Engine & identification
Vehicle identification
| No. of cylinders Type | 4/OHV |
|---|---|
| Capacity cc | 2495 |
| Compression ratio :1 | 19,5 |
Injection system
| Fuel/injection pump assembly Make | Bosch |
|---|---|
| Fuel/injection pump assembly Type | VE4/11F R347 |
| Pump type | Rotary |
| Fuel feed/lift pump delivery pressure bar | 0,42-0,55 |
| Injector nozzle Make | Bosch |
| Nozzle and holder assembly Part No. | KBEL 98 P52 |
| Nozzle and holder assembly Part No. | 0 432 193 879 |
| Nozzle opening pressure - new/used bar | 200-280 |
| Back leak (pressure loss) bar/secs | 150-100/5 |
Injection sequence
The injection sequence for the Land Rover Defender 2.5 TDI (1990–1994) is 1-3-4-2.
| Injection sequence | 1-3-4-2 |
|---|
Valve clearances
Valve clearances for the Land Rover Defender 2.5 TDI (1990–1994) are 0,20 mm inlet and 0,20 mm exhaust, measured cold.
| Valve clearance - INLET mm | 0,20 cold |
|---|---|
| Valve clearance - EXHAUST mm | 0,20 cold |
Engine oil & fluids
Engine oil
The Land Rover Defender 2.5 TDI (1990–1994) takes 6.8 litres of engine oil with the filter.
A listed engine oil option is SAE 5W-30 for cold climates, with API/ACEA classification CF/B2.
A listed engine oil option is SAE 15W-40 for moderate climates, with API/ACEA classification CF/B2.
A listed engine oil option is SAE 10W-40 as an alternative for moderate climates, with API/ACEA classification CF/B2.
A listed engine oil option is SAE 20W-50 for hot climates, with API/ACEA classification CF/B2.
Manual gearbox
The manual gearbox has a listed capacity of 2.7 litres. The specified oil is Dexron II.
Transfer box
The transfer box has a listed capacity of 2.3-2.8 litres. The specified oil is SAE 90W.
Grades, filling conditions and capacities
| Engine oil options | |
|---|---|
| Ambient temperature range | Cold climate |
| Engine oil grade SAE | 5W-30 |
| Engine oil classification API/ACEA | CF/B2 |
| Ambient temperature range | Moderate climate |
| Engine oil grade SAE | 15W-40 |
| Engine oil classification API/ACEA | CF/B2 |
| Ambient temperature range | Moderate climate alternative |
| Engine oil grade SAE | 10W-40 |
| Engine oil classification API/ACEA | CF/B2 |
| Ambient temperature range | Hot climate |
| Engine oil grade SAE | 20W-50 |
| Engine oil classification API/ACEA | CF/B2 |
| Engine with filter(s) litres | 6.8 |
| Other lubricants and capacities | |
| Manual transmission oil grade SAE | Dexron II |
| Manual transmission litres | 2.7 |
| Differential front/AT litres | 1.7 |
| Differential oil grade - rear SAE | 90W |
| Differential rear litres | 2.3 |
| Transfer box oil grade SAE | 90W |
| Transfer box litres | 2.3-2.8 |
| Brake fluid Type | DOT 4 |
| Power steering fluid Type | Dexron II |
| Power steering fluid litres | 2.9 |
Brakes & wear limits
Brake disc thickness
Brake discs on the Land Rover Defender 2.5 TDI (1990–1994) are replaced at a minimum thickness of 12 mm (solid) or 22 mm (ventilated) front and 10 mm rear.
| Minimum disc thickness for replacement - solid Front | 12 mm |
|---|---|
| Minimum disc thickness for replacement - ventilated Front | 22 mm |
| Minimum disc thickness for replacement Rear | 10 mm |
| Maximum drum diameter for replacement Rear | 255,5 mm |
Brake disc and drum dimensions
| Disc runout Front | 0,15 mm |
|---|---|
| Minimum pad thickness Front | 3 mm |
| Minimum pad thickness Rear | 2 mm |
| Minimum shoe thickness Rear | 2 mm |
| Parking brake travel No. of notches | 3-4 |
Bar lengths use a square-root scale so small and large values stay readable.
Service & electrical
Battery
The Land Rover Defender 2.5 TDI (1990–1994) uses a 12 V, 95 Ah battery (reserve capacity 175 minutes).
| Battery V/RC(Ah) | 12/175 (95) |
|---|
Glow plugs
Glow plugs for the Land Rover Defender 2.5 TDI (1990–1994): Beru 783 MJ, Bosch 0 250 201 012, Champion CH70 and Lucas/CAV HDS303. Rated 11 V; activation takes 8 seconds.
