bonnet LAND ROVER DEFENDER 1999 Workshop Manual

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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MAINTENANCE
1
MAINTENANCE UNDERBONNET VIEW - Td5
LHD shown
1.Engine oil dipstick
2.Coolant expansion tank
3.Air cleaner
4.Brake/clutch fluid reservoir filler cap5.Windscreen washer reservior
6.Auxiliary drive belt
7.Engine oil filler cap
8.PAS fluid reservoir
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10MAINTENANCE
10
MAINTENANCE DOOR LOCKS AND HINGES
Front, rear and tail doors
1.Open each door in turn and lubricate door
hinges and check strap using recommended
lubricant.
2.Lubricate door lock, striker and private lock using
PTFE lubricant. Remove excessive lubricant,
particularly from door striker area, to avoid
customer complaint.
3.Check tightness of accessible door lock and
striker fixings
4.Open and close door to check for smooth,
noise-free operation. Ensure door closes
securely.
5.Check for smooth operation of private lock.
Bonnet
1.With bonnet open, lubricate hinges, striker, lock
and safety catch using a suitable lubricant.ENGINE COOLANT
1.Renew engine coolant.See COOLING
SYSTEM, Adjustment.
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MAINTENANCE
23
MAINTENANCE ENGINE AND TRANSMISSION MOUNTINGS
1.Check condition of front LH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
2.Check condition of front RH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
3.Check condition of rear LH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
4.Check condition of rear RH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.ROAD TEST
There are two purposes for conducting a road test.
Firstly, to ensure the work completed within the
dealership meets the standards required as layed
down by dealership processes. Secondly, for a skilled
technician to assess the general condition of the
vehicle and report any conditions that the customer
should be made aware of.
CAUTION: Two wheel roller tests must not
be carried out. Four wheel roller tests
must be restricted to 3 mph (5 kph).
1.Check for correct operation of starter switch.
Ensure the engine starts in a correct manner.
Leave the engine running.
2.With vehicle stationary, turn steering from lock to
lock. Check for smooth operation and ensure
there is no undue noise from the power steering
pump or drive belt.
3.Depress clutch and select all gears in turn.
Check for smooth notch free engagement.
4.Drive vehicle on a short road test. Check all
vehicle systems for correct operation. Pay
particular attention to:
Engine noise
Gearbox noise
Suspension noise
Body noise
Braking system operation
Gear selection
Engine performance
5.Check for correct operation of all instruments
and warning devices where practical.
6.After road test, carry out a final inspection of the
vehicle on vehicle ramps.
7.Check all underbonnet fluid levels and top-up if
necessary.
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COOLING SYSTEM
3
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Remove front grille.See CHASSIS AND
BODY, Repair.
2.Drain cooling system.See Adjustment.
3.Remove cooling fan.See this Section.
4.Remove 5 bolts and move bonnet platform
aside.
5.Release clip and disconnect bleed hose from
radiator.
6.Release clip and disconnect top hose from
radiator.
7.Release clip and disconnect fuel cooler hose
from radiator.
8.Release clip and disconnect coolant rail hose
from radiator.
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COOLING SYSTEM
5
REPAIR Refit
17.Fit rubber mountings to bottom of radiator.
18.Fit lower cooling fan cowl to radiator and secure
with screws.
19.Fit nuts to radiator side brackets.
20.Position intercooler to radiator and tighten bolts.
21.Fit rubber mountings to intercooler.
22.Position mounting spacers and fit radiator.
23.Fit bottom hose into bracket on lower cooling fan
cowl.
24.Position air hose to turbocharger pipe and
secure with clip.
25.Position LH and RH radiator mounting brackets
to body and radiator and tighten bolts.
26.Position coolant rail hose to radiator and secure
with clip.
27.Position fuel cooler hose to radiator and secure
with clip.
28.Position top hose to radiator and secure with
clip.
29.Position bleed hose to radiator and secure with
clip.
30.Position bonnet platform and tighten bolts.
