Defender (1993+). Manual — part 5

ENGINE TUNING DATA

ENGINE

3.9

V8

Type

. . . . . . . . . . . . . . . . . . . . . .

3.9 Litre V8

Firing order

. . . . . . . . . . . . . . . . . . .

1-8-4-3-6-5-7-2

Cylinder Numbers

Left bank

. . . . . . . . . . . . . . . . . . . ..

1-3-5-7

Right bank

. . . . . . . . . . . . . . . . . . .

2-4-6-8

No

1

Cylinder location

. . . . . . . . . . . . . ...

Pulley end

of

left bank

Timing marks

. . . . . . . . . . . . . . . . . ..

On crankshaft vibration damper

Spark plugs

Gap

. . . . . . . . . . . . . . . . . . . . . ..

0.84-0.96mm

Coil

Make/type

. . . . . . . . . . . . . . . . . . .

Bosch 0-221-122-392, (ETC 6574)

Compression ratio

. . . . . . . . . . . . . . . .

9.35:1

Fuel injection system

. . . . . . . . . . . . . .

Lucas 14 CUX Hot-wire air flow sensor system

electronically controlled

Valve Timing

Inlet

Exhaust

Opens

. . . . . . . . . . . . . . . . . . . . ..

32° BTDC

Closes

. . . . . . . . . . . . . . . . . . . . ..

73° ABDC

Duration

. . . . . . . . . . . . . . . . . . . ...

285°

285°

Valve peak

104° ATDC

114° BTDC

Idle speed

-

controlled by

MFI system

. . . . . . . .

700

±

25 rev/min

Base idle speed

. . . . . . . . . . . . . . . . ..

See setting procedure

-

525 ± 25 rev/min.

Ignition Timing

-

dynamic at idle speed,

vacuum disconnected

. . . . . . . . . . . . . ...

5° BTDC ± 1

°

Exhaust gas

CO content at idle

. . . . . . . . . . . . . . . .

0%

to

0.05% max.

70° BBDC
35° ATDC

. . . . . . . . . . . . . . . . . . ...

REISSUED:

FEB

1993

1

TORQUE

WRENCH

SETTINGS

ENGINE

Nm

Alternator mounting bracket to cylinder head

. . . . . ..

40

Alternator

to

mounting bracket

. . . . . . . . . . . .

24

Chainwheel to camshaft

. . . . . . . . . . . . . ...

58

Cylinder head:

Centre row

. . . . . . . . . . . . . . . . . . ...

92

Distributor clamp nut

. . . . . . . . . . . . . . .

21

Fan

to

viscous unit

. . . . . . . . . . . . . . . ...

30

Flywheel

to

crankshaft

. . . . . . . . . . . . . . .

78

Inlet manifold

to

cylinder heads

. . . . . . . . . . ...

51

Lifting eye

to

cylinder heads

. . . . . . . . . . . .

24

Main bearing cap rear bolts

. . . . . . . . . . . . .

92

Manifold gasket clamp bolt

. . . . . . . . . . . . ..

17

Oil plug

. . . . . . . . . . . . . . . . . . . . .

28

Oil

relief valve cap

. . . . . . . . . . . . . . . .

40

Alternator to adjusting link

. . . . . . . . . . . . .

24

Connecting rod bolt

. . . . . . . . . . . . . . . ..

51

Outer row

. . . . . . . . . . . . . . . . . . . .

58

Inner row

. . . . . . . . . . . . . . . . . . . ..

92

Exhaust manifold

to

cylinder heads

. . . . . . . . . .

21

Main bearing cap bolts

. . . . . . . . . . . . . . .

72

Oil pump cover

to

timing cover

. . . . . . . . . . .

13

Oil sump drain plug

. . . . . . . . . . . . . . . ..

45

Oil sump

to cylinder block

. . . . . . . . . . . . .

10

Oil sump rear to cylinder block

. . . . . . . . . . . .

18

Rocker cover to cylinder head

. . . . . . . . . . . .

7

Rocker shaft bracket

to cylinder head

. . . . . . . . ..

37

Spark plug

. . . . . . . . . . . . . . . . . . .

15

Starter motor attachment

. . . . . . . . . . . . . .

44

Damper to crankshaft

. . . . . . . . . . . . . . ...

271

Timing cover

to

cylinder block

. . . . . . . . . . . ..

27

Viscous unit

to

water pump hub

. . . . . . . . . . ...

45

Water pump pulley to water pump hub

. . . . . . . .

10

Water pump timing cover

to cylinder block

. . . . . . ..

27

FUEL LINES

Connections at straight connector

. . . . . . . . . ...

16

Pipe connections at filter

. . . . . . . . . . . . . ..

16

Hose clips

. . . . . . . . . . . . . . . . . . .

2

Connections at vapour separator

. . . . . . . . . . .

16

Connections at Tee-piece

. . . . . . . . . . . . .

16

CLUTCH

Clutch cover bolts

. . . . . . . . . . . . . . . .

27

Slave cylinder bolts

. . . . . . . . . . . . . . . ..

27

REISSUED:

FEB 1993

1

TORQUE WRENCH SETTINGS

MAIN GEARBOX (FIVE-SPEED)

LT77S

Nm

Oil pump body to extension case

. . . . . . . . . . .

9

Clip

to

clutch release lever

. . . . . . . . . ..

Attachment plate

to

gearcase

. . . . . . . . ..

Attachment plate

to

remote housing

. . . . . . . . .

9

Extension case

to

gearcase

. . . . . . . . . . . . .

