oil LAND ROVER DEFENDER 1999 Owner's Manual

10MAINTENANCE
14
MAINTENANCE ENGINE OIL
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Position suitable container beneath sump.
3.Clean arear around drain plug.
4.Remove oil drain plug, discard sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit engine drain plug and tighten to23 Nm (17
lbf.ft).
8.Fill engine with recommended grade of oil to
correct mark on dipstick.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
9.Fit underbelly panel.See CHASSIS AND
BODY, Repair.CENTRIFUGE ROTOR - Td5
1.Renew centrifuge rotor.See ENGINE , Repair.
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MAINTENANCE
15
MAINTENANCE FULL FLOW OIL FILTER
1.Renew full flow oil filter.See ENGINE , Repair.GEARBOX OIL
WARNING: Avoid excessive skin contact
with used gearbox oil. Used gearbox oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Renew gearbox oil.See MANUAL GEARBOX,
Adjustment.
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10MAINTENANCE
16
MAINTENANCE TRANSFER BOX OIL
WARNING: Avoid excessive skin contact
with mineral oil. Mineral oils remove the
natural fats from the skin, leading to
dryness, irritation and dermatitis.
Check
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of oil filler/level
plug hole.
5.Remove all traces of sealant from threads of oil
filler/level plug.
6.Apply Loctite 290 to threads of oil filler/level plug
and tighten to25 Nm (18 lbf.ft).
7.Remove all traces of oil from main casing.
8.Fit underbelly panel.See CHASSIS AND
BODY, Repair.Renew
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Place a suitable container beneath transfer box
to catch any fluid spillage.
3.Clean area around oil filler/level and drain plugs.
4.Remove oil filler/level plug.
5.Remove oil drain plug.
6.Allow oil to drain.
7.Apply Loctite 290 to threads of oil drain plug.
8.Fit transfer box drain plug and tighten to30 Nm
(22 lbf.ft).
9.Fill transfer box with recommended oil to bottom
of oil filler/level plug hole.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
10.Remove all traces of sealant from threads of oil
filler/level plug.
11.Apply Loctite 290 to threads of oil filler/level plug
and tighten to25 Nm (18 lbf.ft).
12.Remove all traces of oil from main casing.
13.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
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MAINTENANCE
17
MAINTENANCE FRONT AND REAR AXLE OIL
Renew
A- Front and rear axle, 90 models, front, 110/130
models.
B- Rear axle, 110/130 models.
WARNING: Avoid excessive skin contact
with used axle oil. Used axle oil contains
potentially harmful contaminants which
may cause skin cancer or other serious skin
disorders.1.Ensure vehicle is level and place suitable tray
under axle to be drained.
2.Using 13mm square drive wrench, remove drain
and filler/level plugs from axle and allow oil to
drain completely.
3.Clean and refit drain plug.
4.Inject new oil, until it runs out from filler/level
hole. Allow excess oil to drain and wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
5.Clean and refit filler/level plug.
Check
1.Ensure vehicle is level.
2.Using 13 mm square drive wrench, remove
filler/level plug.
3.If necessary inject new oiluntil oil runs out from
filler/level hole. Allow excess oil to drain and
wipe clean.See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
4.Clean and refit filler/level plug.
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MAINTENANCE
19
MAINTENANCE PAS PIPES AND UNIONS
Check
1.Check PAS pipes for correct, secure routing and
signs of chafing.
2.Check for signs of fluid leakage from PAS pump,
hoses, and hose unions.ENGINE, GEARBOX, TRANSFER BOX AND AXLES
Check
1.Check for oil leaks from engine, gearbox, tansfer
box, and front and rear axles. Pay particular
attention to areas around oil seals.
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12 - ENGINE
CONTENTS
Page
DESCRIPTION AND OPERATION
TD5 ENGINE 1........................................................................................................
GENERAL 12..........................................................................................................
CYLINDER BLOCK 13............................................................................................
CRANKSHAFT, SUMP AND OIL PUMP 22............................................................
CYLINDER HEAD COMPONENTS 25...................................................................
CAMSHAFT COVER COMPONENTS 30...............................................................
CAMSHAFT TIMING CHAIN COMPONENTS 30...................................................
CYLINDER BLOCK FLOW 32.................................................................................
OIL COOLER / FILTER FLOW 34...........................................................................
CYLINDER HEAD FLOW 36...................................................................................
ADJUSTMENT
ENGINE OIL PRESSURE CHECK 1......................................................................
REPAIR
CAMSHAFT 1.........................................................................................................
PULLEY - CRANKSHAFT 3....................................................................................
OIL SEAL - CRANKSHAFT - REAR 4.....................................................................
BEARING - SPIGOT - CRANKSHAFT 5.................................................................
GASKET - CYLINDER HEAD 6..............................................................................
ROCKER SHAFT ASSEMBLY 11...........................................................................
GASKET - COVER - CAMSHAFT 13......................................................................
ENGINE AND ANCILLARIES 14.............................................................................
MOUNTING - FRONT - LH 19................................................................................
MOUNTING - FRONT - RH 20................................................................................
