1999 LAND ROVER DEFENDER engine oil

MAINTENANCE
1
MAINTENANCE UNDERBONNET VIEW - Td5
LHD shown
1.Engine oil dipstick
2.Coolant expansion tank
3.Air cleaner
4.Brake/clutch fluid reservoir filler cap5.Windscreen washer reservior
6.Auxiliary drive belt
7.Engine oil filler cap
8.PAS fluid reservoir
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MAINTENANCE
9
MAINTENANCE INTERCOOLER / COOLING SYSTEM
1.Visually check for any obstructions in the
radiator and intercooler matrix and remove
debris as necessary.
2.Visually check fan blades for damage.
3.Check cooling, intercooler and heating systems
for leaks, hoses and oil pipes for security and
condition.
4.Check accessible hose clips for tightness.
5.Check coolant level, top-up if necessary
Cooling System Top-Up
1.With engine cold, remove expansion tank filler
cap.
2.Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.
3.Fit expansion tank filler cap.
Intercooler Flush
1.Remove intercooler.See FUEL SYSTEM,
Repair.
2.Flush intercooler element using Unicorn
Chemicals’C’Solve following the manufaturers
instructions.
3.Thoroughly dry intercooler ensuring that no trace
of solvent remains in the element.
4.Refit intercooler.See FUEL SYSTEM, Repair.AMBIENT AIR PRESSURE (AAP) SENSOR - Td5
1.Check ambient air pressure sensor for damage.
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10MAINTENANCE
14
MAINTENANCE ENGINE OIL
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Position suitable container beneath sump.
3.Clean arear around drain plug.
4.Remove oil drain plug, discard sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit engine drain plug and tighten to23 Nm (17
lbf.ft).
8.Fill engine with recommended grade of oil to
correct mark on dipstick.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
9.Fit underbelly panel.See CHASSIS AND
BODY, Repair.CENTRIFUGE ROTOR - Td5
1.Renew centrifuge rotor.See ENGINE , Repair.
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MAINTENANCE
15
MAINTENANCE FULL FLOW OIL FILTER
1.Renew full flow oil filter.See ENGINE , Repair.GEARBOX OIL
WARNING: Avoid excessive skin contact
with used gearbox oil. Used gearbox oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Renew gearbox oil.See MANUAL GEARBOX,
Adjustment.
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MAINTENANCE
19
MAINTENANCE PAS PIPES AND UNIONS
Check
1.Check PAS pipes for correct, secure routing and
signs of chafing.
2.Check for signs of fluid leakage from PAS pump,
hoses, and hose unions.ENGINE, GEARBOX, TRANSFER BOX AND AXLES
Check
1.Check for oil leaks from engine, gearbox, tansfer
box, and front and rear axles. Pay particular
attention to areas around oil seals.
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12 - ENGINE
CONTENTS
Page
DESCRIPTION AND OPERATION
TD5 ENGINE 1........................................................................................................
GENERAL 12..........................................................................................................
CYLINDER BLOCK 13............................................................................................
CRANKSHAFT, SUMP AND OIL PUMP 22............................................................
CYLINDER HEAD COMPONENTS 25...................................................................
CAMSHAFT COVER COMPONENTS 30...............................................................
CAMSHAFT TIMING CHAIN COMPONENTS 30...................................................
CYLINDER BLOCK FLOW 32.................................................................................
OIL COOLER / FILTER FLOW 34...........................................................................
CYLINDER HEAD FLOW 36...................................................................................
ADJUSTMENT
ENGINE OIL PRESSURE CHECK 1......................................................................
REPAIR
CAMSHAFT 1.........................................................................................................
PULLEY - CRANKSHAFT 3....................................................................................
OIL SEAL - CRANKSHAFT - REAR 4.....................................................................
BEARING - SPIGOT - CRANKSHAFT 5.................................................................
GASKET - CYLINDER HEAD 6..............................................................................
ROCKER SHAFT ASSEMBLY 11...........................................................................
