1999 LAND ROVER DEFENDER washer fluid

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.
ProCarManuals.com

33CLUTCH
6
DESCRIPTION AND OPERATION DESCRIPTION
General
The clutch system is a diaphragm type clutch operated by a hydraulic cylinder. The drive plate is of the rigid centre
type with no integral damping springs. The flywheel is of the dual mass type with damping springs integral with the
flywheel. The clutch requires no adjustment to compensate for wear.
Hydraulic Clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir. The master and slave
cylinders are connected to each other hydraulically by plastic and metal pipes. The plastic section of the pipe
allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the fluid reservoir. The bore is also connected to a damper which prevents
engine pulses being transferred hydraulically to the clutch pedal. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coil springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead and secured with two bolts. The cylinder is connected to the
shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat
shield is fitted to protect the underside of the slave cylinder from heat generated from the exhaust system. The
slave cylinder comprises a cylinder with a piston and a rod. A port in the cylinder body provides the attachment for
the hydraulic feed pipe from the master cylinder. A second port is fitted witha bleed nipple used for removing air
from the hydraulic system after servicing. The piston rod locates on a clutch release lever located in the gearbox
housing. The rod is positively retained on the release lever with a clip.
Clutch Mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A
spigot with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the
clutch release lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located
on the ball, the pivot washer seats against the rear face of the release lever. A spring clip is located on the lever
and the pivot washer and secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned
centrally on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever
to pivot freely around the ball.
The clutch release bearing locates on the clutch release lever and release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever
on the carrier. The bearing and carrier are not serviceable individually.
ProCarManuals.com

CLUTCH
3
REPAIR
5.Disconnect multiplug from clutch pedal sensor.
6.Disconnect muliplug and harness clip from pedal
bracket.
7.Position cloth to collect fluid spillage.
8.Loosen pipe union, release pipe and plug pipe
and master cylinder.
9.Move brake master cylinder assembly aside and
lift out clutch master cylinder assembly.
10.Remove 6 screws, remove pedal box top cover
and discard gasket.
11.Remove nut securing push rod to clutch pedal
trunnion.
12.Remove 2 bolts and remove clutch master
cylinder from pedal bracket.
13.Remove clutch pedal sensor and pipe union
from master cylinder and discard sealing
washers.Refit
14.Clean sensor and pipe union.
15.Fit clutch pedal sensor and pipe to master
cylinder using new sealing washers.
16.Position master cylinder to pedal bracket and
align push rod to pedal trunnion.
17.Fit bolts and nuts and secure master cylinder to
pedal bracket.
18.Fit nut securing push rod to clutch pedal trunnion
but do not tighten nut at this stage.
19.Move brake master cylinder aside and position
clutch master cylinder assembly.
20.Clean clutch pipe union.
21.Align pipe and tighten union.
22.Connect multiplug to clutch pedal sensor.
23.Tighten bolts securing clutch pedal and brake
pedal brackets to body.
24.Fit clutch pedal rubber.
25.Position closing panel and tighten screws to
lower’A’post.
ProCarManuals.com

37MANUAL GEARBOX
2
ADJUSTMENT GEARBOX OIL - DRAIN AND REFILL
Service repair no - 37.24.01
Drain
1.The oil should be drained when the gearbox is
warm and the vehicle is standing on a level
surface.
WARNING: Observe due care when
draining gearbox as oil can be very hot.
2.Raise vehicle on ramp.
3.Position container to collect oil.
4.Clean area around filler/level plug.
5.Remove filler/level plug.
NOTE: Later gearboxes: Use No. 55 Torx
bit to remove filler/level plug.
6.Remove gearbox drain plug and discard sealing
washer.Refill
1.Clean gearbox drain plug and fit new sealing
washer.
2.Fit gearbox drain plug and tighten to50 Nm (36
lbf.ft).
3.Fill gearbox with correct grade of oil.See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
4.Apply Loctite 290 to the filler/level plug and
tighten to30 Nm (22 lbf.ft).
5.Remove fluid container.
6.Lower vehicle on ramp.
ProCarManuals.com

