1999 LAND ROVER DEFENDER wheel

MAINTENANCE
23
MAINTENANCE ENGINE AND TRANSMISSION MOUNTINGS
1.Check condition of front LH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
2.Check condition of front RH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
3.Check condition of rear LH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
4.Check condition of rear RH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.ROAD TEST
There are two purposes for conducting a road test.
Firstly, to ensure the work completed within the
dealership meets the standards required as layed
down by dealership processes. Secondly, for a skilled
technician to assess the general condition of the
vehicle and report any conditions that the customer
should be made aware of.
CAUTION: Two wheel roller tests must not
be carried out. Four wheel roller tests
must be restricted to 3 mph (5 kph).
1.Check for correct operation of starter switch.
Ensure the engine starts in a correct manner.
Leave the engine running.
2.With vehicle stationary, turn steering from lock to
lock. Check for smooth operation and ensure
there is no undue noise from the power steering
pump or drive belt.
3.Depress clutch and select all gears in turn.
Check for smooth notch free engagement.
4.Drive vehicle on a short road test. Check all
vehicle systems for correct operation. Pay
particular attention to:
Engine noise
Gearbox noise
Suspension noise
Body noise
Braking system operation
Gear selection
Engine performance
5.Check for correct operation of all instruments
and warning devices where practical.
6.After road test, carry out a final inspection of the
vehicle on vehicle ramps.
7.Check all underbonnet fluid levels and top-up if
necessary.
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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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ENGINE
5
DESCRIPTION AND OPERATION 1.Crankshaft pulley bolt
2.TV Damper to crankshaft pulley bolts (3 off)
3.TV Damper
4.Crankshaft pulley
5.Woodruff key
6.Crankshaft
7.Crankshaft to flywheel dowel
8.Spigot bush
9.Flywheel to crankshaft bolts (8 off)
10.Flywheel assembly
11.Main bearing shells (6 pairs)
12.Main bearing caps (6 off)
13.Main bearing cap bolts (12 off)
14.Thrust washer (2 off at No. 3 Main bearing)
15.Piston lubrication jets (5 off)
16.Piston lubrication jet cap head screw (5 off)
17.Stiffener plate (oil pump integral)
18.Stiffener plate / oil pump assembly to cylinder block bolts (22 off)
19.Oil pick-up pipe O-ring
20.Oil pick-up pipe inserts (2 x 6mm; 1 x 10mm)
21.Upper oil pick-up pipe
22.Oil pick-up pipe gauze
23.Lower oil pick-up pipe
24.Sump
25.Oil drain plug seal
26.Oil drain plug
27.Sump to cylinder block bolts (20 off)
28.Sump gasket
29.Oil pick-up pipe bolts (3 off)
30.Oil pump
31.Chain lubrication jet
32.Chain lubrication jet screw
33.Stiffener to cylinder block dowel (2 off)
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ENGINE
13
DESCRIPTION AND OPERATION CYLINDER BLOCK
The cylinders and crankcase are contained in a single cast iron construction. The cylinders are direct bored and
plateau honed with lubrication oil supplied via lubrication jets for piston and gudgeon pin lubrication and cooling. It
is not possible to rebore the cylinder block if the cylinders become worn or damaged. Three metal core plugs are
fitted to the three centre cylinders on the right hand side of the cylinder block.
Lubrication oil is distributed throughout the block via the main oil gallery to critical moving parts through channels
bored in the block which divert oil to the main and big-end bearings via oil holes machined into the crankshaft. Oil
is also supplied from the cylinder block main gallery to the five lubrication jets which cool and lubricate the piston
and gudgeon pins. Plugs are used to seal both ends of the main oil gallery at front and rear of the engine block.
An oil cooler is fitted to the LH side of the engine block; ports in the oil cooler assembly mate with ports in the
cylinder block to facilitate coolant flow. Oil is diverted through the oil cooler, centrifuge filter and full-flow filter
before supplying the main oil gallery. A tapping in the oil filter housing provides a lubrication source for the
turbocharger bearings and an oil pressure switch is included in a tapping in the oil cooler housing which
determines whether sufficient oil pressure is available to provide engine lubrication and cooling.
Cylinder cooling is achieved by water circulating through chambers in the engine block casting. A threaded coolant
jacket plug is located at the front RH side of the cylinder block.
Cast brackets are bolted to both sides of the engine block for mounting the engine to the chassis on the LH and
RH hydramount studs.
The gearbox bolts directly to the engine block; a gearbox shim plate is located between the adjoining faces of the
gearbox and the flywheel side of the engine block and is fixed to the rear of the engine block by two bolts. Two
hollow metal dowels locate the rear of the cylinder block to the shim plate. The gearbox casing provides the
mounting for the starter motor.
