engine LAND ROVER DEFENDER 1999 Owner's Guide

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
1
DESCRIPTION AND OPERATION TD5 ENGINE
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12ENGINE
2
DESCRIPTION AND OPERATION Cylinder block components
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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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12ENGINE
6
DESCRIPTION AND OPERATION Cylinder head components
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ENGINE
7
DESCRIPTION AND OPERATION 1.Camshaft carrier
2.Dowel - rocker shaft to camshaft carrier (1 off)
3.Cylinder head bolts (12 off)
4.Rocker shaft to camshaft carrier bolts (6 off)
5.Rocker shaft
6.Circlips (10 off)
7.EUI Rocker arms (5 off)
8.Camshaft carrier to cylinder head screws (13 off)
9.Finger follower (10 off)
10.Valve spring collets (20 off)
11.Lash adjuster (10 off)
12.Valve spring retainer (10 off)
13.Valve spring (10 off)
14.Valve stem seal (10 off)
15.Valve guide (10 off)
16.Valve seat insert (10 off)
17.Inlet valve (5 off)
18.Exhaust valve (5 off)
19.Camshaft
20.Camshaft bore seal (rear)
21.Coolant jacket core plug
22.Cylinder head block
23.Water jacket threaded plug
24.Engine lifting bracket (LH)
25.Engine lifting bracket bolts (2 off)
26.Coolant outlet elbow to cylinder head bolts (3 off)
27.Coolant outlet elbow
28.Coolant outlet elbow gasket
29.Cylinder head gasket
30.Non-return valve (not removable, integral in cylinder head)
31.Camshaft bore end cap (front)
32.End cap seal
33.Cylinder head to cam carrier dowel (2 off)
34.Engine lifting bracket (RH)
35.Engine lifting bracket bolts (2 off)
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12ENGINE
8
DESCRIPTION AND OPERATION Camshaft cover and engine cover
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