70BRAKES
6
REPAIR Refit
11.Fit rubber washer and servo assembly to pedal
box.
12.Fit nuts securing servo to pedal box and tighten
to14 Nm. (10 lbf.ft)
13.Position brake pedal to servo push rod.
14.Fit clevis pin and NEW split pin to secure brake
pedal to servo push rod.
15.Fit blanking grommets to each side of pedal box.
16.Attach pedal return springs to brake pedal.
17.Position closing panel and tighten screws to
lower’A’post.
18.Connect vacuum hose to servo.
19.Connect brake switch Lucars.
20.Fit brake master cylinder.See this Section.MODULATOR UNIT - ABS
Service repair no - 70.65.49
Remove
1.Position cloth under modulator to absorb any
fluid spillage.
CAUTION: Do not allow brake fluid to
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid
and clean area with clean warm water.
2.Disconnect 2 inlet brake pipe unions from pump
side of modulator.
3.Disconnect 4 outlet brake pipe unions from top
of modulator.
CAUTION: Plug the connections.
4.Disconnect 2 multiplugs from rear of modulator.
5.Loosen nut securing rear of modulator to
mounting bracket.
6.Remove 2 nuts securing front of modulator to
mounting bracket.
7.Release modulator from mounting bracket.
8.Disconnect multiplug from base of modulator.
9.Remove modulator.
Do not carry out further dismantling if
component is removed for access only.
10.Remove 3 mounting rubbers from old modulator
and fit to new.
ProCarManuals.com

PANEL REPAIRS
1
INFORMATION BODY REPAIRS
Body shells are of riveted, bolted and welded
construction and are bolted to the chassis frame.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
The panel repairs shown in this section are all based
on a 110 Station Wagon. Therefore all illustrations
and text relate only to this model. Although certain
areas of the vehicle, such as the front end, are
relevant to all models.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring.
Where this is necessary use the relevant section in
this manual.
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
Front suspension upper damper
mountings.
Front suspension or sub frame mountings.
Engine mountings on RH and LH chassis
longitudinals.
Rear suspension upper damper mountings.
Rear suspension mountings or lower
pivots.
Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
Inner holes in crossmember - side - main
floor.
Holes in valance front assembly.
Body to chassis mounting holes.
Holes in rear floor.
Holes in rear lower panels or extension
rear floor.
Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can be checked by offering up an undamaged
component as a gauge and also by measuring known
dimensions.See BODY DIMENSIONS section.
ProCarManuals.com

WIPERS AND WASHERS
1
REPAIR PUMP - WINDSCREEN WASHER
Service repair no - 84.10.21
Remove
1.Remove headlamp.See ELECTRICAL,
Repair.
2.Position drain tin to collect any fluid spillage.
3.Disconnect multiplug from washer pump.
4.Disconnect hose from washer pump.
5.Release washer pump from reservoir and
discard sealing washer.
Refit
6.Fit new sealing washer and secure pump to
reservoir.
7.Connect hose and multiplug to washer pump.
8.Fit headlamp.See ELECTRICAL, Repair.
9.Fill reservoir with screen cleaning fluid.JET - REAR SCREEN WASHER
Service repair no - 84.30.09
Remove
1.Release and remove both rear side window
finishers.
2.Remove 8 screws securing both rear grab
handles.
3.Remove both rear grab handles.
ProCarManuals.com

84WIPERS AND WASHERS
2
REPAIR
4.Remove 4 trim studs securing upper rear finisher
to body.
5.Release and remove upper rear finisher.
6.Position drain tin to collect any fluid spillage.
7.Disconnect washer tube from jet.
8.Remove nut securing washer jet to body.
9.Remove washer jet.
Refit
10.Fit washer jet to body and secure with nut.
11.Connect washer tube to jet.
12.Remove drain tin.
13.Fit upper rear finisher and secure with trim studs.
14.Fit both rear grab handles and secure with
screws.
15.Fit both rear side window finishers.ARM - WIPER - FROM 02MY
Service repair no - 84.15.02
Remove
1.Raise nut cover on wiper arm and remove nut.
2.Remove wiper arm from spindle.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
3.Remove wiper blade.
Refit
4.Fit wiper blade.
5.Fit wiper arm to spindle and align blade to
windscreen.
6.Tighten nut securing wiper arm to17 Nm (13
lbf.ft),and fit cover.
ProCarManuals.com