GASKET - COVER - CAMSHAFT 13......................................................................
ENGINE AND ANCILLARIES 14.............................................................................
MOUNTING - FRONT - LH 19................................................................................
MOUNTING - FRONT - RH 20................................................................................
MOUNTING - GEARBOX - REAR - LH 21..............................................................
MOUNTING - GEARBOX - REAR - RH 22.............................................................
FLYWHEEL 22........................................................................................................
FILTER - OIL 23......................................................................................................
STRAINER - OIL PICK-UP 24.................................................................................
PUMP - OIL 24........................................................................................................
GASKET - ENGINE TO SUMP 26..........................................................................
SWITCH - OIL PRESSURE 28...............................................................................
VALVE - RELIEF - OIL PRESSURE 29..................................................................
COOLER - ENGINE OIL 29....................................................................................
CENTRIFUGE ASSEMBLY 30................................................................................
ROTOR - CENTRIFUGE 32....................................................................................
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12 - ENGINE
CONTENTS
Page
OIL SEAL - TIMING COVER 32..............................................................................
TIMING CHAIN AND SPROCKETS 33...................................................................
OVERHAUL
GASKET - INLET MANIFOLD 1..............................................................................
GASKET - EXHAUST MANIFOLD 2.......................................................................
GASKET - CYLINDER HEAD 3..............................................................................
CYLINDER HEAD GASKET SELECTION 7...........................................................
CYLINDER HEAD - OVERHAUL 8.........................................................................
GASKET - ENGINE SUMP 20................................................................................
SEAL - CRANKSHAFT - REAR 21.........................................................................
STARTER RING GEAR 22.....................................................................................
PUMP - OIL 23........................................................................................................
TIMING CHAIN AND SPROCKETS 26...................................................................
BEARINGS - CONNECTING RODS 30..................................................................
PISTONS, CONNECTING RODS AND CYLINDER BORES 32.............................
CRANKSHAFT 36...................................................................................................
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ENGINE
3
DESCRIPTION AND OPERATION 1.Oil dipstick tube
2.Screw - oil dipstick tube to camshaft carrier
3.Oil dipstick
4.2nd piston ring
5.Piston
6.Small-end bush
7.Connecting rod
8.Big-end bearing cap
9.Connecting rod bolt (2 off per connecting rod)
10.Top piston ring
11.Oil control ring
12.Circlips (2 off per gudgeon pin)
13.Gudgeon pin
14.Big-end bearing shells
15.Dowels to cylinder head (2 off)
16.Gearbox shim plate
17.Rear crankshaft seal and housing
18.Screws - crankshaft seal flange to engine block (5 off)
19.Bolts - Gearbox shim plate to cylinder block (2 off)
20.Main oil gallery plug (rear)
21.Oil filter adaptor gasket
22.Oil filter adaptor thermostat
23.Oil filter adaptor assembly
24.Oil filter adaptor insert
25.Oil filter adaptor to cylinder block bolts (3 off)
26.Oil filter
27.Oil pressure switch
28.Oil cooler banjo bolts (2 off)
29.O-rings - oil cooler banjo bolts (2 off)
30.Oil cooler to cylinder block bolts (7 off)
31.Centrifuge assembly
32.Centrifuge to cylinder block bolts (3 off)
33.Centrifuge oil drain pipe
34.Oil drain pipe to sump gasket
35.Centrifuge to oil drain pipe gasket
36.Oil cooler plugs (3 off)
37.Oil cooler assembly
38.Oil cooler matrix ’O’ rings (2 off)
39.Oil cooler matrix
40.Oil cooler gasket
41.Coolant and PAS pump assembly bracket
42.Bracket bolts (5 off + 1 stud/nut)
43.Cylinder block
44.Dowels - timing chain cover (2 off)
45.Oil gallery delivery plug
46.Cross drilling plug
47.Coolant jacket plug
48.Core plugs (3 off)
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