battery LAND ROVER DEFENDER 1999 Workshop Manual

01INTRODUCTION
2
INFORMATION FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic and when
diluted with air becomes a readily ignitable mixture.
The vapour is heavier than air and will always fall to
the lowest level. It can readily be distributed
throughout a workshop by air current, consequently,
even a small spillage of fuel is very dangerous.
Always have a fire extinguisher containingFOAM CO
2
GAS,orPOWDERclose at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1.Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2.Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer’s instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
AFUEL VAPOURwarning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.
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01INTRODUCTION
8
INFORMATION JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1.Position vehicles so that jump leads will reach,
ensuring that vehiclesDO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2.Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected, connect the
jump leads as follows;
A.Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B.Connect other end of first jumper cable to positive
(+) terminal of discharged battery.
C.Connect one end of second jumper cable to
negative terminal of booster battery.
D.Connect other end of second jumper cable to a
good earth point on the disabled vehicle (eg. engine
front lifting eye, as shown in J6086),NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
3.If booster battery is installed in another vehicle,
start engine and allow to idle.
4.Start engine of vehicle with discharged battery,
following starting procedure in Owners’Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalyst, if fitted.
5.Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6.Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.
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01INTRODUCTION
10
INFORMATION CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (A/C)...................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Intake air temperature (IAT).........................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAF).........................................
Open loop (OL)............................................................
Relay module (RM)......................................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TP)........................................
Transmission range (TR)..............................................
Wide open throttle (WOT)............................................OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Intake temperature/ambient temperature (-)................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Relay (-).......................................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Transmission gear (-)...................................................
Full throttle, wide open throttle (WOT).........................
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04GENERAL SPECIFICATION DATA
8
INFORMATION AIR CONDITIONING
System CFC free, expansion valve system.............................................................................
Compressor Nippon Denso.....................................................................
Refrigerant R134a CFC free.......................................................................
Charge quantity 750 g±50 g ................................................................
Refrigerant oil ND-OIL 8...................................................................
WIPER MOTORS
Tailgate wiper motor
Make/type IMOS (non-serviceable)........................................................................
Running current, wet screen at 20°C ambient 1.0 to 2.8 amps.................
Wiper speed, wet screen at 20°C ambient 37 to 43 cycles per minute.......................
Windscreen wiper motor
Make/type Lucas 14W uprated two speed........................................................................
Armature end float 0,1 to 0,2 mm............................................................
Brush length, minimum 4,8 mm....................................................
Brush spring tension 140 to 200 g........................................................
Resistance of armature winding
at 16˚C (69˚F) measured between adjacent
commutatator segments 0.23 to 0.35 ohms...................................................
Light running, rack disconnected: current at 13.5 V 2.0 amps.........
Wiper speed, wet screen, 60 seconds from cold Low speed - 45±3 rev/min, High speed - 65±5 ..............
rev/min
ELECTRICAL
System 12 volt, negative ground.............................................................................
Battery
Make/type Delphi GP31........................................................................
Alternator
Type Nippon Denso.................................................................................
Fuses
Type Autofuse (blade type) blow ratings to suit individual.................................................................................
circuits
Horns
Make/type Mixo TR99........................................................................
Starter motor
Make and type Bosch 12v.................................................................
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GENERAL FITTING REMINDERS
1
INFORMATION GENERAL FITTING REMINDERS
WORKSHOP SAFETY IS YOUR RESPONSIBILITY!
The suggestions, cautions and warnings in the
section are intended to serve as reminders for
trained and experienced mechanics. This manual
is not a definitive guide to automotive mechanics
or workshop safety.
Shop equipment, shop environment, and the use
and disposal of solvents, fluids, and chemicals
are subject to government regulations which are
intended to provide a level of safety. It is your
responsibility to know and comply with such
regulations.
PRECAUTIONS AGAINST DAMAGE
1.Always fit covers to protect fenders before
commencing work in engine compartment.
2.Cover seats and carpets, wear clean overalls
and wash hands or wear gloves before working
inside vehicle.
3.Avoid spilling hydraulic fluid or battery acid on
paint work. Wash off with water immediately if
this occurs. Use Polythene sheets to protect
carpets and seats.
4.Always use a recommended Service Tool where
specified.