MOUNTING - GEARBOX - REAR - LH 21..............................................................
MOUNTING - GEARBOX - REAR - RH 22.............................................................
FLYWHEEL 22........................................................................................................
FILTER - OIL 23......................................................................................................
STRAINER - OIL PICK-UP 24.................................................................................
PUMP - OIL 24........................................................................................................
GASKET - ENGINE TO SUMP 26..........................................................................
SWITCH - OIL PRESSURE 28...............................................................................
VALVE - RELIEF - OIL PRESSURE 29..................................................................
COOLER - ENGINE OIL 29....................................................................................
CENTRIFUGE ASSEMBLY 30................................................................................
ROTOR - CENTRIFUGE 32....................................................................................
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12 - ENGINE
CONTENTS
Page
OIL SEAL - TIMING COVER 32..............................................................................
TIMING CHAIN AND SPROCKETS 33...................................................................
OVERHAUL
GASKET - INLET MANIFOLD 1..............................................................................
GASKET - EXHAUST MANIFOLD 2.......................................................................
GASKET - CYLINDER HEAD 3..............................................................................
CYLINDER HEAD GASKET SELECTION 7...........................................................
CYLINDER HEAD - OVERHAUL 8.........................................................................
GASKET - ENGINE SUMP 20................................................................................
SEAL - CRANKSHAFT - REAR 21.........................................................................
STARTER RING GEAR 22.....................................................................................
PUMP - OIL 23........................................................................................................
TIMING CHAIN AND SPROCKETS 26...................................................................
BEARINGS - CONNECTING RODS 30..................................................................
PISTONS, CONNECTING RODS AND CYLINDER BORES 32.............................
CRANKSHAFT 36...................................................................................................
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ENGINE
3
DESCRIPTION AND OPERATION 1.Oil dipstick tube
2.Screw - oil dipstick tube to camshaft carrier
3.Oil dipstick
4.2nd piston ring
5.Piston
6.Small-end bush
7.Connecting rod
8.Big-end bearing cap
9.Connecting rod bolt (2 off per connecting rod)
10.Top piston ring
11.Oil control ring
12.Circlips (2 off per gudgeon pin)
13.Gudgeon pin
14.Big-end bearing shells
15.Dowels to cylinder head (2 off)
16.Gearbox shim plate
17.Rear crankshaft seal and housing
18.Screws - crankshaft seal flange to engine block (5 off)
19.Bolts - Gearbox shim plate to cylinder block (2 off)
20.Main oil gallery plug (rear)
21.Oil filter adaptor gasket
22.Oil filter adaptor thermostat
23.Oil filter adaptor assembly
24.Oil filter adaptor insert
25.Oil filter adaptor to cylinder block bolts (3 off)
26.Oil filter
27.Oil pressure switch
28.Oil cooler banjo bolts (2 off)
29.O-rings - oil cooler banjo bolts (2 off)
30.Oil cooler to cylinder block bolts (7 off)
31.Centrifuge assembly
32.Centrifuge to cylinder block bolts (3 off)
33.Centrifuge oil drain pipe
34.Oil drain pipe to sump gasket
35.Centrifuge to oil drain pipe gasket
36.Oil cooler plugs (3 off)
37.Oil cooler assembly
38.Oil cooler matrix ’O’ rings (2 off)
39.Oil cooler matrix
40.Oil cooler gasket
41.Coolant and PAS pump assembly bracket
42.Bracket bolts (5 off + 1 stud/nut)
43.Cylinder block
44.Dowels - timing chain cover (2 off)
45.Oil gallery delivery plug
46.Cross drilling plug
47.Coolant jacket plug
48.Core plugs (3 off)
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12ENGINE
4
DESCRIPTION AND OPERATION Crankshaft, sump and oil pump
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ENGINE
5
DESCRIPTION AND OPERATION 1.Crankshaft pulley bolt
2.TV Damper to crankshaft pulley bolts (3 off)
3.TV Damper
4.Crankshaft pulley
5.Woodruff key
6.Crankshaft
7.Crankshaft to flywheel dowel
8.Spigot bush
9.Flywheel to crankshaft bolts (8 off)
10.Flywheel assembly
11.Main bearing shells (6 pairs)
12.Main bearing caps (6 off)
13.Main bearing cap bolts (12 off)
14.Thrust washer (2 off at No. 3 Main bearing)
15.Piston lubrication jets (5 off)
16.Piston lubrication jet cap head screw (5 off)
17.Stiffener plate (oil pump integral)
18.Stiffener plate / oil pump assembly to cylinder block bolts (22 off)
19.Oil pick-up pipe O-ring
20.Oil pick-up pipe inserts (2 x 6mm; 1 x 10mm)
21.Upper oil pick-up pipe
22.Oil pick-up pipe gauze
23.Lower oil pick-up pipe
24.Sump
25.Oil drain plug seal
26.Oil drain plug
27.Sump to cylinder block bolts (20 off)
28.Sump gasket
29.Oil pick-up pipe bolts (3 off)
30.Oil pump
31.Chain lubrication jet
32.Chain lubrication jet screw
33.Stiffener to cylinder block dowel (2 off)
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