1999 LAND ROVER DEFENDER seat adjustment

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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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.
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REAR AXLE AND FINAL DRIVE
5
OVERHAUL
55.Position a suitable dial gauge indicator on casing
with stylus registering on back face of crown
wheel.
56.Rotate differential and check total indicated
run-out on crown wheel back face. This must not
exceed 0,05 mm. If run-out is excessive, check
mating faces for dirt and damage; if necessary,
select a new radial position for crown wheel.
When satisfactory, continue with following check.
Differential bearing adjustment
57.Insert two levers between casing and differential
unit at one side.
58.Move differential unit fully to one side of casing;
do not tilt unit.
59.Rotate differential unit to settle bearings,
continue to lever differential to side, then zero
dial gauge indicator.
60.Lever assembly fully to other side of casing,
rotate unit to settle bearings, then note total
indicator reading.
61.Add 0,127 mm, for bearing pre-load, to total
noted in preceding instruction. The sum is then
equal to nominal value of shims required for
differential bearings. Shims are available in
range 0,07 mm, 0,12 mm, 0,25 mm and 0,76
mm. Select total value of shims required.
62.Remove differential unit and bearings and place
aside. Do not fit shim washers until subsequent
’Differential backlash’checks have been made,
instructions 96 to 102.Fit drive pinion
63.Select shim washers of same thickness value as
those removed from under pinion inner cup,
instruction 35, and place ready for fitting.
64.Position outer bearing replacerLRT-51-505,
detail 2, and outer bearing cup on press
LRT-99-502.
65.Locate assembly into pinion housing nose.
66.Place selected shim washers on to inner bearing
cup seating.
67.Position inner bearing cup in casing.
68.Position inner bearing replacerLRT-51-505,
detail 1, ontoLRT-99-502and secure with fixing
nut.
69.Hold still centre screw and turn butterfly lever to
draw in bearing cups.
Note: If above tools are not available, a suitable piece
of tubing, positioned on bearing inner race and a hand
press may be used.
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REAR AXLE AND FINAL DRIVE
9
OVERHAUL Differential backlash checks
96.Pick up differential unit as left after instruction
52.
97.Fit differential unit and lever unit away from drive
pinion until opposite bearing cup is seated
against housing. Do not tilt unit.
98.Install a dial gauge on casing with its stylus
resting on back face of crown wheel. Zero the
gauge.
99.Lever differential unit to engage crown wheel
teeth in full mesh with drive pinion teeth. Do not
tilt unit.
100.Note total reading obtained on dial gauge.
101.From this figure subtract 0,25 mm to obtain
correct crown wheel backlash when fitted. The
result indicates value of shimming to be fitted
between differential case and bearing cone at
crown wheel side of differential.
102.Fit shim value determined in instruction 101,
taking shims from pack previously determined
during’Differential bearing adjustment’checks,
instructions 57 to 62LRT-51-500details 1 and 2,
pressLRT-99-002, andLRT-51-504.
103.Fit remaining shims from instruction 101 to
opposite side of differential.LRT-51-501details
1 and 2, pressLRT-99-002, andLRT-51-504.
104.Fit differential unit with shims and bearings to
axle casing, using axle compressorLRT-51-503
.
105.Remove axle compressor106.Fit bearing caps in their correct position,
referring to relationship markings on caps and on
axle casing.
107.Tighten bearing caps fixings to135 Nm (100
lbf/ft).
108.Mount a dial gauge on axle casing with stylus
resting on a crown wheel tooth.
109.Prevent drive pinion from rotating and check
crown wheel backlash which must be 0,15 to
0,27 mm. If backlash is not within specified
limits, repeat differential backlash checks,
instructions 96 to 102 looking for possible errors.
110.Fit differential cover and new gasket, coating
both sides of gasket with Hylomar PL 32M or an
equivalent non-setting sealant. Torque load for
fixings is30 Nm (22 lbf/ft).
111.Reverse instructions 3 to 5 and coat threads of
hub driving member bolts with Loctite’Studlock’
grade CVX and fit and tighten bolts evenly to
correct torque.
112.Fit rear axle assembly to vehicleSee Repair.
Rear axle.
113.Replenish differential with recommended
lubricantSee LUBRICANTS, FLUIDS AND
CAPACITIES, Information. Recommended
lubricants and fluids. After initial axle run,
check oil level and replenish as necessary to
filler/level plug hole.
114.Where major running parts have been replaced
during servicing, it is a recommended practice to
allow axle assembly to’run in’by avoiding,
where possible, heavy loads and high speeds
during initial running.
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70BRAKES
8
REPAIR Refit
14.Clean caliper to hub mating faces.
15.Position caliper to hub, fit bolts and tighten to82
Nm (60 lbf.ft).
16.Remove plugs from pipe to caliper connections
and wipe.
17.Connect pipe to caliper, tighten union to15 Nm
(11 lbf.ft).
18.Apply a light film of grease to rear of brake pads.
19.Fit pads to calipers.
From 02MY, ensure pads are correctly fitted,
with leading edge chamfer fitted as shown.
20.Fit pad retainers and springs.
21.Fit split pins to retainers.
22.Remove brake hose clamp.
23.Bleed brakes.See Adjustment.
24.Depress brake pedal to seat pads onto discs.
25.Fit road wheels, remove axle stands and tighten
nuts to130 Nm (96 lbf.ft).BRAKE CALIPER - REAR
Service repair no - 70.55.03
Remove
1.Loosen rear road wheel nuts.
2.Raise rear of vehicle.
WARNING: Support on safety stands.
