1999 LAND ROVER DEFENDER Workshop Manual

04GENERAL SPECIFICATION DATA
2
INFORMATION Gudgeon pins
Type Fully floating, offset towards piston thrust side..................................................................................
Piston rings
Type
Upper compression Barrel edge, chrome plated.................................................
Lower compression Taper faced.................................................
Oil control Bevelled ring with spring................................................................
New ring to groove clearance
Upper compression Not measured.................................................
Lower compression 0.050 - 0.082 mm (0.002 - 0.003 in).................................................
Oil control 0.050 - 0.082 mm (0.002 - 0.003 in)................................................................
Piston ring fitted gap in cylinder bore
Upper compression 0.30 - 0.45 mm (0.0118 - 0.0177 in).................................................
Lower compression 0.40 - 0.60 mm (0.0157 - 0.0236 in).................................................
Oil control 0.25 - 0.40 mm (0.0098 - 0.0157 in)................................................................
Camshaft
Drive Duplex chain.................................................................................
End float 0.6 - 0.16 mm...........................................................................
Number of bearings 6..........................................................
Tappets
Type Hydraulic lash adjusters with followers.................................................................................
Valves
Stem diameter
Exhaust 6.905±0.008 mm (0.271±0.0003 in) ...................................................................
Inlet 6.915±0.008 mm (0.272±0.0003 in) .........................................................................
Head diameter
Exhaust 31.7 mm (1.25 in)...................................................................
Inlet 34.7 mm (1.37 in).........................................................................
Seat face angle
Exhaust 45° ...................................................................
Inlet 30° .........................................................................
Valve face angle
Exhaust 44°48’±12’ ...................................................................
Inlet 29°48’±12’ .........................................................................
Valve springs
Type Parallel, single coil.................................................................................
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GENERAL SPECIFICATION DATA
3
INFORMATION FUEL SYSTEM - Td5
Type Direct injection from pressure regulated supply with.................................................................................
cooled return flow
Pressure regulator setting 4 bar (58 lbf.in
2) ................................................
Pump Electric two stage submersible................................................................................
Pump output
Low pressure 30 l/h (6.6 gal/h) at 0.5 bar (7.25 lbf.in
2) ..........................................................
High pressure 180 l/h (39.6 gal/h) at 4 bar (58 lbf.in2) ..........................................................
Max consumption 30 l/h (6.6 gal/h).............................................................
Injectors Electronic unit injectors...........................................................................
Injector normal operating pressure 1500 bar (21750 lbf.in
2) ..................................
Filter In-line canister filter/water separator with water.................................................................................
detection
COOLING SYSTEM - Td5
Type Pressurised spill return partial flow, thermostatically.................................................................................
controlled
Cooling fans 11 blade axial flow on viscous coupling and 11 blade.....................................................................
axial flow electric
Electric cooling fan switching points
On Vehicle speeds of 50 mph (80 km/h) and below while...........................................................................
ambient temperature is 28°C (82°F) or above
Off Vehicle speeds of 62.5 mph (100 km/h) and above or...........................................................................
ambient temperatures of 25°C (77°F) and below
Coolant pump Centrifugal impeller, belt driven from crankshaft...................................................................
Thermostat Waxstat with pressure relief valve.......................................................................
Thermostat opening temperature
Initial opening 82°C (179°F) ..........................................................
Fully open 96°C (204°F) ...............................................................
Expansion tank cap relief valve operating pressure 1.4 bar (20.3 lbf.in
2) .........
CLUTCH - Td5
Type Diaphragm spring, hydraulically operated with.................................................................................
self-centering pre-loaded release bearing
Drive plate diameter 267 mm.........................................................
Pressure plate diameter 270 mm...................................................
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04GENERAL SPECIFICATION DATA
4
INFORMATION TRANSMISSION - Td5
Main gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward, 1 reverse, all synchromesh.............................................................................
Transfer box
Type LT230TE 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.................................................................................
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.................................................................
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GENERAL SPECIFICATION DATA
5
INFORMATION 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)..................................................................
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04GENERAL SPECIFICATION DATA
6
INFORMATION SUSPENSION
Type Coil springs controlled by telescopic dampers front.................................................................................
and rear.
Front Transverse location of axle by Panhard rod, and fore.................................................................................
and aft location by two radius arms. Anti-roll bar fitted
as standard on 90 models with 265/75 tyres and 130
models.
Rear Fore and aft movement inhibited by two tubular trailing.................................................................................
links. Lateral location of axle by a centrally positioned
’A’frame, upperlink assembly, bolted at the apex to a
ball joint mounting. Anti-roll bar fitted as standard on
90 models with 265/75 tyres, 110 models with self
levelling unit, and 130 models.
