DIESEL FUEL SYSTEM-TURBO CHARGED ENGINE

ENGINE TUNING DATA

ENGINE
Firing order ........................................................ 1-3-4-2
. . .
Injection timing ................................................... 13"

Timing marks:
Valve timing ....................................................... Slot for peg in flywheel and TDC mark on front pulley
Injection timing ................................................... Special tool inserted in D.P.S. pump
Tappet clearances inlet and exhaust .......................... (0.010 in)

Valve timing
Inlet opens ..........................................................
Inlet closes .......................................................... 42" A.B.D.C.
Inlet peak ........................................................... 103" A.T.D.C.
Exhaust opens ..................................................... 51" B.B.D.C.
Exhaust closes ..................................................... 13"A.T.D.C.
Exhaust peak ...................................................... 109" R.T.D.C.

lift
Inlet .................................................................. (0,388 ins)
Exhaust ............................................................. (0.404 ins)

Maximum governed speeds

Full load ............................................................. 4000
N o load (flight speed) ............................................ 4400
Idle speed ........................................................... 670 20
Dic-down time ..................................................... 4 seconds

PUMP
.......................................................... CAV DPS 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.
Direction of rotation ............................................. Clockwise, viewed from drive
Advance box (two stage) ........................................ 7" advance with 3" start retard
Back leakage rate 150-100Atm:
New nozzle ................................................... 7 seconds
Original nozzle .............................................. 5 seconds
Despatch nozzle .............................................

INJECTORS
.......................................................... CAV Pintaux DES5385001
Nozzle size .......................................................... 6209
Opening pressure (working pressure) ........................ to 140
Injector pipe type ................................................. High pressure multi-bundy
size .................................................. to
length .............................................. (18 ins)

HEATER PLUGS
.......................................................... ii
Time to reach operating temperature of 850°C ............ 8 seconds

TURBO-CHARGER
.......................................................... Garrett T2
Maximum boost pressure ....................................... 48 H G (9.3 P.S.I.G.) measured at wastegate actuator
"T" piece
44
 DIESEL FUEL SYSTEM -T U RB O C H A R G ED ENGINE

TORQUE WRENCH SETTINGS

TURBO-CHARGER

Stud-Turbo charger to exhaust manifold 22-28 16-21

Nut-Turbo charger to exhaust manifold 2 1-26 15-19
Adaptor-Oil feed to cylinder block 22-28 16-21
Adaptor-Oil drain to cylinder block 22-28 16-21
Pipc-Oil feed to turbo charger 15-22 11-16
Pipe-Oil drain 32-48 23-35
Stud-Outlet elbow to turbo charger 22-28 16-21
Nut-Outlet elbow to turbo charger 21-26 15-19
Heat shield support to inlet manifold 22-28 16-21
Stud-Exhaust manifold to cylinder head 30-40 22-30
Nut-Exhaust manifold to cylinder head 28-36 21-26
Screw-inlet and exhaust manifold to cylinder head 30-40 22-30

RECOMMENDED ENGINE OILS

The following list of recommended engine oils for temperate climates - range - 10°C to 35°C
should be used for oil changes and topping up. They are SHPD (Super High Performance Diesel) oils that allow a
maximum of 10,000 (6,000 miles) between oil and filter changes.

Vanellus C3 Extra 15/40

CASTROL Deusol Turbomax 15/40
MOBIL Delvac 1400Super 15/40
SHELL Myrina 15/40

The following list of oils is for emergency use only if the above oils arc not can be used for topping-up
without detriment, but if used for engine oil changing, they are limited to a maximum 5,000 (3,000 miles)
between oil and filter

Vanellus C3 15/40
CASTROL Dcusol RX Super 15/40
Hypergrade 15/50
ESSO Essolube XD-3 15/40
MOBIL Delvac Super 15/40
PETROFINA Fina Dilano HPD 15/40
SHELL X 15/40
TEXACO URSA Super Plus 15/40
Use only oils to or API Service levels C D or SECTION

MAINTENANCE SCHEDULE
The following additional maintenance is required for the turbo charged engine to that contained in main
for the non-Turbo Charged 2.5 Litre Diesel cngine.

