drain bolt LAND ROVER DEFENDER 1999 Workshop Manual

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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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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ENGINE
13
DESCRIPTION AND OPERATION CYLINDER BLOCK
The cylinders and crankcase are contained in a single cast iron construction. The cylinders are direct bored and
plateau honed with lubrication oil supplied via lubrication jets for piston and gudgeon pin lubrication and cooling. It
is not possible to rebore the cylinder block if the cylinders become worn or damaged. Three metal core plugs are
fitted to the three centre cylinders on the right hand side of the cylinder block.
Lubrication oil is distributed throughout the block via the main oil gallery to critical moving parts through channels
bored in the block which divert oil to the main and big-end bearings via oil holes machined into the crankshaft. Oil
is also supplied from the cylinder block main gallery to the five lubrication jets which cool and lubricate the piston
and gudgeon pins. Plugs are used to seal both ends of the main oil gallery at front and rear of the engine block.
An oil cooler is fitted to the LH side of the engine block; ports in the oil cooler assembly mate with ports in the
cylinder block to facilitate coolant flow. Oil is diverted through the oil cooler, centrifuge filter and full-flow filter
before supplying the main oil gallery. A tapping in the oil filter housing provides a lubrication source for the
turbocharger bearings and an oil pressure switch is included in a tapping in the oil cooler housing which
determines whether sufficient oil pressure is available to provide engine lubrication and cooling.
Cylinder cooling is achieved by water circulating through chambers in the engine block casting. A threaded coolant
jacket plug is located at the front RH side of the cylinder block.
Cast brackets are bolted to both sides of the engine block for mounting the engine to the chassis on the LH and
RH hydramount studs.
The gearbox bolts directly to the engine block; a gearbox shim plate is located between the adjoining faces of the
gearbox and the flywheel side of the engine block and is fixed to the rear of the engine block by two bolts. Two
hollow metal dowels locate the rear of the cylinder block to the shim plate. The gearbox casing provides the
mounting for the starter motor.
A port is included at the rear left hand side of the cylinder block which connects to the turbocharger oil drain pipe
to return lubrication oil to the sump. A plug sealing the lubrication cross-drilling gallery is located at the front right
hand side of the cylinder block and plugs for the main lubrication gallery are located at the front and rear of the
cylinder block. Two plastic dowels are used to locate the cylinder head to the cylinder block and must be replaced
every time the cylinder head is removed from the cylinder block.
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12ENGINE
18
DESCRIPTION AND OPERATION Oil filters
The Td5 engine features two types of oil filter; the main filter is a standard disposable cartridge-type full flow oil
filter which is augmented with a by-pass centrifuge filter used to filter out particulate matter having a smaller
diameter smaller than 15 micron but greater than 3 micron.
1.Centre spindle
2.Spindle oil holes (2 off)
3.Centrifuge filter housing
4.Centrifuge filter drain pipe
5.Port - centrifuge filter drain pipe to sump6.Filter rotor
7.Internal seal
8.Cover
9.Cover screws (2 off)
The centrifuge filter is located on the left hand side of the engine block by the exhaust manifold and is housed in a
pot which is bolted to the oil cooler housing by means of three bolts. The pot contains a rotor located on a central
spindle which spins at up to 15,000 rev/min when oil is flowing through the unit under pressure. The rotor contains
two fine holes drilled at obtuse angles which cause the rotor to spin about the centre spindle when high pressure
oil is passing through it. The inner surface of the rotor captures carbon deposits and small particulate matter as it
is thrown outwards under centrifugal force to form a sludge on the inner walls of the rotor. The unit is able to trap
very fine impurities that build up in the oil that would be too small to filter using the normal paper-element type
full-flow filters alone.
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12ENGINE
22
DESCRIPTION AND OPERATION CRANKSHAFT, SUMP AND OIL PUMP
The crankshaft, sump and oil pump components are described below:
Sump
The sump is a wet-type, of aluminium construction and is sealed to the engine block by means of a rubber gasket
and twenty fixing bolts. The four bolts at the gearbox end of the sump are longer than the other sixteen bolts.