3.Remove road wheel.
4.Remove split pins from brake pad retaining pins.
5.Remove brake pad retaining pins.
6.Remove brake pad retainer springs.
7.Remove brake pads and shim if fitted.
8.Position container beneath brake caliper to
collect spillage.
9.Loosen brake pipe union and disconnect from
caliper.
CAUTION: Plug the connections.
10.Remove 2 bolts securing caliper.
11.Remove brake caliper.
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BRAKES
9
REPAIR Refit
12.Clean caliper to axle bracket mating faces.
13.Position caliper to axle bracket, fit bolts and
tighten to82 Nm (60 lbf.ft).
14.Remove plugs from pipe and caliper.
15.Clean brake pipe union and caliper.
16.Connect pipe to caliper, tighten union to15 Nm
(11 lbf.ft).
17.Apply a light film of grease to rear of brake pads.
18.Fit brake pads.
From 02MY, ensure shims are correctly fitted,
see illustration.
NOTE: Vehicles from 02MY have leading
and trailing edge chamfers on rear pads.
19.Fit pad retainer springs.
20.Fit brake pad retaining pins and secure with new
split pins.
21.Bleed brakes.See Adjustment.
22.Depress brake pedal to seat pads onto discs.
23.Fit road wheels, remove axle stands and tighten
nuts to130 Nm (96 lbf.ft).SWITCH - STOP LIGHT
Service repair no - 70.35.42
Remove
1.Disconnect 2 Lucars from stop light switch.
2.Remove mastic from around switch.
3.Remove switch from pedal box.
Refit
4.Fit and tighten switch to pedal box.
5.Apply mastic to switch.
6.Connect 2 Lucars to switch.
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76 - CHASSIS AND BODY
CONTENTS
Page
DESCRIPTION AND OPERATION
FRONT SEAT RECLINE - FROM 02MY 1..............................................................
SOFT TOP - FROM 02MY 1...................................................................................
TAIL DOOR - FROM 02MY 2..................................................................................
ADJUSTMENT
TAIL DOOR STRIKER 1.........................................................................................
REPAIR
PANEL - UNDERBELLY - FRONT AND CENTRE 1...............................................
CUBBY BOX 1........................................................................................................
TRIM CASING - TAIL DOOR - UP TO 02MY 2.......................................................
LATCH - TAIL DOOR - UP TO 02MY 3..................................................................
CARPET - LUGGAGE COMPARTMENT 3.............................................................
WING - FRONT 4....................................................................................................
STEP - FOLDING - REAR DOOR 7........................................................................
LINER - FRONT WHEEL ARCH 8..........................................................................
FRONT BUMPER 9.................................................................................................
DOOR - REAR 9.....................................................................................................
DOOR - TAIL - REMOVE 10...................................................................................
GLASS/SEALING RUBBER - TAIL DOOR - UP TO 02MY 11................................
SEAT BELT - FRONT 12........................................................................................
SEAT BELT - CENTRE - REAR 13.........................................................................
SEAT BELT - REAR - SIDE 13...............................................................................
SEAT - REAR 14.....................................................................................................
COVER - CUSHION - REAR SEAT 15...................................................................
COVER - SQUAB - REAR SEAT 16.......................................................................
REGULATOR - REAR DOOR GLASS 16...............................................................
TRIM CASING - REAR DOOR 17...........................................................................
AUXILLIARY SWITCH PANEL 18...........................................................................
LOWER FASCIA PANEL - UP TO 02MY 19...........................................................
PANEL - MOUNTING - FRONT DOOR - FROM 02MY 23.....................................
PANEL - MOUNTING - REAR DOOR - FROM 02MY 25........................................
FACIA CONSOLE - FROM 02MY 27......................................................................
GLASS - REAR DOOR - FROM 02MY 29..............................................................
GLASS/SEALING RUBBER - TAIL DOOR - FROM 02MY 30................................
TRIM CASING - FRONT DOOR - FROM 02MY 31................................................
TRIM CASING - TAIL DOOR - FROM 02MY 33.....................................................
PLASTIC SHEET - FRONT DOOR - FROM 02MY 34............................................
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PANEL REPAIRS
3
REPAIR WHEEL ARCH - FRONT
Remove
The procedure to change the Inner Front Wheelarch is
the same as for the Wing Upper, except for removal of
the ABS sensors and shield, if fitted.
BULKHEAD ASSEMBLY
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove front lower wing.See this Section.
3.Remove RH and LH front upper wing.See this
Section.
4.Remove headlamp mounting panels.See this
Section.
5.Remove screen aperture.See this Section.
6.Remove both front doors.
7.Remove lower fascia panel.See CHASSIS
AND BODY, Repair.
8. Models with A/C:Remove relevant A/C pipes.
9.Remove front grille.
10.Drain cooling system.See COOLING
SYSTEM, Adjustment.
11.Remove radiator and intercooler.
12. Models with A/C:Remove condensor.
13.Remove air cleaner assembly.
14.Remove heater unit.See HEATING AND
VENTILATION, Repair.
15.Remove brake servo assembly.
16.Remove heater ducts.
17.Remove both front seats.
18.Remove front carpets.
19.Release all relevant harnesses and position
aside.
20.Remove facia support bracket.
Refit
21.Prepare and clean panel joint faces. Ensure all
necessary grommets and sealant is applied to
new bulkhead.
22.Reverse removal procedure.
23.Bleed brake system.See BRAKES,
Adjustment.
24.Align headlamps.See ELECTRICAL,
Adjustment.
25.Water test after refitting.
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