Every 500 (250 miles)

- Check engine oil level
At 1,600 (1,000 miles), 10,000 (6,000 miles) and 20.000 (12,000 miles) then every 20,000 (12,000
miles)
- Check tappets,
Every 80.000 (48,000 miles)
- Check maximum turbo-charge boost pressure.
 DIESEL FUEL SYSTEM-TURBO C H A RG ED ENGINE

TURBO-CHARGER 9. Remove the five nuts to release the exhaust elbow

and gasket from the turbo-charger.
Removing
1. Remove
Remove the hose connecting the air clcancr to the
turbo-charger.
3 . Remove the turbo-charger heat shield fixings and
remove the heat shield.
4. Release the clamp securing the turbo-charger
elbow to the exhaust downpipe.
5 . Remove the inlet manifold to the turbo-charger
hose.
6. Disconnect the boost control hose from t h e turbo-
charger.
7. Disconnect from t h e turbo-charger the lubrication
inlet pipe.

Release the lock tabs and the four nuts

.
securing the turbo-charger to the exhaust manifold *-
=-

and remove the turbo-charger and gasket.

Disconnect, at the hose, the lubrication

drain pipe from the turbo-charger.

Fitting
\
\
\
\ \ \
\ \ \
\
11. Fit the raised bead side of a new gasket uppermost
to the exhaust manifold and fit and secure the
turbo-charger with the four nuts, tightening evenly
to the correct torque and secure with lock tabs.
Fit the exhaust elbow, using a new gasket, to
turbo-charger and retain with the five nuts
tightening evcnly to the correct torque.

46
 DIESEL FUEL SYSTEM-TURBO C H A R G E D ENGINE

13. Fit the exhaust downpipe to the turbo-charger

elbow and tighten the clamp bolt.
14. Connect the lubrication inlet pipe to the turbo-
charger.
15. Fit the oil drain pipe to the flexible connection.
Connect the boost control pipe to t h e turbo-
charger.
17. Fit the hose connecting the inlet manifold to turbo- RENEW TURBO-CHARGER ACTUATOR
charger.
18. Fit the heat shield. 1. Remove the two screws securing actuator bracket
19. Fit the air cleaner to turbo-charger hose. to the turbo-charger.
20. Immediately prior to starting the engine release the 2 . Remove the nut and bolt securing actuator to the
oil inlet pipe to the turbo-charger and fill the centre heat shield bracket and disconnect the hose.
housing with a recommended and grade of 3. Remove clip retaining actuator arm to the
engine oil and re-fit the pipe. wastegate lever pin and withdraw the actuator from
the engine.
4. Fit the replacement actuator with the two bolts and
CHECKING TURBO-CHARGER BOOST PRESSURE single nut and bolt. Tighten bolts to 12.5 to 14.0
(111 to 124 in
1. Disconnect, from the turbo-charger, t h e hose to 5 . Push the wastegate lever as far as possible towards
the actuator and insert, into the free end a suitable the actuator and apply pressure to keep lever in
‘T’piece. this position.
2. Connect a short length of slave hose to the turbo- 6. the replacement actuator to 57-62
charger and connect the other end to the ‘T’ piece. (11-12 and hold this pressure.
3 . Connect a further slave hose to the third leg of the
‘T’ piece and the other end to a pressure gauge CAUTION: Use only the threaded rod-end to make
capable of reading in excess of 50 of Mercury. adjustments. Forcing the entire rod in or out will change
The pressure gauge hose must be long enough to the calibration with the possibility of damaging engine
reach into the cab of the vehicle so that the gauge over-boost.
can be observed by the driver or passenger.
4. Drive t h e vehicle in the normal manner Screw the rod-end in either direction until the rod
3,000 full load) and observe the maximum end eye will locate easily over the wastegate pin
pressure obtained and compare with the figure in and secure with retaining clip.
Data Section 8. Release the calibration pressure and tighten the
rod end locknut. Reconnect the hose.
9. Check the boost pressure, on the road, as
described earlier. The pressure should not fall
below 44 or exceed 50 (8.5 -9.7

