - 8.666 mm........................... 0.3406 - 0.3412 in
Stem to guide clearance: Inlet 0.025 - 0.066 mm.................................. 0.0010 - 0.0026 in
Exhaust 0.038 - 0.078 mm........................... 0.0015 - 0.0031 in
Valve lift (Inlet and Exhaust) 9.94 mm............................................ 0.3913 in
Valve spring length fitted 40.4 mm (1.59 in) at pressure of 29.5 kg (65 lb)..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Rotor...................................................................
Oil pressure 2.11 to 2.81 kg/cm
2(30 to 40 psi) at 2400 rev/min with ......................................................................
engine warm
Oil filter-internal Wire screen, pump intake filter in sump................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................
04GENERAL SPECIFICATION DATA
6
INFORMATION FUEL SYSTEM (GEMS) 4.0 V8 ENGINE
Type Sagem - Lucas Gems 8 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 Bosch in-line filter 'canister' type..........................................................................
Mass airflow sensor
Make and type Lucas 'Hot Wire' 20AM.................................................................
Injectors
Make and type Lucas D1000.................................................................
Electronic Control Module
Make and type Lucas GEMS 8.3.................................................................
Fuel pressure regulator
Make and type Lucas 8RV.................................................................
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 - catalyst vehicles
Make and type Lucas 4LS.................................................................
Camshaft position sensor
Make and Land Rover part no. Lucas ERR6170.........................................
Crankshaft position sensor
Make and type Lucas 3VRS, Honeywell ERR6049.................................................................
Knock sensor
Make and type Lucas 2KS.................................................................
Intake air temperature sensor
Make and type Lucas 10TT.................................................................
Ignition coils
Make and type Lucas 2DIS2.................................................................
Fuel temperature sensor
Make and type Lucas 6TT.................................................................
04GENERAL SPECIFICATION DATA
10
INFORMATION COOLING SYSTEM 3.9 V8i
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti-freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler.
Fan and viscous coupling assembly 11 blade axial flow 433mm diameter.................................
Pump type Centifugal, impellor, belt driven.........................................................................
Thermostat opening 88 degrees..........................................................
Expansion tank cap pressure 15 p.s.i. (system pressure)............................................
STEERING
Power steering box
Make/type Adwest Varamatic - worm and roller box........................................................................
Ratio Variable: straight ahead 19.3:1 on lock 14.3:1.................................................................................
Steering wheel turns, lock-to-lock 3.375....................................
Steering pump
Make/type -V8i ZF - Unicorn.................................................................
Make/type - Mpi & Tdi Hobourn-Eaton series 500......................................................
Steering geometry
Steering wheel diameter 405mm..................................................
Steering wheel diameter airbag model 400mm.............................
Toe-out measurement 0 to 2mm toe out......................................................
Toe-out included angle 0Ê to 0Ê 16'.....................................................
Camber angle 0Ê.................................................................. Check with vehicle in static..............
unladen condition, that is, vehicle
with water,
Castor angle 3Ê..................................................................... oil and five gallons of fuel. Rock..............
the vehicle up and down at the
front to allow
Swivel pin inclination static 7Ê............................................... it to take up a position..............
GENERAL SPECIFICATION DATA
11
INFORMATION SUSPENSION
Type Coil springs controlled by telescopic dampers front.................................................................................
and rear.
Front Lateral location of axle by Panhard rod, and.................................................................................
longitudinal location by two radius arms.
Rear Lateral location of axle by a centrally positioned 'A'.................................................................................
frame bolted at the apex to a ball joint mounting.
Longitudinal location of axle by two tubular trailing
links.
ROAD SPRING DATA
V8i - Mpi
LEFT HAND DRIVE Part No Colour Code
Left hand front NRC 4306 Blue/White
Right hand front 572315 Blue
Left/Right hand rear ANR 3477 or Brown/Green
ANR 4352 Orange/Orange *
RIGHT HAND DRIVE Part No Colour Code
Left hand front 572315 Blue
Right hand front 572315 Blue
Left/Right hand rear ANR 3477 or Brown/Green
ANR 4352 Orange/Orange *
Tdi Diesel
RIGHT HAND DRIVE Part No Colour Code
Left hand front ANR 1975 or Blue/Pink/Red
ANR 4350 Brown/Brown **
Right hand front ANR 1976 or Blue/Pink/Yellow
ANR 4351 Grey/Grey **
Left/Right hand rear ANR 3477 or Brown/Green
ANR 4352 Orange/Orange *
LEFT HAND DRIVE Part No Colour Code
Left hand front ANR 1976 or Blue/Pink/Yellow
ANR 4351 Grey/Grey **
Right hand front ANR 1975 or Blue/Pink/Red
ANR 4350 Brown/Brown **
Left/Right hand rear ANR 3477 or Brown/Green
ANR 4352 Orange/Orange *
* VIN 119534 onwards
** VIN 116461 onwards
04GENERAL SPECIFICATION DATA
14
INFORMATION Coil
Make/type Bosch 0221 122 392........................................................................
Distributor
Make/type Lucas 35 DLM8........................................................................
Firing angles 0°-45°-90°(every 45°)±1° ....................................................................
Application 12V Negative ground.......................................................................
Pick-up air gap adjustment
(Pick-up limb/reluctor tooth) 0.20 mm to 0.35 mm.............................................
Pick-up winding resistance 2k to 5k ohms...............................................
Fuses
Type Autofuse (blade type).................................................................................
blow ratings to suit individual circuits
Horns
Make/type Klamix (Mixo) TR99........................................................................
Starter motor
Make and type Bosch 12v.................................................................
04GENERAL SPECIFICATION DATA
18
INFORMATION 300 Tdi 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 63,2333 - 63,246 mm.........................................................
Use 0.010 in U/S bearings
Crankpin journal diameter 58,725 - 58,744 mm................................................
Regrind dimensions 58,4708 - 58,48985 mm.........................................................
Use 0.010 in U/S bearings
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 right angle to gudgeon pin) 0,025 - 0,05 mm.........................................
Maximum height above combustion face 0,8 mm.........................
Gudgeon pins
Type Floating.................................................................................
Fit in piston Hand push fit.......................................................................
Diameter 30,1564 - 30,1625 mm..........................................................................
Clearance in connecting rod 0,0025 - 0,0163 mm............................................