Defender Diesel Turbo Tdi Engine Kit Fitting instructions. Tai Engine Kit. STC939D Instructions de montage. Kit moteur Tdi STC939D Einbauhinweis. Tdi Motorbausatz. STC93SD Istruzioni di montaggio. Kit de| motore Tdi. STC939D Instrucciones de montaje. Tdi Engine Kit STC933D Septemore 1992 September 1992 Settembre 1992 Septiembre de 1982 (TT ay GENUINEImportant - Please read carefully Please read afd understand these instructions carefully before commencing work These conversions have boon devoloped by Land Rover, in response to customer demand for the inereasod perlormance and improved fuel economy offered by the Tdi unit aver earlier engines Groai care has been taken to eneure that the instructions herein are correct for 90 and 110 Land Rover and Land Rover Detender vehicles. Howevar, due to the immense variety of LR models and spacial customer specifications, itis nat passible to cover all vehicles manufactured since the aunch of 90 and 110. Land Rover accepts no liability for extra costs entailed through this conversian should the customer have a tion: standard vehicle or one which has been altered since it left the factory Should you have any queries concerning this procedure, please contact your nearest Land Rover Dealer Whilst overy effort has boon made to ensure their compiotenass, f you hava any holpful comment on the instructions, please forward these te Land Rover Parts, Following the completion of this conversion work, it is advisable to have the installation checkad out by a Land Rover authored dealer Iti nat intonded that this conversion be conduct could be compremised. 1d on any vehiclo still within its Warranty period, etherwise this lattor Anomal Land Rover 12 month Warranty wil be offered on Genuine Parts supplied If in doubt over any of the procedures outlined in the instructions, please consult your Workshop manual, of if still unsure, your nearest Land Rover dealer These ingtructions contain pert numbers refering to left and right hand drive vehicles, to enable us to cator for all markets, Take care to fit the correct handed paris to your vehicle - see the parts list Before any work iscarried out on a vehicle, please ensure that itis in sound mechanical condition. Pay close attention lothe braking system and the {uel system. Ensure yourtyres are capable of handling the higher performance of the Td engine, pariicuarly when replacing an NA dese! or 2.5L petrol Any tyres recommended as standard fit to current Defender Td) will be suitable. A 1?-plate 95H battery is also standard fit with the Tei Please follow thesa instructions precisely. Any deviation from thase notes may be dangercus ar at least detrimental to the performance o! your Land Rover preduct. If in any doubt, consult a workshop manual or your local dealer. WARNING Engines which ate not properly installed can be dangerous, Read the instructions caretully prior to commencing work. Whilst iting, comply with the instructions at all times. itin any doubt, consult your workshop manual or contac! your noarest Land Rever DealerDisconnect battery Note speedometer reading Remove bonnet mounted spare wheel ited Remove bonnet Drain coolant Remove and discard air cleaner assembly, fan, cowl, tadiator (s0e 88and 4M ang air cleaner service gauge, Disconnect oil cooler pipe work and remove cooler from vehicle Remove turbo heat shield. Slackon exhaust down pipe at elbow, engine block and exhaust coupling, Remove heator hoses. Disconnact control cables from rocker cover clip. Remove breather pipes from