1999 LAND ROVER DEFENDER belt

01INTRODUCTION
8
INFORMATION JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1.Position vehicles so that jump leads will reach,
ensuring that vehiclesDO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2.Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected, connect the
jump leads as follows;
A.Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B.Connect other end of first jumper cable to positive
(+) terminal of discharged battery.
C.Connect one end of second jumper cable to
negative terminal of booster battery.
D.Connect other end of second jumper cable to a
good earth point on the disabled vehicle (eg. engine
front lifting eye, as shown in J6086),NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
3.If booster battery is installed in another vehicle,
start engine and allow to idle.
4.Start engine of vehicle with discharged battery,
following starting procedure in Owners’Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalyst, if fitted.
5.Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6.Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.
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01INTRODUCTION
14
INFORMATION READING THIS SUPPLEMENT
This Supplement is divided into sections shown on the
contents page, alongside a range of icons, familiar to
service technicians.
Relevant information is contained within each of these
sections. These are further divided into the following
sub-sections which appear at the foot of each page :-
Description and operation.
Adjustment.
Repair.
Overhaul.
To avoid repeating information through the sections,
where part of the repair operation impacts on another
section, a cross reference is given to direct the reader
to where the information is sited.
For example:
The maintenance section states the need to renew
drive belt. A cross reference sites this information in:
Section 12 Engine
- Sub-section: Repair
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GENERAL SPECIFICATION DATA
3
INFORMATION FUEL SYSTEM - Td5
Type Direct injection from pressure regulated supply with.................................................................................
cooled return flow
Pressure regulator setting 4 bar (58 lbf.in
2) ................................................
Pump Electric two stage submersible................................................................................
Pump output
Low pressure 30 l/h (6.6 gal/h) at 0.5 bar (7.25 lbf.in
2) ..........................................................
High pressure 180 l/h (39.6 gal/h) at 4 bar (58 lbf.in2) ..........................................................
Max consumption 30 l/h (6.6 gal/h).............................................................
Injectors Electronic unit injectors...........................................................................
Injector normal operating pressure 1500 bar (21750 lbf.in
2) ..................................
Filter In-line canister filter/water separator with water.................................................................................
detection
COOLING SYSTEM - Td5
Type Pressurised spill return partial flow, thermostatically.................................................................................
controlled
Cooling fans 11 blade axial flow on viscous coupling and 11 blade.....................................................................
axial flow electric
Electric cooling fan switching points
On Vehicle speeds of 50 mph (80 km/h) and below while...........................................................................
ambient temperature is 28°C (82°F) or above
Off Vehicle speeds of 62.5 mph (100 km/h) and above or...........................................................................
ambient temperatures of 25°C (77°F) and below
Coolant pump Centrifugal impeller, belt driven from crankshaft...................................................................
Thermostat Waxstat with pressure relief valve.......................................................................
Thermostat opening temperature
Initial opening 82°C (179°F) ..........................................................
Fully open 96°C (204°F) ...............................................................
Expansion tank cap relief valve operating pressure 1.4 bar (20.3 lbf.in
2) .........
CLUTCH - Td5
Type Diaphragm spring, hydraulically operated with.................................................................................
self-centering pre-loaded release bearing
Drive plate diameter 267 mm.........................................................
Pressure plate diameter 270 mm...................................................
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10 - MAINTENANCE
CONTENTS
Page
MAINTENANCE
UNDERBONNET VIEW - Td5 1..............................................................................
SEATS AND SEAT BELTS 2..................................................................................
LAMPS, HORNS AND WARNING INDICATORS 2................................................
WIPERS AND WASHERS 3...................................................................................
HANDBRAKE 3.......................................................................................................
BATTERY CONDITION - Td5 4..............................................................................
HANDSET BATTERY 5...........................................................................................
HEADLAMP ALIGNMENT 5....................................................................................
ROAD WHEELS 6...................................................................................................
