1999 LAND ROVER DEFENDER lock

INTRODUCTION
1
INFORMATION INTRODUCTION
This Workshop Manual Supplement covers vehicles
from 1999 and 2002 model year onwards. The Body
Repair Manual has also been incorporated into this
supplement. Amendments and additional pages will
be issued, when necessary, to ensure that the
supplement covers latest models.
This Supplement is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover Defender vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system should
be carried out by a Land Rover Dealer. Repairs to
such items should NEVER be attempted by untrained
individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft end of the engine is referred to as the front.
To reduce repetition, some operations covered in this
Supplement do not include reference to testing the
vehicle after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out, particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer’s specification. Torque spanner values
given in the Supplement must be strictly adhered to.
Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during
removal it must be replaced with a new one. Certain
fasteners must not be re-used. These fasteners are
specified in the Supplement.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.
ProCarManuals.com

INTRODUCTION
7
INFORMATION TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1.Turn ignition key to position’1’to release
steering lock.
2.Select neutral in main gearbox and transfer
gearbox.
3.Secure tow rope, chain or cable to front towing
eyes (alternative types shown).
4.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions,’snatch’recovery
should be avoided.Rear suspended tow by breakdown vehicle
1.If the front axle is to be trailed turn ignition key to
position’1’to release steering lock.
2.Select neutral in main gearbox and transfer box.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.
TRANSPORTING THE VEHICLE BY TRAILER
Lashing/towing eyes are provided on front and rear of
the chassis side members, see J6085, to facilitate the
securing of the vehicle to a trailer or other means of
transportation.
CAUTION: Underbody components must
not be used as lashing points.
Install vehicle on trailer and apply park brake. Select
neutral in main gearbox.
ProCarManuals.com

01INTRODUCTION
12
INFORMATION LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - Td5 Engine
The Td5 engine number is stamped on the LH side of
the cylinder block, below the exhaust manifold.Main gearbox R380 serial number
Stamped on a cast pad on the bottom RH side of the
gearbox.
Transfer gearbox LT230 serial number
The serial number is stamped on the LH side of the
gearbox casing below the mainshaft rear bearing
housing adjacent to the bottom cover.
ProCarManuals.com

GENERAL SPECIFICATION DATA
1
INFORMATION ENGINE - Td5
Type 2.5 litre in-line direct injection Diesel, turbocharged.................................................................................
and intercooled
Number of cylinders 5 in-line, No. 1 cylinder at front of engine.........................................................
Bore 84.450 mm (3.3248 in).................................................................................
Stroke 88.950 mm (3.5020 in)...............................................................................
Capacity 2498 cm
3(152.5 in3) ...........................................................................
Firing order 1 - 2 - 4 - 5 - 3.......................................................................
Compression ratio 19.5:1............................................................
Direction of rotation Clockwise viewed from the front of the engine...........................................................
Dimensions
Length 766 mm (30.1 in).....................................................................
Width 708 mm (27.8 in).......................................................................
Height 788 mm (31.0 in)......................................................................
Emissions standard :-
Engine Serial No. Prefixes 10P to 14P - EU2 Model ECD 2........
Engine Serial No. Prefixes 15P to 19P - EU3 Model ECD 3........
Lubrication
Type Wet sump, pressure fed.................................................................................
Pump type Eccentric rotor, crankshaft driven integral with stiffener........................................................................
plate.
Filter type:
Primary Centrifuge filter....................................................................
Secondary Disposable canister with full flow by-pass...............................................................
Pressure at idle (cold) 3.0 bar (43.5 lbf.in
2) ......................................................
Pressure at 3500 rev/min (hot) 1.5 - 3.0 bar (21.75 - 43.5 lbf.in2) .........................................
Relief valve opening pressure 4.0 bar (58 lbf.in2) ..........................................
Low oil pressure switch opening pressure 0.2 - 0.6 bar (3.0 - 8.8 lbf.in2) .......................
Crankshaft
Main bearing journal diameter 61.9875 - 62.0125 mm..........................................
Crankpin journal diameter 53.99 - 54.01 mm................................................
Crankshaft end float 0.020 - 0.250 mm.........................................................
Main bearings
Number and type 6 half shells (5 main, 1 thrust)..............................................................
Pistons
Type Graphite compound skirt with combustion chamber in.................................................................................
crown.
Clearance in cylinder bore 0.172 - 0.206 mm (measured at bottom of skirt, 90°to ...............................................
gudgeon pin)
Diameter 84.270 - 85.254 mm (measured 90°to gudgeon pin, ..........................................................................
and 40.00 mm from bottom of skirt.)
ProCarManuals.com

04GENERAL SPECIFICATION DATA
4
INFORMATION TRANSMISSION - Td5
Main gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward, 1 reverse, all synchromesh.............................................................................
Transfer box
Type LT230TE Two speed reduction on main gearbox output. Front.................................................................
and rear drive permanently engaged via a lockable
differential
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts, 32°angularity of universal joint on full
lock
Ratio 3.54:1.................................................................................
Propeller shafts
Type, front and rear Tubular 51 mm dia...........................................................
Universal joints Open type Hookes O3EHD.................................................................
ProCarManuals.com