rear engine iting bracket. Refit fing in bracket Disconnect fuel pipe connections: i) fuel feed to injection pump. i) spill return trom ne 4 injector ii) fuel feed to ltt pump, iv) lift pup to tue! fiter connection Note routing, then disconnect throttle cable and remove trom vehicle. If fitted, d'sconnect power steering hoses. Disconnect brake servo vacuum hose from vacuum pump Romove engine harness and lay aside to prevent damage Disconnect heater plug hamness from No. 4 heater plug Support engine with sutabie liting gear. Note engine weighs 270 kg, Remove engine earth strap (turbe side engine mounting). Undo engine mounting rubbers top and bottom Raise engine, remove rubbers, lower back onto chassis mountings Remove starter and hamess. Remove bel housing firings. Lift out engine Remove and discard ai cleaner base Remove and discard fuel fiter from bulkhead letain fixings:2 28, 29, 32. 33, 34. 36. lesa rice oa Parts Required Clean engine bay to-aid re-assembly Sling new engine for fitting [hanging slightly tlywhee! down). Jack’block up gear box bell nousing i! necessary 10 aid litment, Remove viscous tan. Lower pew unit into engine bay and mate up to transmission. Tighten bell housing fovngs. Fit siarter and hamess Whiteired to solenoid spade. Brown to solenoid live Black to earth stud Ensure hamess clears underside of iniet manifold to prevent short eitculting Raise engine, thx mounting rubbers to engine mounting feet loosely. Lower into chassis mounts and tighten Connect earth lead to chassis (ret 6) Ret exhaust down pipe Fit new fuel filter assembly to bulk head with original fixings and in ‘original position Re- ft fuel feed pipe to lit pump. (ene eas Re-ft turbo-charger heat shield Fit new heatar hoses; steal pipe feeds rear ol heater Hose heater matrix, pipe nipple in cylinder head feeds tront. BTR 445 RH BTR 983 LH BIR 447 RH BTR 962 LH Refit oil cooler pipe work, connect to ol filter en100258 housing. Hose Clip x 4 Split Pin, PS603041 x2 Radiator Assy Remove ail cooler pine adaptors from oli radiator and install into nro4s93, new radiatov/intercacler assembly, Oil Cooler Adaptor ESR1262 x 2 Cormect ol cooler pioework to radiator ollesaarPiae: ESRI912 ESR1913| Assemble - Engine Systems. 37 38. 30, 40. Fit new throtle cable routed as orginal Re-connect tuel shut off solenoid white black wire and oll pressure sender white*brown wire Connect spill rotumn to tank: i i) iit) a) Assemble one hall of the brass connector assembly STC 935 connector, STC 936 olive and STC 937 nut, Slide connector onto spill return steel tube at injection pump; ensure fully home and tighten nut to etfect seal Assembie second nut and olive into connector Locate tank return pipe. (This has two metal fittings, a nut at tts end and a banjo fiting approximately 250 down its length). With a sharp knife, cut the nylon pipe through 270mm (approx. ) trom the banjo titing, ‘This pipe must be cut squarely Slide cut pipe through nut and olive into connector unti: uly home. Tighten nut to elfect seal Connect glow plug timer and associated harness. See skeich. figure 1 0) i) vy) y) vi) vi) wi) Identity old brownvred teed t0 giow plugs. Remove eyelet trom end of lead. Crimp on bullet connector Push on connecto’ to isolate wire and tape back to harness. Drill 2mm hole in bulk head to accommodate selt-tapoing screw approx 153mm ftom uel fiter towards centre of vehicle and 25mm down from top edge. or utilise earth eyelet. Fix relay timer to bulkhead, using screw. ‘Snap connector in harness PRC 6083 