engine oil LAND ROVER DEFENDER 1999 Workshop Manual

01 - INTRODUCTION
CONTENTS
Page
INFORMATION
INTRODUCTION 1..................................................................................................
DIMENSIONS 1.......................................................................................................
REFERENCES 1.....................................................................................................
REPAIRS AND REPLACEMENTS 1.......................................................................
POISONOUS SUBSTANCES 1..............................................................................
FUEL HANDLING PRECAUTIONS 2......................................................................
SYNTHETIC RUBBER 3.........................................................................................
RECOMMENDED SEALANTS 3.............................................................................
USED ENGINE OIL 3..............................................................................................
ACCESSORIES AND CONVERSIONS 4...............................................................
WHEELS AND TYRES 4.........................................................................................
STEAM CLEANING 4..............................................................................................
SPECIFICATION 4..................................................................................................
SPECIAL SERVICE TOOLS 4................................................................................
JACKING 5..............................................................................................................
HYDRAULIC VEHICLE RAMP (FOUR POST) 6.....................................................
TWO POST VEHICLE RAMPS 6............................................................................
DYNAMOMETER TESTING 6................................................................................
TOWING 7..............................................................................................................
TRANSPORTING THE VEHICLE BY TRAILER 7..................................................
JUMP STARTING 8................................................................................................
ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL 9.............................
CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY 10....................
VEHICLE IDENTIFICATION NUMBER (VIN) 11.....................................................
LOCATION OF IDENTIFICATION NUMBERS 12...................................................
FAULT DIAGNOSTIC EQUIPMENT 13..................................................................
READING THIS SUPPLEMENT 14........................................................................
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INTRODUCTION
3
INFORMATION SYNTHETIC RUBBER
Many’0’ring seals, flexible pipes and other similar
items which appear to be natural rubber are made of
synthetic materials called Fluoroelastomers. Under
normal operating conditions this material is safe, and
does not present a health hazard. However, if the
material is damaged by fire or excessive heat, it can
break down and produce highly corrosive Hydrofluoric
acid which can cause serious burns on contact with
skin. Should the material be in a burnt or overheated
condition handle only with seamless industrial gloves.
Decontaminate and dispose of the gloves immediately
after use.
If skin contact does occur, remove any contaminated
clothing immediately and obtain medical assistance
without delay. In the meantime, wash the affected
area with copious amounts of cold water or limewater
for fifteen to sixty minutes.
RECOMMENDED SEALANTS
A number of branded products are recommended in
this manual for use during maintenance and repair
work.
These items include:
HYLOMAR GASKET AND JOINTING COMPOUND
and
HYLOSIL RTV SILICONE COMPOUND.
They should be available locally from garage
equipment suppliers. If there is any problem obtaining
supplies, contact the following company for advice
and the address of the nearest supplier.
MARSTON LUBRICANTS LTD.
Hylo House,
Cale Lane,
New Springs,
Wigan WN2 1JR
Tel 01942 824242USED ENGINE OIL
WARNING: Prolonged and repeated
contact with engine or motor oil will result
in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
Used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities should be provided.
Handling precautions
1.Avoid prolonged and repeated contact with oils,
particularly used engine oils.
2.Wear protective clothing, including impervious
gloves where applicable.
3.Do not put oily rags in pockets.
4.Avoid contaminating clothes, particularly
underwear, with oil.
5.Overalls must be cleaned regularly. Discard
unwashable clothing and oil impregnated
footwear.
6.First aid treatment must be obtained immediately
for open cuts and wounds.
7.Use barrier creams, before each work period, to
help the removal of oil from the skin.
8.Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.
9.Do not use gasoline, kerosene, diesel fuel,
petrol, thinners or solvents for washing the skin.
10.If skin disorders develop, obtain medical advice.
11.Where practicable, degrease components prior
to handling.
12.Where there is a risk of eye contact, eye
protection should be worn, for example, goggles
or face shields; in addition an eye wash facility
should be provided.
Disposing of used oils
Environmental protection precaution
It is illegal to pour used oil onto the ground, down
sewers or drains, or into waterways.
Dispose of used oil through authorised waste disposal
contractors. If in doubt contact your Local Authority for
advice on disposal facilities.
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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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GENERAL SPECIFICATION DATA
1
INFORMATION ENGINE - Td5
Type 2.5 litre in-line direct injection Diesel, turbocharged.................................................................................
and intercooled
Number of cylinders 5 in-line, No. 1 cylinder at front of engine.........................................................
Bore 84.450 mm (3.3248 in).................................................................................
Stroke 88.950 mm (3.5020 in)...............................................................................
Capacity 2498 cm
3(152.5 in3) ...........................................................................
Firing order 1 - 2 - 4 - 5 - 3.......................................................................
Compression ratio 19.5:1............................................................
Direction of rotation Clockwise viewed from the front of the engine...........................................................
Dimensions
Length 766 mm (30.1 in).....................................................................
Width 708 mm (27.8 in).......................................................................
Height 788 mm (31.0 in)......................................................................
Emissions standard :-
Engine Serial No. Prefixes 10P to 14P - EU2 Model ECD 2........
Engine Serial No. Prefixes 15P to 19P - EU3 Model ECD 3........
Lubrication
Type Wet sump, pressure fed.................................................................................
Pump type Eccentric rotor, crankshaft driven integral with stiffener........................................................................
plate.
Filter type:
Primary Centrifuge filter....................................................................
Secondary Disposable canister with full flow by-pass...............................................................
Pressure at idle (cold) 3.0 bar (43.5 lbf.in
2) ......................................................
Pressure at 3500 rev/min (hot) 1.5 - 3.0 bar (21.75 - 43.5 lbf.in2) .........................................
