shaft LAND ROVER DEFENDER 1999 Workshop Manual

MANIFOLD AND EXHAUST SYSTEM
5
REPAIR Refit
16.Clean inlet manifold and mating face.
17.Fit new gasket.
18.Fit inlet manifold, and working from the centre
outwards, tighten nuts and bolts to25 Nm (18
lbf.ft).
19.Position harness to sensors and connect
multiplugs.
20.Tighten harness clip bolts to camshaft carrier to
10 Nm (7 lbf.ft).
21.Clean dip stick tube and fit new’O’ring.
22.Fit dip stick tube and tighten bolt to10 Nm (7
lbf.ft).
23.Connect glow plug leads.
24.Fit alternator support bracket and tighten bolts to
45 Nm (33 lbf.ft).
25.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
26.Fit new gasket, position EGR valve and tighten
bolts to9 Nm (7 lbf.ft).
27.Connect multiplug to MAP sensor.
28.Fit cooling fan cowl.
29.Fit engine acoustic cover.
30.Reconnect battery negative lead.
31.Fit battery cover.GASKET - EXHAUST MANIFOLD
Service repair no - 30.15.12
Remove
1.Remove turbocharger.See FUEL SYSTEM,
Repair.
2. Models with A/C:Remove auxiliary drive belt.
See ELECTRICAL, Repair.
3.Remove 4 bolts securing compressor and move
to one side.
All Models
NOTE: EU3 Model illustrated.
4.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
5.Remove 10 nuts securing exhaust manifold to
cylinder head.
6.Remove exhaust manifold and gasket.
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CLUTCH
3
DESCRIPTION AND OPERATION 1.Brake/clutch reservoir
2.Connecting hose
3.Bolt - 2 off
4.Master cylinder
5.Clutch pedal
6.Gearbox housing
7.Primary driveshaft
8.Bolt - 2 off
9.Slave cylinder
10.Bleed nipple
11.Pressure plate
12.Drive plate
13.Dual mass flywheel
14.Metal hydraulic pipe
15.Ball spigot
16.Clutch release bearing sleeve
17.Bolt - 2 off
18.Pivot washer
19.Release lever
20.Release bearing
21.Retaining clip
22.Bolt
23.Plastic hydraulic pipe
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CLUTCH
5
DESCRIPTION AND OPERATION 1.Brake/clutch reservoir
2.Fluid supply pipe
3.Hydraulic feed pipe
4.Damper
5.Master cylinder
6.Piston
7.Clutch pedal
8.Primary driveshaft
9.Engine crankshaft
10.Drive plate
11.Dual mass flywheel
12.Ring gear
13.Leaf spring
14.Cover - pressure plate
15.Diaphragm
16.Release bearing
17.Ball spigot
18.Release bearing sleeve
19.Release lever
20.Slave cylinder
21.Piston
22.Bleed nipple
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CLUTCH
7
DESCRIPTION AND OPERATION Dual Mass Flywheel
1.Ring gear
2.Primary flywheel
3.Inner drive plate
4.Spring housing
5.Secondary flywheel
6.Rivet
7.Ball bearing8.Dowel location hole
9.Mounting hole
10.Inner spring
11.Outer spring
12.Crankshaft position sensing holes
13.Pressure plate locating dowel
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33CLUTCH
8
DESCRIPTION AND OPERATION The dual mass flywheel is bolted on the rear of the crankshaft with eight bolts. A dowel on the crankshaft flange
ensures that the flywheel is correctly located. A ring gear is fitted on the outer diameter of the flywheel. The ring
gear is not serviceable. Thirty blind holes are drilled in the outer diameter of the flywheel adjacent to the ring gear.
The holes are positioned at 10°intervals with four 20°spaces. The holes are used by the crankshaft position
sensor for engine management.
The dual mass flywheel is used to insulate the gearbox from torsional and transient vibrations produced by the
engine. The flywheel comprises primary and secondary flywheels with the drive between the two transferred by a
torsional damper which comprises four coil springs. The springs are located in the inside diameter of the primary
flywheel. Two of the springs are of smaller diameter and fit inside the larger diameter springs.
The primary flywheel locates the ring gear and is attached to the crankshaft flange with eight bolts. The two pairs
of coil springs are located in a recess in the flywheel between two riveted retainers. A roller bearing is pressed
onto the central boss of the primary flywheel and retained with a riveted plate. The bearing provides the mounting
for the secondary flywheel.
The secondary flywheel comprises two parts; an outer flywheel which provides the friction surface for the clutch
drive plate and an inner drive plate which transfers the drive from the primary flywheel, via the coil springs, to the
outer flywheel. The two components of the secondary flywheel are secured to each other with rivets. The inner
drive plate is located between the two pairs of coil springs and can rotate on the ball bearing in either direction
against the combined compression force of the four coil springs. Under high torque loading conditions the
secondary flywheel can rotate in either direction up to 70°in relation to the primary flywheel.
The operating face of the secondary flywheel is machined to provide a smooth surface for the drive plate to
engage on. Three dowels and six studs and nuts provide for the location and attachment of the pressure plate.
