Defender 90 / 110 / 130. Instruction - page 63

DIESEL F

U

EL SYST

E

M

-

TURBO CHARGED ENGINE

TORQUE WRENCH SETTINGS

TURBO-CHARGER

Stud-Turbo charger

to

exhaust manifold

22-28

16-2 1

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

16-2 1

Nut-Outlet elbow to turbo charger

2 1-26

15-19

Heat shield support to inlet manifold

22-28

16-2 1

Stud-Exhaust manifold to cylinder head

30-40

22-30

Nut-Exhaust manifold to cylinder head

28-36

2 1-26

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.

T h e y are SHPD (Super High Performance Diesel) oils that allow a

maximum

of 10,000

(6,000 miles) between oil and filter changes.

CASTROL
MOBIL
SHELL

Vanellus C3 Extra 15/40
Deusol Turbomax 15/40
Delvac 1400 Super 15/40
Myrina 15/40

The following list of

oils is for emergency use only

i f

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 H P D 15/40

SHELL

X

15/40

TEXACO

URSA Super

Plus 15/40

Use

only oils to

o r 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.

TURBO-CHARGER

DIESEL F

U

EL SYSTEM-TURBO CHARGED ENGINE

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.

Disconnect, at the

hose, the lubrication

drain pipe from the turbo-charger.

\

\ \ \

\

\

\

\ \ \

9. Remove the five nuts to release the exhaust elbow

and gasket from the turbo-charger.

.

Release the lock tabs and

the four nuts

securing the turbo-charger to the exhaust manifold
and remove the turbo-charger and gasket.

*-

=-

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

DI

E

SE

L FUEL S

YSTEM

-

T

U

RBO CHARGED ENGINE

13. Fit the exhaust downpipe to the turbo-charger

14. Connect the lubrication inlet pipe to the turbo-

15.

Fit the

oil drain pipe to the flexible connection.

Connect the boost control pipe to t h e turbo-

17. Fit the hose connecting the inlet manifold to turbo-

18.

Fit the heat shield.

19. Fit the air cleaner to turbo-charger hose.

20. Immediately prior to starting the engine release the

oil inlet pipe to the turbo-charger and fill the centre
housing with a recommended

and grade of

engine

oil and re-fit the pipe.

elbow and tighten the clamp bolt.

charger.

charger.

charger.

CHECKING TURBO-CHARGER

BOOST PRESSURE

1.

Disconnect, from the turbo-charger, t h e hose to
the actuator and insert, into the free end a suitable

‘T’

piece.

2. Connect a short length of slave hose to the turbo-

charger and connect t h e other end to the ‘T’ piece.

3 . Connect a further slave hose to the third leg of the

‘T’ piece and the other end to a pressure gauge
capable

of reading in excess of 50

of Mercury.

The pressure gauge hose must be

long enough to

reach into the cab

of the vehicle

so that the gauge

can be observed by the driver

or passenger.

4. Drive t h e vehicle in the normal manner

3,000

full load) and observe the maximum

pressure obtained and compare with the figure

in

Data Section

RENEW TURBO-CHARGER ACTUATOR

1.

Remove the two screws securing actuator bracket

to the turbo-charger.

2 . Remove the nut and bolt securing actuator to the

heat shield bracket and disconnect the hose.

3. Remove clip retaining actuator arm to the

wastegate lever pin and withdraw the actuator from
the engine.

4. Fit the replacement actuator with the two bolts and

single nut and bolt. Tighten bolts to 12.5 to 14.0

(111 to 124

in

5 .

Push the wastegate lever as far

as possible towards

the actuator and apply pressure to keep lever

in

this position.

6 .

the replacement actuator to

57-62

(11-12

and hold this pressure.

CAUTION: Use only the threaded rod-end to make
adjustments. Forcing the entire rod in or out will change
the calibration with the possibility of damaging engine

over-boost

.

Screw the rod-end in either direction until the rod

end eye will locate easily over the wastegate pin
and secure with retaining clip.

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

It is important to be aware that when tracing

a

suspected fault

in

a turbo-charger that a turbo-charger

cannot compensate for incorrect engine operation
deficiencies

in the air,

or

fuel intake systems, exhaust

emission components or for damaged and worn engine
internal parts such as valves and pistons. Before
suspecting the turbo-charger, the engine should be
checked against the tuning data in Section

05.

Replacing a sound turbo-charger with another will not
correct engine deficiencies.

Systematic fault tracing

of

a suspected turbo-charger

failure is important for

t w o

reasons. First, it must be

found what,

if anything, is wrong with the turbo-

charger so that

it

can be

Second,

it

must be

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. T h e 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

CHARGER.

CIRCUMSTANCES, DISMANTLE THE TUKBO-

VISUAL INSPECTION

1.

7

3 .

4

5 .

Inspect

all connections within the intake system.

Tighten loose connections

as

required.

Replace damaged air intake components.
Check the connection between the compressor and

the engine intake manifold.

Tighten loose bolts as required.

Check exhaust system connections at turbine
housing inlet and outlet flanges for oil leakage and

loose connections. Tighten loose connections as
required. If

oil leakage exists, check the general

condition

of the engine.

Check the oil line connections at the centre housing
oil inlet and outlet ports

for leakage.

Tighten loose connections as required. Start engine
and recheck connections.

48

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