| Glow plug nominal rating V/A | 11 |
|---|---|
| Glow plug activation time secs | 8 |
| Glow plug - part no. Beru | 783 MJ |
| Glow plug - part no. Bosch | 0 250 201 012 |
| Glow plug - part no. Champion | CH70 |
| Glow plug - part no. Lucas/CAV | HDS303 |
Tuning and emissions
| Crankshaft position (n = ATDC) °BTDC | — |
|---|---|
| Adjusting method Engine/Pump | Special Tool/Special Tool |
| Dynamic timing v = BTDC, n = ATDC | v |
| - Time Trac Stanadyne, Snap-on °/rpm | 10/800 |
| Idle speed rpm | 790±10 |
| Rated no load speed rpm | 4100-4260 |
| Oil temperature °C | 70 |
| Idle speed - for smoke test rpm | 780-800 |
| Governed speed range - for smoke test rpm | 4100-4260 |
| Maximum time at governed speed secs | 2,0 |
| Test mode A/B | B |
| Probe type 1/2 | 1 |
| Smoke opacity - EU limit m-1 (%) | 3,00 (73) |
| Smoke opacity - homologation value m-1 (%) | 2,50 (66) |
Starting and charging
| Starter motor Make | Paris Rhone |
|---|---|
| Maximum cranking amps A | 257-314 |
| Alternator Make | Lucas |
| Alternator Type | A127-65 |
| Alternator output A/V/rpm | 65/14/3000 |
| Regulated voltage V | 13,6-14,4 |
Service checks and adjustments
| Turbo boost pressure bar/rpm | 0,78/- |
|---|---|
| Oil pressure bar/rpm | 1,7-3,8/- |
| Radiator cap bar | 1,00 |
| Thermostat opens °C | 88 |
| Drive belt tension - alternator/PAS/AC mm | 4/5 |
Tightening torques
Cylinder head bolt torque
The cylinder head bolts on the Land Rover Defender 2.5 TDI (1990–1994) are tightened in 3 stages: 40 Nm, then 60°, then a final 60°.
| Cylinder head | |
|---|---|
| Renew bolts | No |
| Tighten | 40 Nm |
| Tighten | 60° |
| Tighten | 60° |
| Cylinder head instructions | — | |
|---|---|---|
| Other engine tightening torques | ||
| Main bearings Renew bolts/nuts | No | |
| Main bearings Stage 1 | 68 Nm | |
| Main bearings Stage 2 | 136 Nm | |
| Big end bearings Renew bolts/nuts | No | |
| Big end bearings Stage 1 | 30 Nm | |
| Big end bearings Stage 2 | 60 Nm | |
| Oil pump to cylinder block | 25 Nm | |
| Sump bolts | 25 Nm | |
| Sump drain bolt | 45 Nm | |
| Flywheel/driveplate | 139-153 Nm | |
| Clutch pressure plate | 30-38 Nm | |
| Crankshaft pulley/damper centre bolt | 333-350 Nm | |
| Inlet manifold to cylinder head | 25 Nm | |
| Exhaust manifold to cylinder head | 23 Nm | |
| Injector/clamp | 20-25 Nm | |
| Injector pipe unions | 22-25 Nm | |
| Fuel/injection pump flange | 22-28 Nm | |
| Fuel/injection pump mounting | 22-28 Nm | |
| Glow plugs | 15-30 Nm | |
| Chassis tightening torques | ||
| Steering track rod end | 41 Nm | |
| Brake caliper/carrier to hub Front | 145 Nm | |
| Road wheels | 108 Nm | |
Bar lengths use a square-root scale so small and large values stay readable.
Air conditioning
| Air conditioning refrigerant Type | R12 |
|---|---|
| Air conditioning refrigerant quantity grams | 1220±30 |
| Air conditioning oil Type | Suniso 4GS |
| Air conditioning oil quantity cm³ | 313 |
Frequently asked questions
What is the injection sequence of the Land Rover Defender 2.5 TDI?
The injection sequence for the Land Rover Defender 2.5 TDI (1990–1994) is 1-3-4-2.
What glow plugs does the Land Rover Defender 2.5 TDI use?
Glow plugs for the Land Rover Defender 2.5 TDI (1990–1994): Beru 783 MJ, Bosch 0 250 201 012, Champion CH70 and Lucas/CAV HDS303. Rated 11 V; activation takes 8 seconds.
How much oil does the Land Rover Defender 2.5 TDI take?
The Land Rover Defender 2.5 TDI (1990–1994) takes 6.8 litres of engine oil with the filter. A listed engine oil option is SAE 5W-30 for cold climates, with API/ACEA classification CF/B2. A listed engine oil option is SAE 15W-40 for moderate climates, with API/ACEA classification CF/B2. A listed engine oil option is SAE 10W-40 as an alternative for moderate climates, with API/ACEA classification CF/B2. A listed engine oil option is SAE 20W-50 for hot climates, with API/ACEA classification CF/B2.
What are the valve clearances for the Land Rover Defender 2.5 TDI?
Valve clearances for the Land Rover Defender 2.5 TDI (1990–1994) are 0,20 mm inlet and 0,20 mm exhaust, measured cold.
What is the cylinder head torque for the Land Rover Defender 2.5 TDI?
The cylinder head bolts on the Land Rover Defender 2.5 TDI (1990–1994) are tightened in 3 stages: 40 Nm, then 60°, then a final 60°.
What is the minimum brake disc thickness for the Land Rover Defender 2.5 TDI?
Brake discs on the Land Rover Defender 2.5 TDI (1990–1994) are replaced at a minimum thickness of 12 mm (solid) or 22 mm (ventilated) front and 10 mm rear.