check oil LAND ROVER DEFENDER 1999 Owner's Guide

ENGINE
35
OVERHAUL Piston ring gaps - Checking
1.Insert new compression and oil control piston
rings in turn into No. 1 cylinder bore 30 mm (1.25
in) from top of bore and check ring fitted gaps;
ensure rings are kept square to bore when
checking gaps.
1st compression ring fitted gap =0.30 to 0.40
mm (0.012 to 0.016 in)
2nd compression ring fitted gap =0.40 to 0.60
mm (0.016 to 0.024 in)
Oil control ring fitted gap =0.25 to 0.50 mm
(0.01 to 0.02 in)
Repeat for each cylinder bore in turn.
CAUTION: Ensure rings are suitably
identified with the cylinder bore in which
they were checked and are fitted to the
piston for that bore.
2.Fit oil control expander and ring to piston.
3.Fit 2nd compression ring with’TOP’marking
upwards.
4.Fit 1st compression ring with’TOP’marking
upwards.
5.Check piston ring to groove clearance:
1st compression ring -Not measured
2nd compression ring =0.050 to 0.082 mm
(0.02 to 0.003 in)
Oil control ring =0.050 to 0.082 mm (0.02 to
0.003 in)
Pistons and connecting rods - Assembling
1.Lubricate gudgeon pin, gudgeon pin holes in
piston and small-end bush with engine oil.
2.Position piston to its respective connecting rod
with arrow on piston crown on the same side as
the cast boss on the connecting rod.
3.Fit gudgeon pin to its respective piston and
connecting rod; secure with new circlips.
CAUTION: Ensure circlips are fully seated
in their grooves.
4.Repeat above procedures for remaining pistons.
5.Lubricate piston rings and cylinder bores with
engine oil.
6.Check that rings are free to rotate, position ring
gaps at 120°to each other and away from the
thrust - LH side of piston - viewed from front of
piston.
7.Using a suitable piston ring clamp, compress
piston rings.
8.Insert connecting rod and piston into its
respective cylinder bore, ensuring that the arrow
on piston crown and the cast boss on connecting
rod are facing towards the front of the cylinder
block.
CAUTION: Ensure that connecting rod
does not contact cylinder bore or oil squirt
jet. Do not pull connecting rod fully down
cylinder bore at this stage.
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12ENGINE
36
OVERHAUL 9.Check that the cut-out in piston skirt is
positioned above the oil squirt jet.
10.Repeat for other pistons in turn ensuring that
pistons and connecting rods are fitted in cylinder
bores from which they were removed.
11.Fit connecting rod bearings.See this Section.
CAUTION: If new pistons, connecting rods
or crankshaft have been fitted, it will be
necessary to select correct thickness of
cylinder head gasket.See this Section.CRANKSHAFT
Service repair no - 12.21.33.01
Remove
1.Remove timing chain and sprockets.See this
Section.
2.Remove crankshaft rear oil seal.See this
Section.
3.Remove connecting rod bearings.See this
Section.
4.Check that cylinder reference number is on each
main bearing cap. Make suitable alignment
marks between each main bearing cap and
cylinder block.
5.Starting at No. 3 main bearing cap and working
outwards, progressively loosen, then remove 2
bolts securing each cap. Discard main bearing
cap bolts.
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ENGINE
37
OVERHAUL
6.Fit 2 slave bolts into each main bearing cap in
turn and ease bearing caps from cylinder block.
7.Remove and discard bearing shells from each
cap.
NOTE: These bearing shells are plain.
8.Using assistance, remove crankshaft.
9.Remove and discard main bearing shells and 2
thrust washers from cylinder block.
NOTE: These bearing shells are grooved.
10.Remove Torx screw securing each oil squirt jet
to cylinder block, remove squirt jets.Cylinder block - Inspection
1.Clean main bearing shell and thrust washer
locations in cylinder block, ensure bolt holes are
clean and dry.
2.Clean main bearing caps.
