1996 LAND ROVER DEFENDER fuel type

GENERAL SPECIFICATION DATA
3
INFORMATION FUEL SYSTEM
Fuel lift pump type Mechanical with hand primer............................................................
Fuel lift pump pressure 42 - 55 Kgf/cm
2(3 - 4 lbf/in2) at 1800 rpm .....................................................
Fuel filter Paper element in disposable canister..........................................................................
Air cleaner Paper element type........................................................................
COOLING SYSTEM
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler and
turbo intercooler.
Cooling fan 11 blade axial flow 433 mm diameter, 1.29:1 drive.......................................................................
ratio, with viscous coupling.
Pump type Centrifugal, impellor, belt driven........................................................................
Thermostat opening 88°C .........................................................
Expansion tank cap pressure 1,06 Kgf/cm
2(15 Ibf/in2) (system pressure) ...........................................
CLUTCH
Type Valeo diaphragm spring.................................................................................
Centre plate diameter 235 mm.......................................................
Facing material Verto F202 grooved.................................................................
Release bearing Ball journal...............................................................
TRANSMISSION
Main gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward, 1 reverse, all synchromesh.............................................................................
Transfer box
Type LT230 Two speed reduction on main gearbox output. Front......................................................................
and rear drive permanently engaged via a lockable
differential
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................

04GENERAL SPECIFICATION DATA
4
INFORMATIONREV: 05/99 Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts, 32°angularity of universal joint on full
lock
Ratio 3.54:1.................................................................................
Propeller shafts
Type, front and rear Tubular 51 mm dia...........................................................
Universal joints Open type Hookes O3EHD.................................................................
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 Hobourn-Eaton series 500........................................................................
Steering geometry
Steering wheel diameter 412 mm (16.22 in)..................................................
Toe-out measurement 0 to 2 mm toe out......................................................
Toe-out included angle 0°to 0°20' .....................................................
Camber angle 0°* ..................................................................
Castor angle 3°* .....................................................................
Swivel pin inclination static 7°* ...............................................
* Check with vehicle on level ground, in unladen
condition and five gallons of fuel. Rock the front of the
vehicle up and down to allow it to take up a normal
static position.
Turning circle between kerbs
90 models:
265/75 x 16 tyres 12,65 m (41.5 ft)..............................................................
All other tyres 11,70 m (38.4 ft)...................................................................
110 models:
750 x 16 tyres 13,41 m (44 ft)..................................................................
130 models:
750 x 16 tyres 15,24 m (50 ft)..................................................................

ENGINE TUNING DATA
1
INFORMATION 300 Tdi ENGINE
Type2.5 Litre Turbo diesel intercooled .................................................................................
Firing order1-3-4-2 .....................................................................
Injection timing1,54 mm lift at T.D.C. ...............................................................
Injection timing with electronic EGR1,40 mm lift at T.D.C. ............................
Timing marks:
Valve timing - manual Slot for pin in flywheel and TDC mark on front pulley........................................................
Injection timing Timing pin (service tool).................................................................
Tappet clearances inlet and exhaust 0,20 mm cold...............................
Valve timing: Inlet Exhaust
- Opens 16°B.T.D.C. ............................................................................ 51°B.B.D.C.
- Closes 42°A.B.D.C. ............................................................................ 13°A.T.D.C.
- Peak 103°A.T.D.C. ............................................................................... 109°B.T.D.C.
- Lift 9,67 mm.................................................................................. 9,97 mm
Maximum governed speeds:
- No load (neutral/full throttle) 4600 + 40 - 120 rev/min...........................................
- Idle speed at running temperature 720±20 rev/min .................................
- Die-down time 4 seconds................................................................
INJECTION PUMP
Make & type - standard Bosch rotary R509 type with boost control and two....................................................
speed mechanical governor with auto advance and
solenoid electrical shut-off. Tamper proof sealing on,
no load governed speed and fuel adjustment screws.
Constant volume delivery valves
Make & type - Electronic EGR Bosch rotary R509/1 type with boost control and two.........................................
speed mechanical governor with auto advance and
solenoid electrical shut-off. Tamper proof sealing on
flight speed and fuel adjustment screws. Constant
volume delivery valves. Throttle position sensor for
EGR control.
HEATER PLUGS
Make & type Probe type, No.0100226129A Beru 12 volts.....................................................................
Time to reach operating temperature of 850°C 8 seconds...............

07GENERAL FITTING REMINDERS
2
INFORMATION PREPARATION
1.Clean components and surrounding area prior to
removal.
2.Blank off any openings exposed by component
removal using greaseproof paper and masking
tape.
3.Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4.Close open ends of oilways, exposed by
component removal, with tapered hardwood
plugs or readily visible plastic plugs.
5.Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
6.Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7.Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1.Observe scrupulous cleanliness when
dismantling components, particularly when
brake, fuel or hydraulic system parts are being
worked on. A particle of dirt or a cloth fragment
could cause a dangerous malfunction if trapped
in these systems.
2.Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed.
3.Use marking ink to identify mating parts, to
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
4.Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
5.Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
6.Do not discard a part due for renewal until it has
been compared with the new part, to ensure that
its correct replacement has been obtained.INSPECTION-GENERAL
1.Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an incipient
failure.
2.When a component is to be checked
dimensionally against figures quoted for it, use
correct equipment (surface plates, micrometers,
dial gauges, etc.) in serviceable condition.
Makeshift checking equipment can be
dangerous.
3.Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension
is exactly limit size, and is otherwise satisfactory.
4.Use 'Plastigauge' 12 Type PG-1 for checking
bearing surface clearances. Directions for its
use, and a scale giving bearing clearances in
0,0025 mm steps are provided with it.