to base of reay Run heavy brown lead along bulkhead wiring and down engine compartment parallel to main battery lead. Follow routing of battery lead and connect, brown lead to battery + terminal, Use cable tie ‘868680 10 fix cable run in place. See sketch Yellowiolack lead trom timer connects to No 4 low plug. Remaining wires from timer terminate in moulded lug which matches plug in existing harness. Parts Required Throttle Cable ANRT419 NTCaS45 LH Connector STC 935 Olive STC 936 Nut STC 937 Relay Timer PRC 6913 Harness PRC 6083 Bullet 242704 Connector 35491, Screw AB612051 Cable Tie 568680 x 10at 43, 44 & Assemble - Turbo/Cooling Parts Required I fitted, re-connect PAS pump feed and pressure hoses, Ensure correc! fiting of sealing washers and rubber "O° ring. Fit pipe clip NAG 8404 Under old air cleaner position 10 support pipe-work together with plate NRG 8405 Lower radiator onte chassis mountings. Transfer upper mounting rubbers inte new brackets (upper) utlize existing radiator mounting ficings (M6 x12) and fasten to front panel. It fixing hole is occupied (ie. bonnet latch fixing) use longer fixing screw already in place. Remove tadiator transit plugs. See Tdi cooling arrangement. figure 2 Hell bottom hose/expansion tank hose ‘Assemble turbo outlet (downward facing connection) to intercooler ppework, This consists of pipe NTC 5628 which is shaped with a 51mm long bend and has long and short pipe runs eithor sida. Flats allow it to clear inlet manitox ang aternator areas, Hose bend elbow ESR 1906 fits the shorter end of pipe NTC 5628 Fit to turbo charger and arrange so that the sets upward and slightly away trom the engine. Hose elbow ESR 298 has an unequal bend, the long side of which joins pipe NTC 5628 and tha shorter to the intercoolet bottom conection. Joints are tiked and sealed with hose sips CN1 006081 4 off Belore tighiening ensure adequate clearance with alternator and manifolds ete ‘Temporarily remove washer bottle and assemble air cloaner ESR 370 to cradle ESR 276 Connect engine breather hose to stub on air cleaner outlet Fit ‘ebow ESR 228 to air cleaner inlet. Existing fresh air ducting connects to elbow ESR 228 Connect air cleaner to turbo inlet (centre of turbine housing) with hase ESR 415 Push the air cleaner assembly against inner wing and back towards passenger comparimen’ unti air cleaner covers approximately hall of the shock absorber cover. Turbo feed hose ESR 415 will form a tight 'S’ bend. Ensure clearance with adjacent hosas and pipe runs and mark the position of the cradle fixing holes upon ihe inner wing (3 places), Tomporarily remove the air cleaner assembly. Drill three fixing holes 7mmn diameter to mount the cradle to inner wing. Fasten with fixings supplied, Plate NRCBA05 Brackets ESR282 LH ESR283 RH Screw SH105121L x4 Washer WAI06041L x 4 Washer WLIO6001L x 4 Pipe NTC5628 Hose Elbow ESR 1905 Hose Elbow ESR 298 Hose Clip eNto0608L x 4 Air Cleaner ESR 370 Cradle ESR 276 Elbow ESR 228 Hose Clip CNi00308L, Hose ESR 415 Hose Clip STC 128 Hose Clip CNi00308L Screw FS 105161 x9 Washor WATO6041L x 3 Washer Nut NHID6041L x3Assemble - Turbo/Co Parts Required 46. _Re-install viscous tan unit ogether with now tan cowl, Lower Cowl shroud into sits in radiator surtoune wih fan stowee in shrauc ESR 995 {safely warning uppermost) Fix cow! to two siuds on ‘op edge of radiator assembly with nut Maslior: and washer supplied. Locate fan on waterpump spingle and ws10s001 x 2 tighten down Nut NH105041 x 2 Fit intercooler to inlet maniiolé pipe work. Steel