3.Clean crankshaft bearing journals, check oilways
are clear.
4.Ensure drillings in oil squirt jets are clear.
5.Check core plugs in cylinder block for corrosion
or signs of leakage, seal replacement plugs with
Loctite 243.
Crankshaft - Inspection
1.Check crankshaft main and big-end bearing
journals for scoring, wear and ovality, make 3
checks at 120°intervals in centre of journals.
Crankshaft bearing journal diameters:
Main bearings =
62.000 mm±0.013 mm (2.441 in±0.001 in)
Big-end bearings =
54.000±0.01 mm (2.125±0.0004in)
CAUTION: Crankshafts may not be
reground, only one size of main and
big-end bearing shell is available and if
journals are found to be scored, oval or worn,
crankshaft must be replaced. Main and big-end
bearing shells and thrust washers must be
replaced whenever they are removed.
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12ENGINE
38
OVERHAUL Crankshaft spigot bush
1.Check crankshaft spigot bush for wear, replace if
necessary using the following procedures:
2.Secure crankshaft in a suitably padded vice.
3.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
4.Fit impulse extractor to spigot bush.
5.Remove spigot bush.
6.Clean spigot bush recess in crankshaft.
7.Fit new spigot bush to crankshaft using a
suitable mandrel.
Crankshaft - Refit
1.Fit oil squirt jets, fit Torx screws and tighten to8
Nm (6 lbf.ft).
2.Lubricate new, grooved, main bearing shells with
engine oil and fit to cylinder block.
3.Lubricate new thrust washers with engine oil and
fit, grooved side facing outwards, to recess in
each side of cylinder block No. 3 main bearing.
4.Lubricate crankshaft journals with engine oil and
using assistance, position crankshaft in cylinder
block.
5.Lubricate new, plain, main bearing shells with
engine oil and fit to main bearing caps.
6.Fit main bearing caps in their original fitted
positions ensuring that reference marks are
aligned.
7.Fit and lightly tighten new main bearing cap
bolts.
CAUTION: Do not lubricate bolt threads.
8.Starting with No. 3 main bearing cap and
working outwards, tighten main bearing cap bolts
to:
Stage 1 -33 Nm (24 lbf.ft)
Stage 2 -Further 90
°
CAUTION: Do not carry out stages 1 and 2
in one operation.
9.Check that crankshaft rotates smoothly.
10.Assemble a magnetic base DTI to front of
cylinder block with stylus of gauge on end of
crankshaft.
11.Using suitably padded levers, move crankshaft
rearwards and zero DTI.
12.Move crankshaft forwards and note crankshaft
end-float reading on gauge.
Crankshaft end-float =0.02 to 0.25 mm (0.001
to 0.011 in)
CAUTION: Oversize thrust washers are not
available, if end-float exceeds figure given,
crankshaft must be replaced.
13.Remove DTI.
14.Fit connecting rod bearings.See this Section.
15.Fit timing chain and sprockets.See this
Section.
16.Fit crankshaft rear oil seal.See this Section.
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EMISSION CONTROL
7
DESCRIPTION AND OPERATION CRANKCASE EMISSION CONTROL
All internal combustion engines generate oil vapour and smoke in the crankcase as a result of high crankcase
temperatures and piston ring and valve stem blow-by. A closed crankcase ventilation system is used to vent
crankcase gases back to the air induction system and so reduce the emission of hydrocarbons.
Gases from the crankcase are drawn into the inlet manifold to be burnt in the combustion chambers with the fresh
air/fuel mixture. The system provides effective emission control under all engine operating conditions.
Crankcase gases are drawn through the breather port in the top of the camshaft cover and routed through the
breather hose and breather valve on the flexible air intake duct to be drawn into the turbocharger intake for
delivery to the air inlet manifold via the intercooler.
