1999 LAND ROVER DEFENDER coolant level

01INTRODUCTION
10
INFORMATION CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (A/C)...................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Intake air temperature (IAT).........................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAF).........................................
Open loop (OL)............................................................
Relay module (RM)......................................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TP)........................................
Transmission range (TR)..............................................
Wide open throttle (WOT)............................................OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Intake temperature/ambient temperature (-)................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Relay (-).......................................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Transmission gear (-)...................................................
Full throttle, wide open throttle (WOT).........................
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LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Pints
Engine sump oil - Td5 7.20...................................................... 12.67
Extra when refilling after fitting new filter 1.00.......................... 1.76
Manual gearbox 2.38............................................................... 4.19
Transfer gearbox oil 2.30......................................................... 4.00
Front differential 1.70............................................................... 3.00
Rear differential
90 Models 1.70............................................................... 3.00
110 Models 2.26............................................................. 4.00
Power steering box and reservoir LHD 2.90............................ 5.00
Power steering box and reservoir RHD 3.40............................ 6.00
Swivel pin housing oil/grease (each) 0.35................................ 0.60
Fuel tank usable fuel
90 Models 60.00............................................................... 13.20 gall
110 & 130 Models 75.00................................................... 16.50 gall
Cooling system - Td5 13.00....................................................... 22.88
Washer bottle 3,0................................................................... 5.28
NOTE: * All levels must be checked by dipstick or level plugs as applicable.
ANTI-FREEZE
PERCENTAGE CONCENTRATION - 50%
PROTECTION - LOWER TEMPERATURE LIMIT
Complete protection
Vehicle may be driven away immediately from cold,
-33°C (-36°F).
Safe limit protection
Coolant in semi-frozen state. Engine may be started
and driven away after warm-up period, -41°C (-42°
F).
Lower protection
Prevents frost damage to cylinder head, block and
radiator. Thaw out before starting engine, -47°C (-53°
F).
CAUTION: Anti-freeze content must never
be allowed to fall below 50% otherwise
damage to the engine is liable to occur.
Also, anti-freeze content should not exceed 60%
as this will greatly reduce the cooling effect of the
coolant.RECOMMENDED FUEL
Diesel fuel oil, distillate, diesel fuel, automotive gas or
Derv to British standard 2869, Class A1 or A2
Using diesel fuel with a class rating lower than stated
above could seriously impair vehicle performance.
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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
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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ENGINE
29
REPAIR VALVE - RELIEF - OIL PRESSURE
Service repair no - 12.60.56
Remove
1.Remove sump gasket.See this Section.
2.Remove and discard oil pressure relief valve
plug from oil pump housing.
3.Remove spring and valve.
Refit
4.Clean valve and spring.
5.Clean valve seating inside oil pump housing.
6.Lubricate valve and seating.
7.Fit valve and spring to pump.
8.Apply Loctite 243 sealant to threads of a new
plug.
9.Fit plug and tighten to23 Nm ( 17 lbf.ft).
10.Fit sump gasket.See this Section.
11.Check engine oil level, top-up if necessary.COOLER - ENGINE OIL
Service repair no - 12.60.68
Remove
1.Drain cooling system.See COOLING
SYSTEM, Adjustment.
2.Remove centrifuge assembly.See this
Section.
3.Remove clutch housing bolt and release coolant
pipe from rear of engine.
4.Release clip and coolant hose from oil cooler.
5.Disconnect oil pressure switch multiplug.
6.Remove oil filter element using a suitable strap
wrench.
7.Remove 3 bolts, remove oil filter adaptor and
discard gasket.
8.Remove 7 bolts, remove oil cooler and discard
gasket.
9.Remove oil pressure switch.
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26COOLING SYSTEM
6
DESCRIPTION AND OPERATION By-pass flow valve
The by-pass flow valve is held closed by a light spring. It operates to further aid heater warm-up. When the main
valve is closed and the engine speed is below 1500 rev/min, the coolant pump does not produce sufficient flow
and pressure to open the valve. In this condition the valve prevents coolant circulating through the by-pass circuit
and forces the coolant through the heater matrix only. This provides a higher flow of warm coolant through the
heater matrix to improve passenger comfort in cold conditions.
When the engine speed increases above 1500 rev/min the coolant pump produces a greater flow and pressure
than the heater circuit can take. The pressure acts on the flow valve and overcomes the valve spring pressure,
opening the valve and limiting the pressure in the heater circuit. The valve modulates to provide maximum coolant
flow through the heater matrix and yet allowing excess coolant to flow into the by-pass circuit to provide the
engines cooling needs at higher engine rev/min.