ppe NTC $627 Pipe is coupled to intercooler wih hose ESR 289. Pipe NTC 5027 NTC s6a7 is joined to inlot manifold hose with hose ESR 1906. fix and Hoses seal hoses with hose clips CN100603, ESR 1905 Hose Clip CNt00608L x4 Hose ESR 289 Fit new top hoge NTC 4895 with hose clips CN 100508 Hose this passes under intercooler pipe NTC 5627. oe 4896 cn100508 x 2 Remove and discard existing bonnet prop. Locate new bonne! prop MTC 2220 in bracket to ght of one Prop proviously used in bonnet leading edge. MTC 2220 Secure with anti-rat spring washer WS 6000611 and spit Washer pin PS 106161 ws 600061 Split pin PS 100161L Bonnet prop securing clip locates on a bracket in the cantre of the Clip panel and is secured by screw SP104101L. spring wasner nut MRC 7623 WL104001L and NH1 040411. Screw Align clip with prop and tighten into place. refit benno SP1O9101L Washer WL104001L Nut NHT04041L, Replace coolant, oil, PAS fuid iif fitted) and star up. Chock for leaks etc and alow 19 warm up as normal On PAS-itled vehicles, move steering wheel from lock to lock to fil PAS system. Top up if necessary. Re-check tluid levels in usual manner after engine has cooled, 52. Aix warning label to top of radiator as shown Label in cooling eysion diagram ERR 321 58. Record new engine number lor log book, Decal BTR 510MUB 54. Apply Tdi decals to wing lowers, forward of bulkhead joint linePart description Complete Tei Engine Heater Hose Heater Ho: Worn Drive Chip Throttle Cable Brace Fuol connector As Split Pin Glow Plug Harness Glow Plug Timer Rolay Sell Tappino Screw Bullet connector Connector tube Gable Tie Riackator‘ntercooler Assy Radiator Mounting LH Radiator Wounting PH Label Plato - PAS pipe Pipe Hose w Sealing Washer Pipe Hose Elbow Hose Elbow Hose Elbow Woim Drive Hose Clip Air Cleaner Assembly Cradle Hoee Clip Hose Clip Hose Flange Sciew Plain Washer Lock Washer Nut Fan Cowl Washer Spring Nut Goolent Hose Hose Clip Bonnat Prop) Washer Spring Washor Plain Spi Pin Securing Clio Screw Lock Washer ut Tei wing decal Hamess Bulb Capless Cable OI Cooler Adaptor Ol Cooler Pipe Part number sTosa7e/STC1092 BTR 445, BTR 447 CNT00258 x 4 ANAS STC 935, 936 & 937 Psp0g041 x 2 PAC 6083 PAC 6913 43612091 2H2708 35401 568680 « 10 NTC 4393 FSR 282 ESR 283 ERR 325 NRC 8405, NTC 5628: ESR 298 ESR 354 x4 NTC 5627 ESR 1906 x 2 ESR 289 ESR 208 CN1 006081. x 8 SR 370 ESR 276 Nt 009081. x 2 STC 128 ESR 41S S 106161 «3 WA 106041L x3 WL 108001L x3 NH 1030411 x3 ESR 935 WS 105001 x2 NH 105041L x2 NTC 4895 ON190808 x 2 MIC 2220 ws 600061 WA 110081L Ps 105761L NRC 7623 SP104101L WLip4go1L. NH1O4041L BTR 516MUB x2 STCS34 RTC3635 DACTS48 «5 ESR1202 x2 ESRI912 ESRI913 Part number Left-hand drive Only BTA 98a TR oa NTO 4945bainéig YaINIL ONId MO1D O1 G334 40 ONILNOYzeinbls W3LSAS ONITOOS IPL 50€®> DEFENDER 110 1987 onwards 177 | ENGINE Model DEFENDER 110 1987 onwards Page — AFBMOCIA ENGINE - ENGINE MOUNTINGS - 200 TDI il Part No. wit 10001L Qty Remarks€@® DEFENDER 110 1987 onwards 535 | FUEL SYSTEM AND AIR CLEANER Model DEFENDER 110 1987 onwards Page —AFUXEC2A IM, Part No. Description Litt pump to filtor 1 ESR39¢ Pipe tuo! 2 NTCIII6 Bolt banio 3 ESRISa Washor copper Filter to fuel Injection pump 4 ESRI95 Pipe fool 5 NTC3d6 Bolt banjo 6 ESRa5s Washer copoer FUEL SYSTEM - PIPES - 200TDI - FROM VIN HAsSSD46 Qty Remarks 1 2 4 1 1 2( ( EP DEFENDER 110 1987 onwards 547 | FUEL SYSTEM AND AIR CLEANER Model OEFENDER 110 1987 onwards Page — AFIXGCOA FUEL SYSTEM - FILTER - 200TDI Description Oty Remarks Fier assembly fuel alBUILT