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Defender 300Tdi (1996+). Manual - part 7

GENERAL SPECIFICATION DATA

INFORMATION

VEHICLE DIMENSIONS

90 models
Overall length:

Soft top and Pick-up

3722 mm (146.5 in)

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

Hard top and Station wagon

3883 mm (152.9 in)

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

Overall width:

1790 mm (70.5 in)

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

Overall height:

Soft top

1965 mm (77.4 in)

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

Pick-up and Station wagon

1963 mm (77.3 in)

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

Hard top

1972 mm (77.6 in)

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

Wheelbase

2360 mm (92.9 in)

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

Track front/rear

1486 mm (58.5 in)

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

Width between wheel boxes

925 mm (36.4 in)

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

110 models
Overall length:

Soft top and Pick-up

4438 mm (175 in)

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

High capacity pick-up

4631 mm (182 in)

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

Hard top/Station and County

4599 mm (181 in)

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

Overall width:

1790 mm (70.5 in)

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

Overall height:

2035 mm (80.1 in)

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

Wheelbase

2794 mm (110 in)

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

Track front/rear

1486 mm (58.5 in)

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

Width between wheel boxes:

High capacity pick-up

1090 mm (43 in)

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

all other models

925 mm (36.4 in)

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

130 models
Overall length

5132 mm (202 in)

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

Overall width

1790 mm (70.5 in)

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

Overall height

2035 mm (80.1 in)

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

Wheelbase

3226 mm (127 in)

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

Track front/rear

1486 mm (58.5 in)

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

Width between wheel boxes

1090 mm (43 in)

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

ENGINE TUNING DATA

INFORMATION

300 Tdi ENGINE

Type

2.5 Litre Turbo diesel intercooled

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

Firing order

1-3-4-2

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

Injection timing

1,54 mm lift at T.D.C.

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

Injection timing with electronic EGR

1,40 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

B.T.D.C.

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

B.B.D.C.

- Closes

A.B.D.C.

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

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

8 seconds

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

ENGINE TUNING DATA

INFORMATION

INJECTORS

Make & type - standard

Bosch KBAL 90 P37

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

Nozzle type

DSLA 145P366

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

Opening pressure (working pressure)

Initial pressure 200 atmospheres, Secondary 280

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

atmospheres

TURBOCHARGER

Make & type

Garrett T250 - 04

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

Maximum boost pressure

0,93 - 1,07 bar (13.5 - 15.5 lbf/in

) measured at

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

wastegate actuator ’T’ piece

GENERAL FITTING REMINDERS

INFORMATION

GENERAL FITTING REMINDERS

WORKSHOP SAFETY IS YOUR RESPONSIBILITY!

The suggestions, cautions and warnings in the
section are intended to serve as reminders for
trained and experienced mechanics. This manual
is not a definitive guide to automotive mechanics
or workshop safety.

Shop equipment, shop environment, and the use
and disposal of solvents, fluids, and chemicals
are subject to government regulations which are
intended to provide a level of safety. It is your
responsibility to know and comply with such
regulations.

PRECAUTIONS AGAINST DAMAGE

1. Always fit covers to protect fenders before

commencing work in engine compartment.

2. Cover seats and carpets, wear clean overalls

and wash hands or wear gloves before working
inside vehicle.

3. Avoid spilling hydraulic fluid or battery acid on

paint work. Wash off with water immediately if
this occurs. Use Polythene sheets to protect
carpets and seats.

4. Always use a recommended Service Tool where

specified.

5. Protect temporarily exposed screw threads by

replacing nuts or fitting plastic caps.

SAFETY PRECAUTIONS

1. Whenever possible, use a lift when working

beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.

WARNING: Do not use a pit when
removing fuel system components.

2. Never rely on a jack alone to support vehicle.

Use axle stands carefully placed at jacking
points to provide rigid support.

3. Ensure that a suitable form of fire extinguisher is

conveniently located.

4. Check that any lifting equipment used has

adequate capacity and is fully serviceable.

5. Disconnect battery.

WARNING: Do not disconnect any pipes in
air conditioning system, unless trained
and instructed to do so. A refrigerant is

used which can cause blindness if allowed to
contact eyes.

6. Ensure that adequate ventilation is provided

when volatile degreasing agents are being used.

7. Do not apply heat in an attempt to free stiff

fixings; as well as causing damage to protective
coatings, there is a risk of damage to electronic
equipment and brake linings from stray heat.

Content .. 5 6 7 8 ..