19FUEL SYSTEM
2
DESCRIPTION AND OPERATION A mechanical lift pump, with a hand priming facility, is
driven by the camshaft, and is mounted on the RH
side of the engine.
A fuel filter, with a replaceable element and
incorporating a water separator, is mounted on the
front RH side of the engine compartment.
A fuel sedimentor may be fitted when the vehicle is
operating in more arduous conditions, and is used to
minimise water deposits in the fuel system before
reaching the fuel pump and filter.
Fuel injection is carried out by a Bosch direct injection
pump, incorporating a cold start advance unit and a
high idle setting. The pump is mounted on the RH side
of the engine and is driven directly by gears in the
front cover from the crankshaft. The pump meters and
distributes fuel to 4 pintle type injectors located in
pre-combustion chambers in the cylinder head. Four
heater plugs, located in the cylinder head directly
below each injector, are fitted to improve cold starting.
An optional hand throttle, for use with a centre power
take off, is located on the fascia to the LH side of the
fuse box, and is linked independently to the fuel
injection pump throttle lever.
Air intake
The air cleaner is mounted on the RH side of the
engine and is connected by hoses to the cold air
intake duct and turbocharger inlet. Fitted between the
air cleaner and turbocharger is the crankcase breather
hose which connects to a breather filter on the rocker
cover.
A single stage turbocharger, fitted between the
exhaust manifold and exhaust down pipe, is
connected by hoses to the air cleaner and an
intercooler which is mounted on the LH side of the
radiator. The intercooler is connected by a hose to the
inlet manifold. When an EGR valve is fitted to the
turbocharger, additional pipes/hoses are used to
connect the components.Exhaust gas recirculation (EGR), when fitted.
Exhaust gas recirculation is controlled by an ECU
mounted under the front centre seat or cubby box and
receives the following inputs:
·Engine temperature from coolant temperature
sender unit on LH side of cylinder head.
·Throttle position from potentiometer on injection
pump.
·Engine speed from speedometer.
When all correct signals are received, the EGR
solenoid allows vacuum to open EGR valve and
recirculate a portion of the exhaust gas. See J6196 for
the EGR system component location and 'Operation'
for full system function.

ELECTRICAL
3
DESCRIPTION AND OPERATION Door and bonnet switches
Perimetric protection for the vehicle is provided by
ECU inputs connected to the starter switch, bonnet
switch and door switches.
Ultrasonic sensor
The ultrasonic sensor operates by emitting an air
pressure carrier wave which is subsequently received
by the sensor as it bounces back from objects inside
the vehicle. Once armed, the alarm will sound if wave
is disturbed by a door opening, or if movement is
detected inside the vehicle.
When the volumetric sensor is activated it monitors
movement within the vehicle for 15 seconds before
detecting and responding to intrusions. If the sensor
detects movement it delays arming until a quiet period
has lapsed; if continuous movement is detected, the
alarm will not arm volumetrically.
NOTE: Interior protection will not operate
until 15 seconds after alarm is set.
The ultrasonic sensor is positioned in a different
location, according to vehicle type, as follows:
·90/110 Station Wagon - RH cantrail trim
·90/110 Pick-up - On headlining, between interior
lamp and rear view mirror
·130 Crewcab - On headlining above RH door
Alarm sounder
Two types of alarm sounder can be fitted, one with a
battery back-up facility and or without battery back-up,
both providing an audible warning whenever the alarm
is triggered. The vehicle horn will also operate if the
alarm sounds.
The alarm sounder is fitted to LH inner front wing in
the engine compartment.
NOTE: Disconnecting the battery on
vehicles fitted with the battery backed-up
facility will result in the alarm sounding, if
correct procedure has not been followed.Engine immobilisation warning light
The engine immobilisation warning light is located on
the instrument panel, and provides a visual indication
that the engine is immobilised.
Anti-theft alarm indicator light
The anti-theft alarm indicator light is located on the
instrument panel, between the fuel and coolant
temperature indicators, and provides a visual
indication of the alarm/ immobiliser status.

86ELECTRICAL
4
DESCRIPTION AND OPERATION REV: 05/99 ALARM SYSTEM COMPONENT LOCATION
COMPONENT LOCATION
1. Electronic control unit (ECU) Under dash, LH and RH drive
2. Anti-theft alarm indicator light Instrument panel
3. Engine immobilisation warning light Instrument panel
4. Immobilisation spider* Inside vehicle battery box
5. Passive coil Over starter switch barrel
6. Bonnet switch Engine compartment, LH and RH drive
7. Door switches
8. Ultrasonic sensor Varies according to vehicle type
9. Handset and key
10. Alarm sounder (without battery back-up) LH inner front wing
11. Alarm sounder (with battery back-up) LH inner front wing
* Replaced in some markets by a digital diesel shut-off valve (DDS), secured directly to fuel shut-off solenoid on
injection pump.