Defender 300Tdi (1996+). Manual — part 4
INTRODUCTION
13
INFORMATION
FAULT DIAGNOSTIC EQUIPMENT
TESTBOOK
For Defender models fitted with the vehicle Anti-theft
Immobilisation and Alarm System, diagnostic
equipment, named TestBook, is available to assist in
the diagnostic and fault finding abilities of the Dealer
workshop. A diagnostic connector, located under the
front centre seat, or cubby box, as shown below, is
provided to facilitate the procedures.
If an exhaust gas recirculation (EGR) system is fitted,
this too can be checked using TestBook. A diagnostic
connector, also located under the front centre seat or
cubby box, is provided.
Features of Testbook include :-
Fully upgradable support for the technician.
Structured diagnostics to accommodate all skill levels.
Touch screen operation.
Direct print out of screen information and test results.
READING THIS MANUAL
This manual is divided into sections shown on the
contents page, alongside a range of icons, familiar to
service technicians.
Relevant information is contained within each of these
sections. These are further divided into the following
sub-sections which appear at the foot of each page :-
Description and operation.
Fault diagnosis.
Adjustment.
Repair.
Overhaul.
Specifications, Torque.
To avoid repeating information through the sections,
where part of the repair operation impacts on another
section, a cross reference is given to direct the reader
to where the information is sited.
For example:
The maintenance section states the need to renew
drive belt. A cross reference sites this information in:
Section 12 Engine
- Sub-section: Repairs
- Heading: Drive belt renew.
GENERAL SPECIFICATION DATA
1
INFORMATION
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
Fuly 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
. . . . . . . . . . . . . . . ..
04
GENERAL 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/in
2
)
. .
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
3
INFORMATION
FUEL SYSTEM
Fuel lift pump type
Mechanical with hand primer
. . . . . . . . . . . . . . .
Fuel lift pump pressure
42 - 55 Kgf/cm
2
(3 - 4 lbf/in
2
) 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/in
2
) (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
. . . . . . . . . . . . . . . . . . . . .
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