Relief valve opening pressure 4.0 bar (58 lbf.in2) ..........................................
Low oil pressure switch opening pressure 0.2 - 0.6 bar (3.0 - 8.8 lbf.in2) .......................
Crankshaft
Main bearing journal diameter 61.9875 - 62.0125 mm..........................................
Crankpin journal diameter 53.99 - 54.01 mm................................................
Crankshaft end float 0.020 - 0.250 mm.........................................................
Main bearings
Number and type 6 half shells (5 main, 1 thrust)..............................................................
Pistons
Type Graphite compound skirt with combustion chamber in.................................................................................
crown.
Clearance in cylinder bore 0.172 - 0.206 mm (measured at bottom of skirt, 90°to ...............................................
gudgeon pin)
Diameter 84.270 - 85.254 mm (measured 90°to gudgeon pin, ..........................................................................
and 40.00 mm from bottom of skirt.)
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GENERAL FITTING REMINDERS
5
INFORMATION JOINTS AND JOINT FACES
1.Always use correct gaskets where they are
specified.
2.Use jointing compound only when
recommended. Otherwise fit joints dry.
3.When jointing compound is used, apply in a thin
uniform film to metal surfaces; take great care to
prevent it from entering oilways, pipes or blind
tapped holes.
4.Remove all traces of old jointing materials prior
to reassembly. Do not use a tool which could
damage joint faces.
5.Inspect joint faces for scratches or burrs and
remove with a fine file or oil stone; do not allow
removed material or dirt to enter tapped holes or
enclosed parts.
6.Blow out any pipes, channels or crevices with
compressed air, fit new’O’rings or seals
displaced by air blast.FLEXIBLE HYDRAULIC PIPES, HOSES
1.Before removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
2.Obtain appropriate plugs or caps before
detaching hose end fittings, so that ports can be
immediately covered to exclude dirt.
3.Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any hose found faulty.
4.When refitting hose, ensure that no unnecessary
bends are introduced, and that hose is not
twisted before or during tightening of union nuts.
5.Containers for hydraulic fluid must be kept
absolutely clean.
6.Do not store brake fluid in an unsealed
container. It will absorb water, and fluid in this
condition would be dangerous to use due to a
lowering of its boiling point.
7.Do not allow brake fluid to be contaminated with
mineral oil, or use a container which has
previously contained mineral oil.
8.Do not re-use brake fluid bled from system.
9.Always use clean brake fluid to clean hydraulic
components.
10.Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of dirt.
11.Absolute cleanliness must be observed with
hydraulic components at all times.
12.After any work on hydraulic systems, inspect
carefully for leaks underneath the vehicle while a
second operator applies maximum pressure to
the brakes (engine running) and operates the
steering.
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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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LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Pints
Engine sump oil - Td5 7.20...................................................... 12.67
Extra when refilling after fitting new filter 1.00.......................... 1.76
Manual gearbox 2.38............................................................... 4.19
Transfer gearbox oil 2.30......................................................... 4.00
Front differential 1.70............................................................... 3.00
Rear differential
90 Models 1.70............................................................... 3.00
110 Models 2.26............................................................. 4.00
Power steering box and reservoir LHD 2.90............................ 5.00
Power steering box and reservoir RHD 3.40............................ 6.00
Swivel pin housing oil/grease (each) 0.35................................ 0.60
Fuel tank usable fuel
90 Models 60.00............................................................... 13.20 gall
110 & 130 Models 75.00................................................... 16.50 gall
Cooling system - Td5 13.00....................................................... 22.88
Washer bottle 3,0................................................................... 5.28
NOTE: * All levels must be checked by dipstick or level plugs as applicable.
ANTI-FREEZE
PERCENTAGE CONCENTRATION - 50%
PROTECTION - LOWER TEMPERATURE LIMIT
Complete protection
Vehicle may be driven away immediately from cold,
-33°C (-36°F).
Safe limit protection
Coolant in semi-frozen state. Engine may be started
and driven away after warm-up period, -41°C (-42°
F).
Lower protection
Prevents frost damage to cylinder head, block and
radiator. Thaw out before starting engine, -47°C (-53°
F).
CAUTION: Anti-freeze content must never
be allowed to fall below 50% otherwise
damage to the engine is liable to occur.
Also, anti-freeze content should not exceed 60%
as this will greatly reduce the cooling effect of the
coolant.RECOMMENDED FUEL
Diesel fuel oil, distillate, diesel fuel, automotive gas or
Derv to British standard 2869, Class A1 or A2
Using diesel fuel with a class rating lower than stated
above could seriously impair vehicle performance.
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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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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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MAINTENANCE
9
MAINTENANCE INTERCOOLER / COOLING SYSTEM
1.Visually check for any obstructions in the
radiator and intercooler matrix and remove
debris as necessary.
2.Visually check fan blades for damage.
3.Check cooling, intercooler and heating systems
for leaks, hoses and oil pipes for security and
condition.
4.Check accessible hose clips for tightness.
5.Check coolant level, top-up if necessary
Cooling System Top-Up
1.With engine cold, remove expansion tank filler
cap.
2.Top-up with recommended mixture of coolant
until level reaches mark on expansion tank.
3.Fit expansion tank filler cap.
Intercooler Flush
1.Remove intercooler.See FUEL SYSTEM,
Repair.
2.Flush intercooler element using Unicorn
Chemicals’C’Solve following the manufaturers
instructions.
3.Thoroughly dry intercooler ensuring that no trace
of solvent remains in the element.
4.Refit intercooler.See FUEL SYSTEM, Repair.AMBIENT AIR PRESSURE (AAP) SENSOR - Td5
1.Check ambient air pressure sensor for damage.
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