31.Fit cooling fan.See this Section.
32.Fit front grille.See CHASSIS AND BODY,
Repair.
33.Fill cooling system.See Adjustment.
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CHASSIS AND BODY
5
REPAIR
13.Remove 4 bolts securing radiator mounting
bracket to wing.
14.Loosen screw and release bonnet lock inner
cable from bonnet lock.
15.Release bonnet lock outer cable from from
bonnet lock.
16.Push centre pins from studs securing wheel arch
extension to wing, remove studs and remove
wheel arch extension.
17.Remove bolt securing inner and outer wing to
chassis.
18.Remove nut and bolt securing support stay to
wing.
19.Remove 4 bolts securing wing to’A’post.
20.Remove bolt securing wing to bulkhead.
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76CHASSIS AND BODY
6
REPAIR
21.Disconnect headlamp, side lamp, repeater and
indicator multiplugs.
22.With assistance, remove wing.
23.Remove bolt, remove grille support bracket.
24.Remove 4 screws securing side and indicator
lamps.
25.Remove 2 screws securing headlamp finisher to
wing, remove finisher.
26.Remove 4 screws and remove headlamp from
wing, collect sealing ring.
27.Release side repeater lamp from wing.
28.Remove bonnet cable grommet.
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CHASSIS AND BODY
7
REPAIR Refit
29.Fit bonnet cable grommet.
30.Fit side repeater lamp to wing.
31.Fit headlamp sealing ring, fit headlamp and
tighten screws.
32.Fit headlamp finisher, side and indicator lamps
and tighten screws.
33.Fit grille support bracket and tighten bolt.
34.With assistance, position and align wing to body
and locate bonnet cable to wing.
35.Connect headlamp, indicator, side lamp and side
repeater lamp multiplugs.
36.Fit bolt securing wing to bulkhead.
37.Fit bolts securing wing to’A’post.
38.Fit nut and bolt securing support stay to wing.
39.Fit bolt securing inner and outer wing to chassis.
40.Fit bolts securing radiator bracket to wing.
41.Fit bolts securing outer wing to inner wing.
42.Align wing and finally tighten all bolts.
43.Position wheel arch extension to wing, and fit
securing studs.
44.Position PAS reservoir to wing and tighten bolts.
45.Position expansion tank pipe and secure with
studs.
46.Position EGR solenoid and tighten bolts.
47.Position heater air intake seal and fit air intake.
48.Fit heater air intake bracket and tighten bolts.
49.Fit heater air intake grille and tighten screws.
50.Align air cleaner intake elbow, tighten screws
and fit grille.
51.Fit wheel arch liner.See this Section.
52.Position bonnet release cable to lock and tighten
screw.
53.Fit cooling fan cowl.
54.Fit front grille.See this Section.STEP - FOLDING - REAR DOOR
Service repair no - 76.10.41
Remove
1.Remove 2 bolts securing step to chassis
member, remove step and collect spacers.
Refit
2.Position step, fit spacer washers and tighten
bolts.
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PANEL REPAIRS
1
INFORMATION BODY REPAIRS
Body shells are of riveted, bolted and welded
construction and are bolted to the chassis frame.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
The panel repairs shown in this section are all based
on a 110 Station Wagon. Therefore all illustrations
and text relate only to this model. Although certain
areas of the vehicle, such as the front end, are
relevant to all models.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring.
Where this is necessary use the relevant section in
this manual.
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
Front suspension upper damper
mountings.
Front suspension or sub frame mountings.
Engine mountings on RH and LH chassis
longitudinals.
Rear suspension upper damper mountings.
Rear suspension mountings or lower
pivots.
Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
Inner holes in crossmember - side - main
floor.
Holes in valance front assembly.
Body to chassis mounting holes.
Holes in rear floor.
Holes in rear lower panels or extension
rear floor.
Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can be checked by offering up an undamaged
component as a gauge and also by measuring known
dimensions.See BODY DIMENSIONS section.
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