Defender (1999-2002). Manual — part 4
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INTRODUCTION
13
INFORMATION
Front axle serial number
Stamped on the front of LH axle tube, inboard of
radius arm mounting bracket.
Rear axle serial number
Stamped on the rear of LH axle tube, inboard of
spring mounting.
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.
01
INTRODUCTION
14
INFORMATION
READING THIS SUPPLEMENT
This Supplement 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.
Adjustment.
Repair.
Overhaul.
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: Repair
GENERAL SPECIFICATION DATA
1
INFORMATION
ENGINE - Td5
Type
2.5 litre in-line direct injection Diesel, turbocharged
. . . . . . . . . . . . . . . . . . . . .
and intercooled
Number of cylinders
5 in-line, No. 1 cylinder at front of engine
. . . . . . . . . . . . . . .
Bore
84.450 mm (3.3248 in)
. . . . . . . . . . . . . . . . . . . . .
Stroke
88.950 mm (3.5020 in)
. . . . . . . . . . . . . . . . . . . ...
Capacity
2498 cm
3
(152.5 in
3
)
. . . . . . . . . . . . . . . . . . ...
Firing order
1 - 2 - 4 - 5 - 3
. . . . . . . . . . . . . . . . . ...
Compression ratio
19.5:1
. . . . . . . . . . . . . . .
Direction of rotation
Clockwise viewed from the front of the engine.
. . . . . . . . . . . . . . ..
Dimensions
Length
766 mm (30.1 in)
. . . . . . . . . . . . . . . . . .
Width
708 mm (27.8 in)
. . . . . . . . . . . . . . . . . ...
Height
788 mm (31.0 in)
. . . . . . . . . . . . . . . . . ..
Emissions standard :-
Engine Serial No. Prefixes 10P to 14P - EU2 Model
ECD 2
. .
Engine Serial No. Prefixes 15P to 19P - EU3 Model
ECD 3
. .
Lubrication
Type
Wet sump, pressure fed
. . . . . . . . . . . . . . . . . . . . .
Pump type
Eccentric rotor, crankshaft driven integral with stiffener
. . . . . . . . . . . . . . . . . .
plate.
Filter type:
Primary
Centrifuge filter
. . . . . . . . . . . . . . . . .
Secondary
Disposable canister with full flow by-pass
. . . . . . . . . . . . . . . ...
Pressure at idle (cold)
3.0 bar (43.5 lbf.in
2
)
. . . . . . . . . . . . . ..
Pressure at 3500 rev/min (hot)
1.5 - 3.0 bar (21.75 - 43.5 lbf.in
2
)
. . . . . . . . . . .
Relief valve opening pressure
4.0 bar (58 lbf.in
2
)
. . . . . . . . . . ..
Low oil pressure switch opening pressure
0.2 - 0.6 bar (3.0 - 8.8 lbf.in
2
)
. . . . . ...
Crankshaft
Main bearing journal diameter
61.9875 - 62.0125 mm
. . . . . . . . . . ..
Crankpin journal diameter
53.99 - 54.01 mm
. . . . . . . . . . . .
Crankshaft end float
0.020 - 0.250 mm
. . . . . . . . . . . . . . .
Main bearings
Number and type
6 half shells (5 main, 1 thrust)
. . . . . . . . . . . . . . . ..
Pistons
Type
Graphite compound skirt with combustion chamber in
. . . . . . . . . . . . . . . . . . . . .
crown.
Clearance in cylinder bore
0.172 - 0.206 mm (measured at bottom of skirt, 90
°
to
. . . . . . . . . . . ...
gudgeon pin)
Diameter
84.270 - 85.254 mm (measured 90
°
to gudgeon pin,
. . . . . . . . . . . . . . . . . . ..
and 40.00 mm from bottom of skirt.)
04
GENERAL 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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