An oil separator plate is included in the camshaft cover which removes the heavy particles of oil before the
crankcase gas leaves via the camshaft cover port. The rocker cover features circular chambers which promote
swirl in the oil mist emanating from the cylinder head and camshaft carrier. As the mist passes through the series
of chambers between the rocker cover and oil separator plate, oil particles are thrown against the separator walls
where they condense and fall back into the cylinder head via two air inlet holes located at each end of the rocker
cover.
The breather valve is a pressure depression limiting valve which progressively closes as engine speed increases,
thereby limiting the depression in the crankcase. The valve is of moulded plastic construction and has a port on
the underside which plugs into a port in the flexible air duct. A port on the side of the breather valve connects to
the camshaft cover port by means of a breather hose which is constructed from a heavy duty braided rubber hose
which is held in place by hose clips. A corrugated plastic sleeve is used to give further protection to the breather
hose. The breather valve is orientation sensitive, and’TOP’is marked on the upper surface to ensure it is
mounted correctly.
It is important that the system is air tight. Hose connections to ports should be checked and the condition of the
breather hose should be periodically inspected to ensure it is in good condition.
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41TRANSFER GEARBOX
6
REPAIR 71.Release propeller shaft, align flange markings
and connect to studs.
72.Fit nuts securing propeller shaft and tighten to48
Nm (33 lbf.ft).
73.Clean front propeller to transfer gearbox flange
mating faces.
74.Fit propeller shaft, align flange markings and
tighten nuts to48 Nm (33 lbf.ft).
75.Using new gasket, fit intermediate silencer and
tighten nuts to25 Nm (18 lbf.ft).
76.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
77.Refill transfer gearbox with recommended oil.
78.Fit cooling fan cowl.
79.Fit high/low operating rod and secure with
retaining clip.
80.Position handbrake outer cable to heelboard.
81.Position handbrake cable to lever, fit clevis pin,
washer and new split pin.
82.Position handbrake gaiter and secure with trim
studs.
83.Fit insulation pad to tunnel.
84.Fit gear lever cover.
85.Fit gear lever knobs.
86.Position diagnostic plug bracket, access panel
and tighten screws.
87.Fit carpet to transmission tunnel.
88.Fit cubby box.See CHASSIS AND BODY,
Repair.
89.Fit cooling fan.See COOLING SYSTEM,
Repair.
90.Reconnect battery negative lead.
91.Fit battery cover.GASKET - REAR COVER PLATE
Service repair no - 41.20.30
Remove
1.Raise vehicle on’4 post ramp’.
2.Mark rear cover plate to bearing housing for
assembly purposes.
3.Noting fitted position of stud bolt and harness
clip bracket, remove 5 bolts and stud bolt
securing cover plate.
4.Collect harness clip bracket.
5.Remove cover plate.
Refit
6.Clean cover plate and mating face.
7.Apply Hylosil RTV 102 to rear cover mating face.
8.Align reference marks, fit cover plate.
9.Clean cover bolts and apply Loctite 290 threads
of bolts and stud nut.
10.Position clip bracket, fit stud nut and bolts,
tighten by diagonal selection to25 Nm (18
lbf.ft).
11.Check/top-up transfer gearbox oil.
12.Lower vehicle.
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41TRANSFER GEARBOX
10
REPAIR Refit
8.Clean oil seal recess.
9.Lubricate new input shaft oil seal with transfer
gearbox oil.
10.Fit oil seal usingLRT-41-012.
NOTE: Use end of tool marked ’FRONT’ to
fit seal.
11.Position drive flange, fit new felt and steel
washers.
12.PositionLRT-51-003fit new drive flange nut and
tighten to148 Nm (109 lbf.ft).
13.Align marks and position front propeller shaft to
output flange. Fit new nuts and tighten to48 Nm
(35 lbf.ft).
14.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
15.Check/top-up transfer gearbox oil.SEAL - REAR OUTPUT SHAFT
Service repair no - 41.20.54
Remove
1.Loosen brake shoe adjuster bolt.
2.Remove rear propeller shaft.See PROPELLER
SHAFTS, Repair.