ON SUCCESS 1991 Introduction The now 200 Tel Diesel Engine Alvhe hoortel Lard 8 word ning Dacor is 2 now be of diesel engine ~ fhe 200 Idi % a This echicallyadeanced, proton enginsered power Unit hos st new stancbrd er diesel power, excnomy aid relly Now the proven quits the 200 Tal engne-oré bene mace tclabe to irjecl new hes ints ster, alder land Raver vances The 200 Td hos ahendy deranstated dear poten oy 2 pawerzock in ts widely praised apploation forthe erren rodcton Deencar uiliy veil rorge ton Rover Parts hale ttl ag conon ges for athe: Land Rover rel = i ‘The reavons why the 200 Idi certain tobe the Art chowe ol owners ‘onc-epercere aretha sone os hose whch hese mace the Dcavery he Exroordineny sewer Inleose torque. raster acceleration Removable ‘sonemy, Longer service nterale Lower manterares co's Gueter peromancn Clana essen ‘Tig! ond tested ovr two lion mies through bisering desert heat and froezing Arctic westes, the 200 T6i hos emerged os the power Unitshich dimancing fet snore ord owner pects have boon Seting = Performance The 2 Sra, 4sq/indenrbockarged inercoled, rect injection desl 200 Td produces 107 thp [BOW] mara hon enough ta delve the ‘ower need forthe toes ks ‘4 Tdi powored vehicle hos bate climbing abiby, inpraved alfred porn de grecie capacity for payload thon previons ord Rover diesel engines It 8 nore ralexng 9 drive and needs fear gearchenges Economy co bo the Tange Obed 90 ck Fer Hera 12.9 mpg oto constant $6 ph, 26.9 mpg athe voor ye 212 magia o constant 75 ph Wits fl nese accounting oe around « fh af vehi opereion cass, the 200 Téi con make a spite contitaton to reduced Spovating bil Low Ownership Costs The 200 Te in deigne for more oficen runring al dong sevice intel. Which mons lt tno of he road en lover eae con 12.500 males 0¢ 20.000 Llmareseporcte cach ruc, wiki one fier changes neoded only every 8.000 mts, Engine darign ond undetrense! lt rakes miitenanc sir tin ‘ones routine checks to br eared ov quicely, Replacomen Garaine Pt oppo ond Land Rover Sorc reall eval rv en Lvl Rover Franchised Newark Dealer Easy Insiallotion Each Lonel Ravor 200 Td conersin is engcerel oi exit, vthaut onphomert Each onion cle coed wih ave Genuo Fors component, ond ancileres needed o complet th ik. A anger ove bos ocr by ad over ngewe eieea ein clentie ced cna clon hay donee Built-in Quality These voeproniting abproach prin strdorda whi hs ge tad Sane on ural epucion lr bul qucy, Gtetton fp dol end Edenh strong hos ensed ely of the 200 7 sogine Lend Raver fsoy echniiane ware th highot vas quay Prodicolo ensure he eer engine meus wcctng stirards Sascel process cons make bly crc tht tay got i igh Fis ne. ety he 0eh 200 id epgigurdaegoes demanding tt tes ore ech has a see sore promenade Sd coy Quieter Operation Diesel noises dramericaly reduced nthe 200 Ta hough a two-stage res nection system which cates evr less combustion noea han ‘her deg injschen eqaloped motors lt sons recicd lms of sound intrason, beth nee and eutido| Environmental Concern The design cn corstuction ofthe 200 Ti engine ens ower srissane of erbon dowd The grenhawnagjte esorico wi loka Ergin eninion ol CO2 and oxides of wirogon hydrocrbons re dso ~fumad toleves wovantaly dow ini "Monsfoctires data te ins ep, ih 5begs BUILT TO ADAPT ‘ley aluminium ender heed Bosch two stage lit injoce Ingeoved news chorocers8c Fst response tied heater sn a re Instllotion Kit ev full buld Tai engine ich sembly Filing inshrtions Foiled intron arated The Td instlrion sive, even including the Tok decels