ROAD SPRING DATA
90 (2400 Kg) Part No. Colour Code
Front - Driver’s side NRC 9446 Blue/green
Front - Passenger side NRC 9447 Blue/yellow
Rear - Driver’s side NRC 9448 Blue/red
Rear - Passenger side NRC 9449 Yellow/white
90 (2550 Kg)
Front - Driver’s side NRC 9446 Blue/green
Front - passenger side NRC 9447 Blue/yellow
Rear - Driver’s side NRC 9462 Green/yellow/red
Rear - Passenger side NRC 9463 Green/yellow/white
110 (3050 Kg)
Front - both sides NRC 8045 Yellow/yellow
Rear - both sides NRC 6904 Red/green
110 Levelled (2950 Kg)
Front - both sides NRC 8045 Yellow/yellow
Rear - both sides NRC 7000 Green/white
110 (3400 Kg)
Front - both sides NRC 8045 Yellow/yellow
Rear - both sides NRC 6904 Red/green
Rear helper springs - both sides RRC 3266 No colour code
110 (3600 Kg)
Front - Driver’s side NRC 9448 Blue/red
Front - passenger side NRC 9449 Yellow/white
Rear - both sides NRC 6904 Red/green
Rear helper springs - both sides RRC 3226 No colour code
130 (3500 Kg)
Front - driver’s side NRC 9448 Blue/red
Front - passenger side NRC 9449 Yellow/white
Rear - driver’s side NRC 6389 Red/red
Rear - passenger side NRC 6904 Red/green
Front/rear helper springs - both sides RRC 3266 No colour code
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GENERAL SPECIFICATION DATA
7
INFORMATION SHOCK ABSORBERS
Type Telescopic, double-acting non-adjustable.................................................................................
Bore diameter 35.47mm...................................................................
BRAKES
Front brake
Caliper AP Lockheed, four opposed pistons..............................................................................
Operation Hydraulic, self adjusting.........................................................................
Disc 90 - Solid, outboard, 110/130 - Ventilated, outboard..................................................................................
Disc diameter 298 mm (11.73 in)...................................................................
Disc thickness 90 - 14,1 mm (0.56in), 110/130 - 24mm (0.95 in)..................................................................
Wear limit 1 mm (0.04in) per side of disc.........................................................................
Disc run-out maximum 0,15mm (0.006 in).....................................................
Pad area 58 cm
2(9.0 in2) ..........................................................................
Total swept area 801,3 cm2(124.2 in2) ...............................................................
Pad material Ferodo 3440 non asbestos.....................................................................
Pad minimum thickness 3 mm (0.12in)...................................................
Rear brake
Caliper AP Lockheed opposed piston..............................................................................
Operation Hydraulic, self adjusting.........................................................................
Disc Solid, outboard..................................................................................
Disc diameter 90 - 290 mm (11.42 in), 110/130 - 298 mm (11.73)...................................................................
Disc thickness 90 - 12,5 mm (0.49 in), 110/130 - 14,1 mm (0.56 in)..................................................................
Wear limit 90 - 0,38 mm (0.015 in), 110/130 - 1,0 mm (0.04 in).........................................................................
per side of disc
Disc run-out maximum 0,15 mm (0.006 in).....................................................
Pad area 90 - 30,5 cm
2(4.37 in2), 110/130 - 36,2 cm2(5.61 in2) ..........................................................................
Total swept area 90 - 694 cm2(106.98 in2) ...............................................................
Pad material Ferodo 3440 non asbestos.....................................................................
Pad minimum thickness UP TO 02MY - 3 mm (0.12 in)...................................................
Pad minimum thickness From 02MY - 2 mm (0.08 in)...................................................
Parking brake
Type Mechanical, cable operated drum brake on the rear of.................................................................................
the transfer gearbox output shaft
Drum internal diameter 254 mm (10.0 in).....................................................
Width 70 mm (2.75 in)................................................................................
Pad material Ferodo 3611 non asbestos.....................................................................
Servo/master cylinder
Manufacturer Lucas....................................................................
Servo type LSC 80........................................................................
Master cylinder type 25,4 mm (1.0 in) diameter, tandem.........................................................
Pressure reducing valve, failure conscious Cut-in pressure, 90 - 24 bar (360 Ibf/in
2) ratio 4.0:1, ......................
110 - 43 bar (645 Ibf/in2) ratio 2.9:1*
NOTE: * Pressure reducing valves are not fitted to all 110 specifications.
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04GENERAL SPECIFICATION DATA
8
INFORMATION AIR CONDITIONING
System CFC free, expansion valve system.............................................................................
Compressor Nippon Denso.....................................................................
Refrigerant R134a CFC free.......................................................................
Charge quantity 750 g±50 g ................................................................
Refrigerant oil ND-OIL 8...................................................................
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 16˚C (69˚F) 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 Delphi GP31........................................................................
Alternator
Type Nippon Denso.................................................................................
Fuses
Type Autofuse (blade type) blow ratings to suit individual.................................................................................
circuits
Horns
Make/type Mixo TR99........................................................................
Starter motor
Make and type Bosch 12v.................................................................
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GENERAL SPECIFICATION DATA
9
INFORMATION BULBS
REPLACEMENT BULBS TYPE
Headlamps 12V 60/55W Halogen
Front side lamps 12V 5W
Side repeater lamps 12V 5W
Tail lamps 12V 21W
Cente High Mounted Stop Lamp 12V 21W
Direction indicator lamps 12V 21W
Number plate lamp 12V 4W
Reverse lamp 12V 21W
Rear fog guard lamp 12V 21W
Interior roof lamps 12V 10W
Instrument illumination 12V 1.2W
Warning light panel 12V 1.2W
Hazard warning switch 12V 1.2W
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.
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