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CLUTCH
11
DESCRIPTION AND OPERATION Drive plate
1.Friction material
2.Inner plate3.Hub
4.Spring steel plate
The drive plate is of the rigid centre type and is sandwiched between the flywheel and the pressure plate. The
drive plate has a splined hub which engages with the splines on the primary drive shaft from the gearbox. The hub
is attached to an inner plate which is pressed onto the hub. A spring steel plate is riveted to the inner plate with
eight rivets and provides the attachment surface for the drive plate friction material. The spring steel plate allows
some axial compliance and contributes to smooth clutch operation. The friction material comprises two 267 mm
(10.5 in.) discs which are secured with rivets to each side of the spring steel plate. The rivets are installed through
recessed holes in the disc and emerge in recessed holes in the opposite disc.
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33CLUTCH
12
DESCRIPTION AND OPERATION OPERATION
Hydraulic operation
When the clutch pedal is depressed, the master cylinder piston is pushed into the master cylinder. The movement
of the piston pressurises the fluid in the master cylinder, forcing the pressurised fluid into the hydraulic feed pipe to
the slave cylinder. The hydraulic pressure is felt at the slave cylinder piston which moves under the hydraulic force
applied, pushing the clutch release lever via the piston rod.
When the clutch pedal is released, the force applied to the release lever by the fingers of the diaphragm, moves
the release lever, which pushes the slave cylinder piston into the cylinder. The displaced hydraulic fluid is pushed
up the hydraulic feed pipe and returns to the master cylinder.
Mechanism operation
When the clutch pedal is depressed, hydraulic pressure extends the piston and rod in the slave cylinder. The
extension of the piston pushes the rod against the outer end of the release lever which pivots around the ball
spigot.
The inner end of the release lever pivots towards the engine applying pressure to the release bearing. The release
bearing slides along the release bearing sleeve and pushes on the fingers of the diaphragm. The diaphragm
pivots around the chamfered rivets in the cover. As the diaphragm is deflected, it removes pressure from the
pressure plate. The pressure plate moves away from the drive plate assisted by the three leaf springs.
The removal of force from the pressure plate on the drive plate reduces the friction between the dual mass
flywheel, drive plate and pressure plate. The drive plate slips between the flywheel and the pressure plate
preventing rotary movement being transferred from the flywheel and pressure plate to the primary driveshaft.
When the clutch pedal is released, hydraulic force is removed from the piston in the slave cylinder. This allows the
fingers of the diaphragm to push the release bearing along the release bearing sleeve. The movement of the
release bearing moves the release lever which pivots on the ball spigot, pushing the piston and rod back into the
slave cylinder.
The removal of pressure from the release bearing on the diaphragm, causes the diaphragm to pivot around the
chamfered rivets in the cover. The force applied to the pressure plate from the diaphragm overcomes the force of
the leaf springs and the pressure plate moves towards the drive plate and flywheel.
The pressure plate applies pressure to the drive plate which is pushed against the flywheel. As the clutch pedal is
progressively released, the friction between the drive plate, flywheel and pressure plate increases. The increase in
friction transfers the rotary movement of the flywheel and pressure plate to the drive plate, which in turn starts to
rotate the primary drive shaft. When the clutch pedal is released fully, the force applied by the diaphragm to the
pressure plate forces the drive plate onto the flywheel with no slippage.
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CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01.01
Remove
1.Remove gearbox assembly.See MANUAL
GEARBOX, Repair.
2.Restrain flywheel.
3.Working in sequence, loosen 6 nuts securing
clutch cover to flywheel.
4.Remove clutch cover and clutch plate.
Refit
5.Clean clutch cover and flywheel mating faces
and spigot bush in end of crankshaft.
6.Position clutch drive plate to flywheel with
’gearbox side’ facing towards gearbox.
7.PositionLRT-12-152alignment tool through
drive plate into spigot bearing in crankshaft.8.Fit clutch cover and locate on dowels.
9.Position clutch cover nuts and tighten in diagonal
sequence to25 Nm (18 lbf.ft).
10.Fit gearbox assembly.See MANUAL
GEARBOX, Repair.
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37 - MANUAL GEARBOX
CONTENTS
Page
ADJUSTMENT
SPRINGS - GEAR LEVER BIAS 1..........................................................................
GEARBOX OIL - DRAIN AND REFILL 2.................................................................
REPAIR
COVER - FRONT - RESEAL AND FIT NEW INPUT SHAFT OIL SEAL 1..............
LEVER - GEAR CHANGE 3....................................................................................
MECHANISM AND HOUSING - GEAR SELECTOR 4...........................................
MECHANISM AND HOUSING - GEAR SELECTOR - RESEAL 6..........................
GEARBOX 7...........................................................................................................
SWITCH - REVERSE LIGHT 12.............................................................................
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MANUAL GEARBOX
1
REPAIR COVER - FRONT - RESEAL AND FIT NEW INPUT
SHAFT OIL SEAL
Service repair no - 37.12.33.01
Remove
1.Remove gearbox.See this Section.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch release
fork.
4.Remove 2 bolts securing release bearing sleeve,
remove bearing sleeve.
5.Remove 6 bolts securing clutch housing, remove
housing.
6.Remove and discard 6 bolts securing front
cover, remove cover.
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