Outlet Housing
A cast aluminium outlet housing is attached to the cylinder head with three bolts and sealed with a gasket. Coolant
leaves the engine through the outlet housing and is directed through a hose to the heater matrix, the radiator or
the by-pass circuit.
An Engine Coolant Temperature (ECT) sensor is installed in a threaded port on the side of the outlet housing. The
sensor monitors coolant temperature emerging from the engine and sends signals to the Engine Control Module
(ECM) for engine management and temperature gauge operation.
Expansion Tank
The expansion tank is located in the engine compartment. The tank is made from moulded plastic and attached to
brackets on the right hand inner wing. A maximum coolant when cold level is moulded onto the tank.
Excess coolant created by heat expansion is returned to the expansion tank from the radiator bleed pipe at the top
of the radiator. An outlet pipe is connected into the coolant pump feed hose and replaces the coolant displaced by
heat expansion into the system when the engine is cool.
The expansion tank is fitted with a sealed pressure cap. The cap contains a pressure relief valve which opens to
allow excessive pressure and coolant to vent through the overflow pipe. The relief valve is open at a pressure of
1.4 bar (20 lbf.in) and above.
Heater Matrix
The heater matrix is fitted in the heater assembly inside the passenger compartment. Two pipes pass through the
bulkhead into the engine compartment and provide coolant flow to and from the matrix. The pipes from the
bulkhead are connected to the matrix, sealed with’O’rings and clamped with circular rings.
The matrix is constructed from aluminium with two end tanks interconnected with tubes. Aluminium fins are
located between the tubes and conduct heat from the hot coolant flowing through the tubes. Air from the heater
assembly is warmed as it passes through the matrix fins. The warm air is then distributed in to the passenger
compartment as required.
When the engine is running, coolant from the engine is constantly circulated through the heater matrix.
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COOLING SYSTEM
9
DESCRIPTION AND OPERATION Viscous Fan
1.Idler pulley drive attachment
2.Fan blades3.Bi-metallic coil
4.Body
The viscous fan provides a means of controlling the speed of the fan relative to the operating temperature of the
engine. The fan rotation draws air through the radiator, reducing engine coolant temperatures when the vehicle is
stationary or moving slowly.
The viscous fan is attached to an idler pulley at the front of the engine which is driven at crankshaft speed by the
auxiliary drive belt. The fan is secured to the pulley by a right hand threaded nut. The nut is positively attached to
the fan spindle which is supported on bearings in the fan body. The viscous drive comprises a circular drive plate
attached to the spindle and driven from the idler pulley. The drive plate and body have interlocking annular
grooves with a small clearance which provides the drive when silicone fluid enters the fluid chamber. A bi-metallic
coil is fitted externally on the forward face of the body. The coil is connected to and operates a valve in the body.
The valve operates on a valve plate with ports that connect the reservoir to the fluid chamber. The valve plate also
has return ports which, when the valve is closed, scoop fluid from the fluid chamber and push it into the reservoir
under centrifugal force.
Silicone fluid is retained in a reservoir at the front of the body. When the engine is off and the fan is stationary, the
silicone fluid level stabilises between the reservoir and the fluid chamber. This will result in the fan operating when
the engine is started, but the drive will be removed quickly after the fan starts rotating and the fan will’freewheel’.
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COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL
Service repair no - 26.10.01
WARNING: Hot coolant
Drain
1.Remove engine acoustic cover.
2.Visually check engine and cooling system for
signs of coolant leaks.
3.Examine hoses for signs of cracking, distortion
and security of connections.
4.Position drain tray to collect coolant.
5.Remove expansion tank filler cap.
6.Loosen clip screws securing air inlet hose to
intercooler and inlet manifold, release and
remove hose.
7.Release clip and disconnect bottom hose from
radiator.
8.Allow cooling system to drain.
9.Disconnect bottom hose from radiator.Refill
1.Flush system with water under low pressure.
2.Do not use water under high pressure as it could
damage the radiator.
3.Connect bottom hose to radiator and secure
hose with clip.
4.Prepare coolant to required concentration.
5.Position heater temperature control to maximum
hot position.
6.Remove bleed screw from top hose.
7.Fill system slowly through coolant expansion
tank until a steady flow of coolant is emitted from
the bleed hole in top hose.
8.Fit bleed screw to top hose.
9.Continue filling system until coolant level
reaches’MAX’mark on expansion tank.
10.Fit expansion tank filler cap.
11.Position air intake hose and tighten clip screws.
12.Start and run engine until normal running
temperature is reached.
13.If fitted, DO NOT operate air conditioning.
14.Switch off engine and allow to cool.
15.Check for leaks and top-up coolant to’MAX’
mark on expansion tank.
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