The sump gasket incorporates compression limiters (integrated metal sleeves) at the bolt holes, which are
included to prevent distortion of the gasket when the sump to cylinder block bolts are being tightened.
An oil drain plug is fitted at the bottom of the oil sump reservoir. An oil return drain pipe is also attached to the oil
sump which returns oil from the centrifugal filter.
Stiffener Plate
The stiffener plate assembly provides lower engine block rigidity and utilises dowels to align it to the bottom of the
cylinder block. A rotary oil pump is integral with the stiffener plate and an oil pick-up and strainer assembly is fitted
to the underside of the stiffener plate. The stiffener and oil pump assembly is secured to the cylinder block by 22
bolts.
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12ENGINE
26
DESCRIPTION AND OPERATION Fuel connector block
Type A - Non EU3 Models - Engine Serial No. Prefixes 10P to 14P
Type B - EU3 Models - Engine Serial No. Prefixes 15P to 19P
1.Fuel connector block assembly
2.Outlet stub pipe
3.Stub pipe - to fuel cooler4.Fuel temperature sensor
5.Fuel pressure regulator
6.Spill return fuel connection (EU3 models only)
A cast and machined aluminium alloy fuel connector block assembly is located at the rear RH side of the cylinder
head, attached by three flanged bolts. A metal gasket is used to seal the faces between the fuel connector block
and the cylinder head, which must be replaced every time the fuel connector block is removed.
CAUTION: The cylinder head incorporates drillings for the fuel injection system, any
contamination which enters these drillings could cause engine running problems or injector
failure. It is therefore, essential that absolute cleanliness is maintained when carrying out work on
the cylinder head.
CAUTION: The valve heads, tips of the injectors and glow plugs protrude below the face of the
cylinder head and will be damaged if the cylinder head is stored face down.
Camshaft carrier
The cast aluminium alloy camshaft carrier is bolted to the cylinder head by thirteen screws. The camshaft carrier
and cylinder head assembly is attached to the cylinder block by twelve cylinder head retaining bolts which pass
through the camshaft carrier and the cylinder head to secure the assembly to the cylinder block.
The carrier is machined together with the cylinder head to form a matched pair for carrying the camshaft.
Non-return valve
A non-return valve is located at the front, bottom LH side of the cylinder head. The non-return valve prevents oil
from draining from the lash adjusters and is an integral component within the cylinder head and is
non-serviceable.
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12ENGINE
30
DESCRIPTION AND OPERATION CAMSHAFT COVER COMPONENTS
The camshaft cover cover components are described below:
Camshaft cover
The camshaft cover is cast from aluminium alloy and is fixed to the camshaft carrier / cylinder head assembly by
thirteen bolts. The cover has spacers and sealing washers inserted into each of the thirteen bolt holes.
A breather hose is connected to a port at the top of the camshaft cover by means of a hose clip which vents
crankcase gases back to the air intake via a breather valve in the air intake tract, located forward of the
turbocharger in the flexible air intake duct.
A rubber seal is fitted between the camshaft cover and camshaft carrier.
An oil filler aperture is included in the top of the camshaft cover, which is sealed with a plastic cap with integral
rubber seal.
CAMSHAFT TIMING CHAIN COMPONENTS
The timing chain cover and timing chain components are described below:
Timing chain cover
The timing chain cover is cast and machined aluminium alloy and is attached to the cylinder head by a bolt at the
RH top of the cover and by a stud and nut at the LH top of the cover. Eight screws are used to attach the timing
chain cover to the front of the engine block. The timing cover is located to the cylinder block front face by two
dowels.
A viscous fan is attached to an idler pulley at the front of the engine block. The fan bearing is located on a shaft
and held in place by a circlip and a bearing flange, the inner race of the fan bearing is an interference fit on the
shaft. The fan idler pulley is attached to the bearing hub by three bolts and the fan itself is secured to the pulley
and bearing shaft by a left-hand threaded nut.
The front of the crankshaft passes through a hole in the lower part of the timing cover. An oil seal is pressed into a
recess in the front of the timing cover to seal the interface between the front of the crankshaft and the timing
cover.
