1999 LAND ROVER DEFENDER oil

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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12ENGINE
4
DESCRIPTION AND OPERATION Crankshaft, sump and oil pump
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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
9
DESCRIPTION AND OPERATION 1.Acoustic cover
2.Oil filler flap
3.Rear acoustic cover
4.Rear acoustic cover inserts (2 off)
5.Rear acoustic cover grommets (2 off)
6.Rear acoustic cover screws (2 off)
7.Acoustic cover grommets (3 off)
8.Acoustic cover bolts (3 off)
9.Camshaft cover isolators (13 off)
10.Camshaft cover flange screws (13 off)
11.Breather hose clip
12.Breather hose
13.Breather hose to breather valve clip
14.Breather valve
15.Camshaft cover gasket
16.Oil separator plate
17.Oil separator plate gasket
18.Camshaft cover
19.Acoustic cover to camshaft cover seal
20.Oil filler cap and seal
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ENGINE
11
DESCRIPTION AND OPERATION 1.Vacuum pump stub pipe
2.Cylinder head to timing chain cover bolt
3.Cylinder head to timing chain cover nut
4.Cylinder head to timing chain cover stud
5.Tensioner assembly pivot screw
6.Tensioner adjuster
7.Tensioner arm assembly
8.Duplex timing chain - crankshaft to camshaft sprocket
9.Camshaft sprocket bolts (3 off)
10.Camshaft sprocket
11.Fixed chain guide
12.Fixed guide pin
13.Fixed chain guide to cylinder block screws
14.Oil pump drive chain
15.Oil pump sprocket
16.Oil pump sprocket screw
17.Crankshaft sprockets
18.Bearing to viscous fan shaft
19.Viscous fan to cover bearing
20.Circlip
21.Hub - viscous fan to bearing flange
22.Timing chain cover
23.Timing chain cover to crankshaft seal
24.Timing chain to cylinder head screws (8 off)
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