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41TRANSFER GEARBOX
12
REPAIR
10.Fit new seal usingLRT-41-012.
NOTE: Use end of tool marked’REAR’to
fit seal.
11.Position drive flange, fit new felt and steel
washers.
12.PositionLRT-51-003fit and tighten new drive
flange nut to148 Nm (109 lbf.ft).
13.Position brake drum and tighten screw.
14.Tighten adjuster bolt to25 Nm (18 lbf.ft)then
back off 1 1/2 turns.
15.Check that brake drum is free to rotate.
16.Fit propeller shaft.See PROPELLER SHAFTS,
Repair.
17.Top-up transfer gearbox oil.GASKET - REAR OUTPUT SHAFT HOUSING
Service repair no - 41.20.55
Remove
1.Drain transfer gearbox oil.See
MAINTENANCE ,
2.Remove rear output shaft seal.See this
Section.
3.Mark output shaft housing to main casing for
assembly purposes.
4.Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
5.Clean output shaft housing, mating face on main
casing and sealant from bolt threads.
6.Apply Hylosil RTV 102 to mating flange on
output shaft housing.
7.Fit output shaft housing to main casing ensuring
that splines of output shaft are engaged in
differential.
8.Apply Loctite 290 to bolt threads.
9.Fit bolts and tighten by diagonal selection to45
Nm (33 lbf.ft).
10.Fit rear output shaft seal.See this Section.
11.Fill transfer gearbox with oil.See
MAINTENANCE ,
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REAR AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication from the hub seals can
be caused by a faulty internal seal. For example, if the
seals which separate the differential from the hubs are
faulty and the vehicle is operating or parked on an
embankment, oil from the differential may flood one
hub resulting in a lack of lubrication in the differential.
When a seal is found to be leaking check the axle
ventilation system, as a blockage can cause internal
pressure to force oil past the seals.
See’Description and Operation’for illustrations of oil
seal locations.
When investigating hub seal leaks check the grease
for dilution with oil. Also check the differential oil level,
for signs of metal particles in the oil and the condition
of internal seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and raise
the differential oil level, giving a false impression that
the housing has been over filled.
Do not assume that a high oil level in the
differential is due to over filling or, that a low level
is because of an external leak.
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51REAR AXLE AND FINAL DRIVE
8
OVERHAUL 86.Before adjusting shim thickness, check pinion
face marking and if it has a plus (+) figure,
subtract that from shim thickness figure obtained
in previous instruction. Alternatively if pinion has
a minus (-) figure, add amount to shim thickness
figure.
87.Adjust shim thickness under pinion inner cup as
necessary, by amount determined in instructions
85 and 86.
88.Recheck pinion height setting instructions 82 to
84. If setting is correct, mean reading on dial
gauge will agree with figure marked on pinion
end face. For example, with an end face marking
of +3, dial gauge reading should indicate that
pinion is 0.003 in (0.0762 mm) below nominal.
89.When pinion setting is satisfactory, temporarily
remove pinion outer bearing.
90.Fit a new collapsable bearing spacer, flared end
outward, to drive pinion and refit outer bearing.
91.Fit pinion oil seal.
92.Fit oil seal gasket.
93.Fit pinion oil seal, lipped side first, using general
purpose grease or, where available, a
molybdenum disulphide based grease on seal
lip, usingLRT-51-002to drift in seal.
94.Fit coupling flange and plain washer and loosely
fit a new flange nut. SecureLRT-51-003to
coupling flange, using slave fixings.
95.Alternately tighten flange nut and check drive
pinion resistance to rotation until following
figures are achieved, as applicable:
A.Assemblies re-using original pinion bearings:
17,3 to 34,5 kgf cm.
B.Assemblies with new pinion bearings: 34,5 to
46,0 kgf cm.
NOTE: Once the bearing spacer has
started to collapse the torque resistance
build-up is rapid, therefore check
frequently, using a spring balance, to ensure the
correct figures are not exceeded, otherwise a new
collapsable bearing spacer will be required.
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