A stub pipe is fitted to the front RH side of the timing cover which is used to attach the oil drain pipe from the
vacuum pump by means of a hose and spring clip.
Timing chains
The timing chain between the camshaft and crankshaft sprockets is a duplex type, each chain having 56 links.
The timing chain is contained between a fixed plastic guide and an hydraulically adjustable plastic tensioner arm
which are attached to the front of the engine block.
To cope with the higher injection loads of the EU3 engine, the timing drive between the camshaft and crankshaft
has been upgraded. This requires thicker chain links to be used, therefore the individual pre EU3 and EU3
components are not interchangeable.
To distinguish between the two timing chains the links are different colours. A pre EU3 chain has blue links. An
EU3 chain has bronze links.
The oil pump timing chain is a single type and traverses the oil pump sprocket and the rear crankshaft sprocket.
The timing chains are oil lubricated, with oil being provided by a chain lubrication jet and from oil flow returning
back to the sump from the cylinder head. An oil hole is included at the front left hand side of the cylinder head
which supplies oil from the cylinder head oil galleries.
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12ENGINE
6
REPAIR GASKET - CYLINDER HEAD
Service repair no - 12.29.02
Remove
NOTE: The following procedures cover
engines fitted with or without an EGR
cooler. The EGR cooler is bolted to the
front of the cylinder head.
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain cooling system.See COOLING
SYSTEM, Adjustment.
3.Remove camshaft cover gasket.See this
Section.
4.Remove cooling fan.See COOLING SYSTEM,
Repair.
5.Release clips and disconnect air flow meter from
air filter.
6.Disconnect multiplug from air flow meter.
7.Loosen clip and remove air inlet hose from
turbocharger.
8.Remove 3 bolts and remove exhaust manifold
heat shield.
9.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
10.Remove 3 nuts, release turbocharger from
exhaust manifold, discard gasket and tie
turbocharger aside.
11.Remove 2 bolts securing engine harness to
camshaft carrier.
12.Disconnect fuel injector, coolant and compressor
sensors.
13.Disconnect 4 heater plug connectors.
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12ENGINE
14
REPAIR
9. Not EU3 model:-Apply two 3 mm diameter
beads of sealant, Part No.STC 5433 to areas’A’
shown on illustration.
CAUTION: Excessive use of sealant could
result in blockage of oil drain hole,
arrowed’B’in illustration.
10.Fit new gasket to camshaft cover. fit cover and
tighten bolts to10 Nm (7 lbf.ft).
11.Position breather hose and secure clip.
12.Fit engine acoustic cover.
13.Reconnect battery negative lead.
14.Fit battery cover.ENGINE AND ANCILLARIES
Service repair no - 12.41.01.99
Remove
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain engine oil.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Remove turbocharger.See FUEL SYSTEM,
Repair.
5.Remove starter motor.See ELECTRICAL,
Repair.
6.Remove air filter.See FUEL SYSTEM, Repair.
7.Loosen clip screw and release air intake hose
from intake elbow.
8.Release clips and disconnect coolant hoses
from fuel cooler and coolant rail.
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12ENGINE
26
REPAIR
15.Position oil pump drive sprocket and chain on to
oil pump ensuring that the’D’shape on the drive
sprocket is located on flat on the oil pump drive
shaft.
16.Clean oil pump drive sprocket retaining bolt and
apply Loctite 242 to bolt threads.
17.Fit oil pump drive sprocket retaining bolt and
tighten to25 Nm (18 lbf.ft).
18.Fit new sump gasket.See this Section.GASKET - ENGINE TO SUMP
Service repair no - 12.60.38
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove exhaust front pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
4.Drain engine oil.
5.Loosen 4 bolts securing sump to gearbox bell
housing.
6.Remove 2 bolts securing centrifuge drain pipe to
sump and discard gasket.
7.Using sequence shown and noting their fitted
position, remove 20 bolts securing sump.
8.Remove sump, remove and discard gasket.
CAUTION: Do not lever between sump and
cylinder block.
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