5.Protect temporarily exposed screw threads by
replacing nuts or fitting plastic caps.SAFETY PRECAUTIONS
1.Whenever possible, use a lift when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
WARNING: Do not use a pit when
removing fuel system components.
2.Never rely on a jack alone to support vehicle.
Use axle stands carefully placed at jacking
points to provide rigid support.
3.Ensure that a suitable form of fire extinguisher is
conveniently located.
4.Check that any lifting equipment used has
adequate capacity and is fully serviceable.
5.Disconnect battery.
WARNING: Do not disconnect any pipes in
air conditioning system, unless trained
and instructed to do so. A refrigerant is
used which can cause blindness if allowed to
contact eyes.
6.Ensure that adequate ventilation is provided
when volatile degreasing agents are being used.
7.Do not apply heat in an attempt to free stiff
fixings; as well as causing damage to protective
coatings, there is a risk of damage to electronic
equipment and brake linings from stray heat.
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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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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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10MAINTENANCE
4
MAINTENANCE BATTERY CONDITION - Td5
Remove
1.Remove drivers seat base.
2.Release clip securing battery cover.
3.Remove battery cover.
NOTE: The vehicle may be fitted with an
alarm and immobilisation system. To
prevent the alarm from sounding, it is
important that the following procedure is used
when disconnecting the battery.
4.Turn the ignition switch to position’II’, and then
to position’0’.
5.Remove the ignition key.
6.Disconnect the vehicle -ve terminal within 15
seconds.
NOTE: Always disconnect the -ve terminal
first. When replacing, connect the +ve
terminal first.
Check
The battery fitted to Td5 models is designed to be
maintenance free, so topping-up is not possible. On
the top of the battery is a battery indicator. When the
indicator shows:
GREEN - The battery is in a good state of charge.
DARK (turning to black) - The battery needs
charging.
CLEAR (or light yellow) - The battery needs
replacing. Do not charge the battery or jump start
the vehicle in this condition.
If the green dot is missing, the battery needs
charging.
NOTE: If the indicator shows clear or
yellow, tap the indicator with the handle of
a screwdriver to disperse any air bubbles.
If the indicator colour remains unchanged, the
battery will need replacing.
Refit
7.Clean and grease battery terminals and leads
with petroleum jelly.
8.Connect leads to battery (+ve first) and tighten
clamp bolts.
9.Fit battery cover and secure with clip.
10.Fit drivers seat base.
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MAINTENANCE
5
MAINTENANCE HANDSET BATTERY
Remove
NOTE: Do not remove a battery until you
are ready to install the replacement.
Always fit a Land Rover STC4080 or a
Panasonic CR2032 replacement battery.
1.Unlock the vehicle and disarm the alarm system.
2.Turn the ignition switch to position’II’, then turn
to position’0’and remove the key.
3.Carefully prise the handset apart, starting from
the keyring end. Avoid damaging the seal
between the two halves of the case.
CAUTION: Do not allow moisture to get
inside the handset.
4.Slide the battery out of its clip, taking care to
avoid touching the circuit board or the contact
surfaces of the clip.
5.Press and hold one of the buttons for at least 5
seconds to drain any residual power from the
handset.
Refit
6.Fit the new battery, ensuring that correct polarity
is maintained (+ve side facing up). Finger marks
will adversely affect battery life. Avoid touching
the flat surfaces of the battery, and wipe clean
before fitment.
7.Reassemble the two halves of the handset.
Operate the Padlock symbol button at least 4
times within range of the vehicle to
resynchronise the hanset.HEADLAMP ALIGNMENT
1.Check alignment of headlamps.See
ELECTRICAL, Adjustment.
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10MAINTENANCE
8
MAINTENANCE FUEL FILTER ELEMENT
1.Renew fuel filter element.See FUEL SYSTEM,
Repair.FUEL FILTER SEDIMENTER - Td5
WARNING: Fuel vapour is highly
flammable and in contained speces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2, GAS OR
POWDER close at hand when handling or draining
fuel.
1.Disconnect battery negative lead.
2.Position suitable container beneath fuel filter
3.Disconnect multiplug from sedimenter
4.Rotate sedimenter anti-clockwise until water
flows from drain tube.
5.Allow to drain until diesel fuel flows from drain
tube.
6.Rotate sedimenter fully clockwise.
7.Connect multiplug.
8.Reconnect battery negative lead.
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