GENERAL SPECIFICATION DATA
5
INFORMATION STEERING
Power steering box
Make/type Adwest Varamatic - worm and roller box........................................................................
Ratio Variable: straight ahead 19.3:1 on lock 14.3:1.................................................................................
Steering wheel turns, lock-to-lock 3.375....................................
Steering pump
Make/type Hobourn-Eaton series 500........................................................................
Steering geometry
Steering wheel diameter 412 mm (16.22 in)..................................................
Toe-out measurement 0 to 2 mm toe out......................................................
Toe-out included angle 0°to 0°20’ .....................................................
Camber angle 0°* ..................................................................
Castor angle 3°* .....................................................................
Swivel pin inclination static 7°* ...............................................
* Check with vehicle on level ground, in unladen
condition and five gallons of fuel. Rock the front of the
vehicle up and down to allow it to take up a normal
static position.
Turning circle between kerbs
90 models:
265/75 x 16 tyres 12,65 m (41.5 ft)..............................................................
All other tyres 11,70 m (38.4 ft)...................................................................
110 models:
750 x 16 tyres 13,41 m (44 ft)..................................................................
130 models:
750 x 16 tyres 15,24 m (50 ft)..................................................................
ProCarManuals.com

GENERAL SPECIFICATION DATA
7
INFORMATION SHOCK ABSORBERS
Type Telescopic, double-acting non-adjustable.................................................................................
Bore diameter 35.47mm...................................................................
BRAKES
Front brake
Caliper AP Lockheed, four opposed pistons..............................................................................
Operation Hydraulic, self adjusting.........................................................................
Disc 90 - Solid, outboard, 110/130 - Ventilated, outboard..................................................................................
Disc diameter 298 mm (11.73 in)...................................................................
Disc thickness 90 - 14,1 mm (0.56in), 110/130 - 24mm (0.95 in)..................................................................
Wear limit 1 mm (0.04in) per side of disc.........................................................................
Disc run-out maximum 0,15mm (0.006 in).....................................................
Pad area 58 cm
2(9.0 in2) ..........................................................................
Total swept area 801,3 cm2(124.2 in2) ...............................................................
Pad material Ferodo 3440 non asbestos.....................................................................
Pad minimum thickness 3 mm (0.12in)...................................................
Rear brake
Caliper AP Lockheed opposed piston..............................................................................
Operation Hydraulic, self adjusting.........................................................................
Disc Solid, outboard..................................................................................
Disc diameter 90 - 290 mm (11.42 in), 110/130 - 298 mm (11.73)...................................................................
Disc thickness 90 - 12,5 mm (0.49 in), 110/130 - 14,1 mm (0.56 in)..................................................................
Wear limit 90 - 0,38 mm (0.015 in), 110/130 - 1,0 mm (0.04 in).........................................................................
per side of disc
Disc run-out maximum 0,15 mm (0.006 in).....................................................
Pad area 90 - 30,5 cm
2(4.37 in2), 110/130 - 36,2 cm2(5.61 in2) ..........................................................................
Total swept area 90 - 694 cm2(106.98 in2) ...............................................................
Pad material Ferodo 3440 non asbestos.....................................................................
Pad minimum thickness UP TO 02MY - 3 mm (0.12 in)...................................................
Pad minimum thickness From 02MY - 2 mm (0.08 in)...................................................
Parking brake
Type Mechanical, cable operated drum brake on the rear of.................................................................................
the transfer gearbox output shaft
Drum internal diameter 254 mm (10.0 in).....................................................
Width 70 mm (2.75 in)................................................................................
Pad material Ferodo 3611 non asbestos.....................................................................
Servo/master cylinder
Manufacturer Lucas....................................................................
Servo type LSC 80........................................................................
Master cylinder type 25,4 mm (1.0 in) diameter, tandem.........................................................
Pressure reducing valve, failure conscious Cut-in pressure, 90 - 24 bar (360 Ibf/in
2) ratio 4.0:1, ......................
110 - 43 bar (645 Ibf/in2) ratio 2.9:1*
NOTE: * Pressure reducing valves are not fitted to all 110 specifications.
ProCarManuals.com

07 - GENERAL FITTING REMINDERS
CONTENTS
Page
INFORMATION
GENERAL FITTING REMINDERS 1.......................................................................
PRECAUTIONS AGAINST DAMAGE 1..................................................................
SAFETY PRECAUTIONS 1....................................................................................
PREPARATION 2....................................................................................................
DISMANTLING 2.....................................................................................................
INSPECTION-GENERAL 2.....................................................................................
BALL AND ROLLER BEARINGS 3.........................................................................
OIL SEALS 4...........................................................................................................
JOINTS AND JOINT FACES 5................................................................................
FLEXIBLE HYDRAULIC PIPES, HOSES 5.............................................................
FUEL SYSTEM HOSES 6.......................................................................................
METRIC BOLT IDENTIFICATION 6........................................................................
METRIC NUT IDENTIFICATION 6..........................................................................
KEYS AND KEYWAYS 6........................................................................................
TAB WASHERS 6...................................................................................................
COTTER PINS 7.....................................................................................................
NUTS7 ...................................................................................................................
LOCKING WIRE 7...................................................................................................
SCREW THREADS 7..............................................................................................
UNIFIED THREAD IDENTIFICATION 7..................................................................
ProCarManuals.com