1999 LAND ROVER DEFENDER washer

CONTENTS
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE
17 EMISSION CONTROL
18 ENGINE MANAGEMENT SYSTEM
19 FUEL SYSTEM
26 COOLING SYSTEM
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
47 PROPELLER SHAFTS
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
76 CHASSIS AND BODY
77 PANEL REPAIRS
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
88 INSTRUMENTS
01
04
05
07
09
10
12
17
18
19
26
30
33
37
41
47
57
60
64
70
76
77
82
84
86
88
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INTRODUCTION
1
INFORMATION INTRODUCTION
This Workshop Manual Supplement covers vehicles
from 1999 and 2002 model year onwards. The Body
Repair Manual has also been incorporated into this
supplement. Amendments and additional pages will
be issued, when necessary, to ensure that the
supplement covers latest models.
This Supplement is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover Defender vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system should
be carried out by a Land Rover Dealer. Repairs to
such items should NEVER be attempted by untrained
individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft end of the engine is referred to as the front.
To reduce repetition, some operations covered in this
Supplement do not include reference to testing the
vehicle after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out, particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer’s specification. Torque spanner values
given in the Supplement must be strictly adhered to.
Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during
removal it must be replaced with a new one. Certain
fasteners must not be re-used. These fasteners are
specified in the Supplement.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.
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07 - GENERAL FITTING REMINDERS
CONTENTS
Page
INFORMATION
GENERAL FITTING REMINDERS 1.......................................................................
PRECAUTIONS AGAINST DAMAGE 1..................................................................
SAFETY PRECAUTIONS 1....................................................................................
PREPARATION 2....................................................................................................
DISMANTLING 2.....................................................................................................
INSPECTION-GENERAL 2.....................................................................................
BALL AND ROLLER BEARINGS 3.........................................................................
OIL SEALS 4...........................................................................................................
JOINTS AND JOINT FACES 5................................................................................
FLEXIBLE HYDRAULIC PIPES, HOSES 5.............................................................
FUEL SYSTEM HOSES 6.......................................................................................
METRIC BOLT IDENTIFICATION 6........................................................................
METRIC NUT IDENTIFICATION 6..........................................................................
KEYS AND KEYWAYS 6........................................................................................
TAB WASHERS 6...................................................................................................
COTTER PINS 7.....................................................................................................
NUTS7 ...................................................................................................................
LOCKING WIRE 7...................................................................................................
SCREW THREADS 7..............................................................................................
UNIFIED THREAD IDENTIFICATION 7..................................................................
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07GENERAL FITTING REMINDERS
6
INFORMATION FUEL SYSTEM HOSES
CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber outer
sleeve and an inner viton core. If any of
the fuel system hoses have been disconnected, it
is imperative that the internal bore is inspected to
ensure that the viton lining has not become
separated from the amoured outer sleeve. A new
hose must be fitted if separation is evident.
METRIC BOLT IDENTIFICATION
1.An ISO metric bolt or screw, made of steel and
larger than 6 mm in diameter can be identified by
either of the symbols ISO M or M embossed or
indented on top of the head.
2.In addition to marks to identify the manufacture,
the head is also marked with symbols to indicate
the strength grade, e.g. 8.8, 12.9 or 14.9, where
the first figure gives the minimum tensile
strength of the bolt material in tens of kgf/mm
2.
3.Zinc plated ISO metric bolts and nuts are
chromate passivated, a gold-bronze colour.METRIC NUT IDENTIFICATION
1.A nut with an ISO metric thread is marked on
one face or on one of the flats of the hexagon
with the strength grade symbol 8, 12 or 14.
Some nuts with a strength 4, 5 or 6 are also
marked and some have the metric symbol M on
the flat opposite the strength grade marking.
2.A clock face system is used as an alternative
method of indicating the strength grade. The
external chamfers or a face of the nut is marked
in a position relative to the appropriate hour
mark on a clock face to indicate the strength
grade.
3.A dot is used to locate the 12 O’clock position
and a dash to indicate the strength grade. If the
grade is above 12, two dots identify the 12
O’clock position.
KEYS AND KEYWAYS
1.Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to
refit key.
2.Clean and inspect key closely; keys are suitable
for refitting only if indistinguishable from new, as
any indentation may indicate the onset of wear.
TAB WASHERS
1.Fit new washers in all places where they are
used. Always fit a new tab washer.
2.Ensure that the new tab washer is of the same
design as that replaced.
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GENERAL FITTING REMINDERS
7
INFORMATION COTTER PINS
1.Fit new cotter pins throughout when replacing
any unit.
2.Always fit cotter pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a cotter pin.
3.All cotter pins should be fitted as shown unless
otherwise stated.
NUTS
1.When tightening a slotted or castellated nut
never loosen it to insert cotter pin or locking wire
except in those recommended cases where this
forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should
be selected, or washer thickness reduced.
2.Where self-locking nuts have been removed it is
advisable to replace them with new ones of the
same type.
NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.
LOCKING WIRE
1.Fit new locking wire of the correct type for all
assemblies incorporating it.
2.Arrange wire so that its tension tends to tighten
the bolt heads, or nuts, to which it is fitted.SCREW THREADS
1.Both UNF and Metric threads to ISO standards
are used. See below for thread identification.
2.Damaged threads must always be discarded.
Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and
is not recommended.
3.Always ensure that replacement bolts are at
least equal in strength to those replaced.
4.Do not allow oil, grease or jointing compound to
enter blind threaded holes. The hydraulic action
on screwing in the bolt or stud could split the
housing.
5.Always tighten a nut or bolt to the recommended
torque value. Damaged or corroded threads can
affect the torque reading.
6.To check or re-tighten a bolt or screw to a
specified torque value first loosen a quarter of a
turn, then re-tighten to the correct value.
7.Oil thread lightly before tightening to ensure a
free running thread, except in the case of
threads treated with sealant/lubricant, and
self-locking nuts.
UNIFIED THREAD IDENTIFICATION
1. Bolts
A circular recess is stamped in the upper surface
of the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter
for a short length at its extremity.
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09LUBRICANTS, FLUIDS AND CAPACITIES
2
INFORMATION Propeller shaft Front
and RearNLGI - 2 Multi-purpose Lithium based GREASE
Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker
Brake and clutch
reservoirsBrake fluids having a minimum boiling point of 260°C (500°F) and complying with
FMVSS 116 DOT4
Engine coolant Use Texaco XLC long life coolant. Use one part anti-freeze to one part water for
protection down to -36°C (-33°F).
IMPORTANT: Coolant solution must not fall below 50% anti-freeze otherwise
damage to engine is liable to occur. Maximun concentration is 60%.
Battery lugs, Petroleum jelly.
Earthing surfacesNOTE: Do not use Silicone Grease
where paint has
been removed
Air Conditioning
System Refrigerant Use only refrigerant R134a
Compressor Oil ND-OIL 8
LUBRICATION PRACTICE
Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.
Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.
WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze, windscreen washer additives, lubricants and various adhesives.
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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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