TYRE PRESSURES, CONDITION AND TREAD DEPTH 6....................................
BRAKE PADS, CALIPERS AND DISCS 7..............................................................
ROAD WHEEL SPEED SENSOR HARNESS - Td5 7............................................
FUEL FILTER ELEMENT 8.....................................................................................
FUEL FILTER SEDIMENTER - Td5 8.....................................................................
INTERCOOLER / COOLING SYSTEM 9................................................................
AMBIENT AIR PRESSURE (AAP) SENSOR - Td5 9..............................................
DOOR LOCKS AND HINGES 10............................................................................
ENGINE COOLANT 10...........................................................................................
BRAKE FLUID 11....................................................................................................
AIR FILTER ELEMENT AND DUMP VALVE 11.....................................................
AUXILIARY DRIVE BELT 12...................................................................................
PAS FLUID, CLUTCH FLUID AND SCREEN WASHER LEVELS 12.....................
STEERING BOX 13................................................................................................
ENGINE OIL 14.......................................................................................................
CENTRIFUGE ROTOR - Td5 14.............................................................................
FULL FLOW OIL FILTER 15...................................................................................
GEARBOX OIL 15...................................................................................................
TRANSFER BOX OIL 16.........................................................................................
FRONT AND REAR AXLE OIL 17..........................................................................
PROPELLER SHAFTS 18.......................................................................................
CLUTCH PIPES AND UNIONS 18..........................................................................
PAS PIPES AND UNIONS 19.................................................................................
ENGINE, GEARBOX, TRANSFER BOX AND AXLES 19.......................................
EXHAUST SYSTEM 20...........................................................................................
STEERING BOX AND SUSPENSION 20...............................................................
STEERING BALL JOINTS 21.................................................................................
SHOCK ABSORBERS 22.......................................................................................
TOWING BRACKET 22...........................................................................................
ENGINE AND TRANSMISSION MOUNTINGS 23..................................................
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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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10MAINTENANCE
2
MAINTENANCE SEATS AND SEAT BELTS
1.Check seat frames are secured to floor and
show no signs of movement.
2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Check tightness of accessible seat fixings.
4.Fully extract seat belt and allow it to return under
its own recoil mechanism.
5.Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for all belts.
6.Check security of seat belt upper mountings.
7.Check security of seat belt buckle mountings.
8.Connect each belt to the correct buckle, check
seat belt buckle and tongue are secure. Release
seat belt buckle and check for correct operation.
9.Check tightness of accessible seat belt
mountingsLAMPS, HORNS AND WARNING INDICATORS
1.Switch on side, head and tail lights and check
operation.
2.Check headlamp dim/dip operation.
3.Check headlamp levelling operation.
4.Check turn signals and hazard warning lights
operation.
5.Press brake pedal and check operation of brake
lights.
6.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to head lamp
lenses for signs of stone chips or damage.
7.Check horn for loud clear sound.
8.Check operation of all instrument pack warning
and indicator lights.
9.Check for correct operation of interior courtesy
lights.
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10MAINTENANCE
12
MAINTENANCE AUXILIARY DRIVE BELT
Check
1.Check auxiliary drive belt for signs of splits,
fraying, oil contamination and wear.
NOTE: Any requirement to replace the
auxiliary drive belt should be advised to
the customer as this will incur additional
labour and/or material cost and should not be
carried out without the authorisation of the
customer.
Renew
1.Renew auxiliary drive belt.See ELECTRICAL,
Repair.
NOTE: Additional time is built into the
96,000/8 year service time to allow for
auxiliary drive belt renewal.PAS FLUID, CLUTCH FLUID AND SCREEN
WASHER LEVELS
PAS Fluid
1.Clean arear around PAS reservoir filler cap, and
remove cap.
2.Check fluid level in PAS reservoir.
3.Top-up if necessary to the correct level using
recommended fluid.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
4.Fit filler cap.
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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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