A port is included at the rear left hand side of the cylinder block which connects to the turbocharger oil drain pipe
to return lubrication oil to the sump. A plug sealing the lubrication cross-drilling gallery is located at the front right
hand side of the cylinder block and plugs for the main lubrication gallery are located at the front and rear of the
cylinder block. Two plastic dowels are used to locate the cylinder head to the cylinder block and must be replaced
every time the cylinder head is removed from the cylinder block.
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12ENGINE
24
DESCRIPTION AND OPERATION Crankshaft
1.Front end to crankshaft sprocket
2.Oil supply cross-drillings
3.Main journals4.Big-end journals
5.Rear end to flywheel
The crankshaft is constructed from cast iron and is surface-hardened. The areas between the crankshaft journals
and the adjoining webs and balance weights are compressed using the cold roll process to form journal fillets.
Cross-drillings in the crankshaft between adjoining main and big-end bearings are used to divert lubrication oil to
the big-end bearings.
A torsional vibration damper is attached to the crankshaft pulley by three bolts.
The crankshaft is carried in six main bearings, with end-float being controlled by thrust washers positioned on both
sides of No. 3 main bearing.
Main bearings
There are six main bearings used to carry the crankshaft. Each of the bearing caps are of cast iron construction
and are attached to the cylinder block by two bolts.
The bearing shells are of the split cylindrical type. The upper half bearing shells are grooved to facilitate the supply
of lubrication oil to the bearings and fit into a recess in the underside of the cylinder block. The lower half bearing
shells are smooth and fit into the bearing caps.
Steel-backed, thrust washers are included at each side of No. 3 main bearing to control crankshaft end-float. One
side of each of the thrust washers is grooved, the grooved side of each of the thrust washers is fitted facing
outward from No. 3 main bearing.
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12ENGINE
4
REPAIR Refit
9.Position new crankshaft pulley to vice.
10.Remove 3 bolts and remove damper from
crankshaft pulley.
11.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
12.Fit crankshaft pulley.
13.FitLRT-51-003to crankshaft pulley and secure
with 2 bolts.
14.Fit new crankshaft pulley bolt and tighten to460
Nm (340 lbf.ft).
NOTE: It is recommended that a torque
multiplier is used to tighten crankshaft
pulley bolt.
15.Remove 2 bolts and removeLRT-51-003from
crankshaft pulley.
16.Fit damper to crankshaft pulley, fit bolts and
tighten to80 Nm (60 lbf.ft).
17.Fit auxiliary drive belt.
18.Fit radiator.See COOLING SYSTEM, Repair.
19.Fit underbelly panel.See CHASSIS AND
BODY, Repair.OIL SEAL - CRANKSHAFT - REAR
Service repair no - 12.21.20
Remove
1.Remove flywheel.See this Section.
2.Remove sump gasket.See this Section.
3.Remove 5 bolts securing oil seal housing to
cylinder block.
4.Remove seal housing.
Refit
5.Clean seal housing mating face on cylinder
block.
6.Position seal protector,LRT-12-061over
crankshaft boss. Fit new seal and housing
assembly and remove toolLRT-12-061.
CAUTION: Oil seal must be fitted dry.
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ENGINE
5
REPAIR
7.Fit oil seal housing bolts and using sequence
shown, tighten to9 Nm (7 lbf.ft).
8.Fit sump gasket.See this Section.
9.Fit flywheel.See this Section.BEARING - SPIGOT - CRANKSHAFT
Service repair no - 12.21.45
Remove
1.Remove clutch assembly.See CLUTCH,
Repair.
2.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
3.Fit extractor to spigot bush.
4.Remove spigot bush from crankshaft.
Refit
5.Clean spigot bush and mating face in rear of
crankshaft.
6.Fit new spigot bush to crankshaft using a
suitable drift.
7.Fit clutch assembly.See CLUTCH, Repair.
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12ENGINE
22
REPAIR MOUNTING - GEARBOX - REAR - RH
Service repair no - 12.45.09
Remove
1.Remove LH rear gearbox mounting.See this
Section.
2.Remove 4 bolts securing mounting bracket to
transfer gearbox.
3.Remove 2 nuts, remove mounting and mounting
bracket.
Refit
4.Clean mounting and mating faces.
5.Position mounting and mounting bracket and
tighten nuts to48 Nm (35 lbf.ft)and bolts to85
Nm (63 lbf.ft).
6.Fit LH rear gearbox mounting.See this
Section.FLYWHEEL
Service repair no - 12.53.07
Remove
1.Remove clutch assembly.See CLUTCH,
Repair.
2.Remove and discard 8 bolts securing flywheel to
crankshaft and remove flywheel.
NOTE: Dowel located.
Refit
3.Clean flywheel and crankshaft mating face.
4.Position flywheel to crankshaft.
5.Fit new flywheel retaining bolts and tighten by
diagonal selection to:
Stage 1 -40 Nm (30 lbf.ft)
Stage 2 -Further 90°
CAUTION: Do not carry out stages 1 and 2
in one operation.
6.Fit clutch assembly.See CLUTCH, Repair.
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