47
 DIESEL FUEL SYSTEM- TURBO CHARGED ENGINE

TURBO-CHARGER FAULT TRACING VISUAL INSPECTION

It is important to be aware that when tracing a 1. Inspect all connections within the intake system.
suspected fault in a turbo-charger that a turbo-charger Tighten loose connections as required.
cannot compensate for incorrect engine operation 7 Replace damaged air intake components.
deficiencies in the air, or fuel intake systems, exhaust 3 . Check the connection between the compressor and
emission components or for damaged and worn engine the engine intake manifold.
internal parts such as valves and pistons. Before Tighten loose bolts as required.
suspecting the turbo-charger, the engine should be 4 Check exhaust system connections at turbine
checked against the tuning data in Section 05. housing inlet and outlet flanges for oil leakage and
Replacing a sound turbo-charger with another will not loose connections. Tighten loose connections as
correct engine deficiencies. required. If oil leakage exists, check the general
condition of the engine.
Systematic fault tracing of a suspected turbo-charger 5 . Check the oil line connections at the centre housing
failure is important for two reasons. First, it must be oil inlet and outlet ports for leakage.
found what, if anything, is wrong with the turbo- Tighten loose connections as required. Start engine
charger so that it can be Second, it must be and recheck connections.
decided what action is necessary to prevent a repeat
failure.

In many cases, evidence pointing to the cause of a

failure is destroyed removing the turbo-charger
from the engine. For example, if a turbo-charger failed
because of a faulty installation, such as loose
connections that allowed dirt to enter the compressor,
this would not be evident once the turbo-charger was
removed from the engine. Failure to correct the
installation, such as reinstalling defective manifold
flange Connections, could cause an identical failure of
the replacement unit. The hose connecting the air
cleaner to the compressor, which could contain dirt or
harmful particles, should cleaned or renewed if
necessary.

In general, the fault tracing procedures that can be

done with the least effort and in the least amount of
time should be first. Do not remove and renew
the turbo-charger until the following visual checks and
repairs that can be made with the turbo-charger
installed, have been done. DO NOT, UNDER ANY
CIRCUMSTANCES, DISMANTLE THE TUKBO-
CHARGER.

48
 COOLING SYSTEM

- . ..
ENGINE PROTECTION DRAIN AND FILL ENGINE COOLING SYSTEM
To prevent corrosion of the aluminium alloy engine WARNING: Do not remove the radiator filler cap when
parts it is imperative that the cooling system is filled the engine is hot because the cooling system is
with a solution of clean water and the correct type of pressurized and personal scalding could result.
anti-freeze, winter and or water and inhibitor
if frost precautions are not required. Never fill or 1. Remove the radiator filler plug.
top-up with water only, always add an inhibitor
(Marstons if anti-freeze is not used. NEVER
salt water with an inhibitor otherwise corrosion will
occur. In certain territories where the only available
water supply may have some salt content, use only
clean rainwater or distilled water.

Recommended solutions
Anti-freeze Universal Anti-freeze or
permanent type ethylene base, without methanol, with
a suitable inhibitor for aluminium engines and engine
parts.
Use one part of anti-freeze one part water.
Inhibitor Lubricants SQ36 inhibitor
concentrate.
Use 100 of inhibitor per litre of water.
Anti-freeze can remain in the cooling system and will
provide protection for two years provided
that the specific gravity of the coolant is checked before
onset second winter and topped-up with new 2. Remove radiator drain plug and allow
anti-freeze as required. coolant to drain, if neccssary, into suitable
Land Rovers leaving the factory have the cooling container. Refit drain plug and washer. The
system filled with 50% of anti-freeze mixture. This drain plug is situated on the left-hand side of
gives protection against frost down to minus 47°C radiator towards t h e bottom facing the engine
(minus 53°F). Vehicles so filled can be identified by a compartment.
label affixed to t h e windscreen and radiator.
After the second winter the system should be drained NOTE: Disconnect bottom hose to drain on radiators
and thoroughly flushed. adding new anti-freeze without a drain plug. Connect hose after draining.
examine all joints and renew hoses t o make
sure that the system is leakproof. Inhibitor solution
should be drained and flushed out and new
solution introduced every two years, or where
the purity of the water is qucstionablc.
See the ‘General specification data’ section for
protection quantities.

3 . Remove the engine drain plugs, one each side of the

cylinder block, beneath the exhaust manifolds.
Allow the coolant to drain and refit plugs and
washers.
1