25

Pivot plate

. . . . . . . . . . . . . . . . . . .

25

Remote selector housing to extension case

. . . . . .

25

Gear lever housing

to

remote housing

. . . . . . . . .

25

Guide clutch release sleeve

. . . . . . . . . . . . .

25

Slave cylinder

to

clutch housing

. . . . . . . . . . ...

25

Front cover

to

gearcase

. . . . . . . . . . . . . ...

25

5th support bracket

. . . . . . . . . . . . . . . ..

25

Plunger housing to remote housing

. . . . . . . . . .

25

Blanking plug extension case

. . . . . . . . . . . ..

9

Gear lever retainer

. . . . . . . . . . . . . . . ...

9

Yoke

to

selector shaft

. . . . . . . . . . . . . . ..

25

Fixing gear lever assembly nut

. . . . . . . . . . .

44

Reverse pin

to centre plate nut

. . . . . . . . . . .

25

Clutch housing

to

gearbox bolt

. . . . . . . . . . .

72

Plug

-

detent spring

. . . . . . . . . . . . . . . ..

25

Oil drain plug

. . . . . . . . . . . . . . . . . .

51

Oil filter plug

. . . . . . . . . . . . . . . . . . .

72

Plug oil filler

-

remote housing

. . . . . . . . . . . ..

30

Breather

. . . . . . . . . . . . . . . . . . . ...

9

Oil level plug

. . . . . . . . . . . . . . . . . .

30

Blanking plug

-

reverse switch hole

. . . . . . . . . .

24

Fifth gear layshaft nut

. . . . . . . . . . . . . . ..

217

c

2

REISSUED:

FEB

1993

TORQUE WRENCH

SETTINGS

TRANSFER

GEARBOX

LT230T

Nm

Pinch bolt operating arm

. . . . . . . . . . . . . ..

9

Gate plate

to

grommet plate

. . . . . . . . . . . .

9

Bearing housing to transfer case

. . . . . . . . . . .

9

Speedometer cable retainer

. . . . . . . . . . . . .

9

Locating plate to gear change

. . . . . . . . . . . ..

6

Bottom cover to transfer

. . . . . . . . . . . . . ...

25

Fixings securing mounting brackets

to

gearbox

. . . . ...

90

Speedometer housing

. . . . . . . . . . . . . . ..

See note

Front output housing to transfer

. . . . . . . . . . ...

25

Front output housing

to

transfer

. . . . . . . . . . ...

25

Cross shaft housing to front output housing

. . . . . .

25

Gear change

. . . . . . . . . . . . . . . . . .

25

Gear change

. . . . . . . . . . . . . . . . . .

25

Cross shaft to high/low lever

. . . . . . . . . . . .

25

Pivot shaft to link arm

. . . . . . . . . . . . . . ...

25

Connecting rod

. . . . . . . . . . . . . . . . . .

25

Front

output

housing cover

. . . . . . . . . . . . ..

25

Pivot

bracket to

extension housing

. . . . . . . . . ..

25

Mainshaft bearing housing to transfer case

. . . . . . .

25

Anti-rotation plate intermediate shaft

. . . . . . . . ...

25

Finger housing

to front output housing

. . . . . . . .

25

Brake drum to coupling flange

. . . . . . . . . . . .

25

Gearbox to transfer case

. . . . . . . . . . . . . .

45

End cover bearing housing to transfer case

. . . . . .

45

Speedometer housing to transfer

. . . . . . . . . . .

45

Selector finger

to cross shaft (high/low)

. . . . . . . ...

25

Selector fork high/low

to

shaft

. . . . . . . . . . . . ...

25

Transmission brake

to speedometer housing

. . . .

72

Gearbox

to

transfer case

. . . . . . . . . . . . . .

45

Oil drain plug

. . . . . . . . . . . . . . . . . .

30

Detent plug

. . . . . . . . . . . . . . . . . . ...

Plug

to

be coated with Hylomar and peened Screw

.

Transfer case assembly

. . . . . . . . . . . . . ...

See

note

plug fully in (spring solid) then turn two complete turns
back

.

Differential casings

. . . . . . . . . . . . . . . ...

60

Front and rear out flange

. . . . . . . . . . . . . .

162

Differential case rear

. . . . . . . . . . . . . . .

72

Oil filler and level plug transfer

. . . . . . . . . . . .

30

Transfer breather

. . . . . . . . . . . . . . . . .

9

Inner shaft stake nut

. . . . . . . . . . . . . . .

135

N0TE:

Studs

to

be assembled

into

casings with

sufficient torque to wind them

fully home, but this

torque must not exceed the maximum figure quoted

for the associated nut on final assembly

.

FRONT AXLE

Hub driving member

to

hub

. . . . . . . . . . . . ..

65

Stub axle

to

swivel pin housing

. . . . . . . . . . .

65

Upper swivel pin to swivel pin housing

. . . . . . . .

65

Lower swivel pin

to

swivel pin housing. . . . . .

25

Oil

seal retainer to swivel pin housing

. . . . . . . .

9

Swivel

bearing housing to axle case

. . . . . . . . .

72

Pinion housing

to

axle case

. . . . . . . . . . . . .

41

Crown wheel

to

differential case

. . . . . . . . . . ..

58

Differential bearing cap to pinion housing

. . . . . . .

90

Universal Joint flange to propeller shaft

. . . . . . . ...

47

Mudshield

to

swivel pin housing

. . . . . . . . . . ..

9

Bevel pinion nut

. . . . . . . . . . . . . . . . ...

129

REISSUED:

FEB

1993

3