light LAND ROVER DEFENDER 1999 Workshop Manual

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.
ProCarManuals.com

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.................................................................
ProCarManuals.com

GENERAL SPECIFICATION DATA
9
INFORMATION BULBS
REPLACEMENT BULBS TYPE
Headlamps 12V 60/55W Halogen
Front side lamps 12V 5W
Side repeater lamps 12V 5W
Tail lamps 12V 21W
Cente High Mounted Stop Lamp 12V 21W
Direction indicator lamps 12V 21W
Number plate lamp 12V 4W
Reverse lamp 12V 21W
Rear fog guard lamp 12V 21W
Interior roof lamps 12V 10W
Instrument illumination 12V 1.2W
Warning light panel 12V 1.2W
Hazard warning switch 12V 1.2W
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.
ProCarManuals.com

07GENERAL FITTING REMINDERS
2
INFORMATION PREPARATION
1.Clean components and surrounding area prior to
removal.
2.Blank off any openings exposed by component
removal using greaseproof paper and masking
tape.
3.Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4.Close open ends of oilways, exposed by
component removal, with tapered hardwood
plugs or readily visible plastic plugs.
5.Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
6.Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7.Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1.Observe scrupulous cleanliness when
dismantling components, particularly when
brake, fuel or hydraulic system parts are being
worked on. A particle of dirt or a cloth fragment
could cause a dangerous malfunction if trapped
in these systems.
2.Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed.
3.Use marking ink to identify mating parts, to
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
4.Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
5.Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
6.Do not discard a part due for renewal until it has
been compared with the new part, to ensure that
its correct replacement has been obtained.INSPECTION-GENERAL
1.Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an incipient
failure.
2.When a component is to be checked
dimensionally against figures quoted for it, use
correct equipment (surface plates, micrometers,
dial gauges, etc.) in serviceable condition.
Makeshift checking equipment can be
dangerous.
3.Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension
is exactly limit size, and is otherwise satisfactory.
4.Use’Plastigauge’12 Type PG-1 for checking
bearing surface clearances. Directions for its
use, and a scale giving bearing clearances in
0,0025 mm steps are provided with it.
ProCarManuals.com

GENERAL FITTING REMINDERS
7
INFORMATION COTTER PINS
1.Fit new cotter pins throughout when replacing
any unit.
2.Always fit cotter pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a cotter pin.
3.All cotter pins should be fitted as shown unless
otherwise stated.
NUTS
1.When tightening a slotted or castellated nut
never loosen it to insert cotter pin or locking wire
except in those recommended cases where this
forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should
be selected, or washer thickness reduced.
2.Where self-locking nuts have been removed it is
advisable to replace them with new ones of the
same type.
NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.
LOCKING WIRE
1.Fit new locking wire of the correct type for all
assemblies incorporating it.
2.Arrange wire so that its tension tends to tighten
the bolt heads, or nuts, to which it is fitted.SCREW THREADS
1.Both UNF and Metric threads to ISO standards
are used. See below for thread identification.
2.Damaged threads must always be discarded.
Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and
is not recommended.
3.Always ensure that replacement bolts are at
least equal in strength to those replaced.
4.Do not allow oil, grease or jointing compound to
enter blind threaded holes. The hydraulic action
on screwing in the bolt or stud could split the
housing.
5.Always tighten a nut or bolt to the recommended
torque value. Damaged or corroded threads can
affect the torque reading.
6.To check or re-tighten a bolt or screw to a
specified torque value first loosen a quarter of a
turn, then re-tighten to the correct value.
7.Oil thread lightly before tightening to ensure a
free running thread, except in the case of
threads treated with sealant/lubricant, and
self-locking nuts.
UNIFIED THREAD IDENTIFICATION
1. Bolts
A circular recess is stamped in the upper surface
of the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter
for a short length at its extremity.
ProCarManuals.com

10MAINTENANCE
2
MAINTENANCE SEATS AND SEAT BELTS
1.Check seat frames are secured to floor and
show no signs of movement.
2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Check tightness of accessible seat fixings.
4.Fully extract seat belt and allow it to return under
its own recoil mechanism.
5.Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for all belts.
6.Check security of seat belt upper mountings.
7.Check security of seat belt buckle mountings.
8.Connect each belt to the correct buckle, check
seat belt buckle and tongue are secure. Release
seat belt buckle and check for correct operation.
9.Check tightness of accessible seat belt
mountingsLAMPS, HORNS AND WARNING INDICATORS
1.Switch on side, head and tail lights and check
operation.
2.Check headlamp dim/dip operation.
3.Check headlamp levelling operation.
4.Check turn signals and hazard warning lights
operation.
5.Press brake pedal and check operation of brake
lights.
6.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to head lamp
lenses for signs of stone chips or damage.
7.Check horn for loud clear sound.
8.Check operation of all instrument pack warning
and indicator lights.
9.Check for correct operation of interior courtesy
lights.
ProCarManuals.com

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.
ProCarManuals.com

12ENGINE
14
DESCRIPTION AND OPERATION Connecting rods
1.Small-end oil holes
2.Small-end bushing3.Connecting rod
4.Serrated fracture
The connecting rods are machined, H-section steel forgings which feature a fracture-split at the big-end between
the connecting rod and the bearing cap. The connecting rod features a serrated fracture across the big-end at
right angles to the length of the connecting rod, this forms a unique mating surface between the connecting rod
and the fractured end which is used as the big-end cap. The use of a fracture split in the big-end of the connecting
rod ensures a perfect match for assembly on the crankshaft bearing journals and provides the connecting rod with
strong resistance to lateral movement.
The end-cap fixing bolts are offset to ensure that the cap is fitted to the connecting rod in the correct orientation. If
the end-cap is fitted incorrectly and the end-cap bolts tightened, the connecting rod must be replaced, since the
matching serrations will have been damaged.
The big-end bearing shells are plain split halves without location tags. On EU2 vehicles the two halves of the
bearing shells are of different construction. The upper half bearing shell fitted to the connecting rod is treated
using the sputtering process to improve its resistance to wear. The connecting rod bearing shell can be identified
by having a slighter darker colouration than the big-end bearing cap shell, and the back face of the connecting rod
bearing shell has a shinier finish than the front face.
On EU3 vehicles both bearing shells are of the same construction as the connecting rod bearing shell.
The small-end of the connecting rod has a bushed solid eye which is free to move on the gudgeon pin, the
bushing is a hand push, interference fit. The steel bushing has two slots machined in its upper surface for
providing oil lubrication to the moving surface of the gudgeon pin. The oil slots must be correctly aligned to the oil
slots provided in the small end of the connecting rod. The small-end lubrication is supplied by squirt feed from the
piston lubrication jets.
ProCarManuals.com

ENGINE
21
DESCRIPTION AND OPERATION Oil pressure switch
The oil pressure switch is located in a port on the outlet side of the oil cooler housing. It detects when a safe
operating pressure has been reached during engine starting and initiates the illumination of a warning light in the
instrument pack if the pressure drops below a given value.
ProCarManuals.com

12ENGINE
2
REPAIR
13.Position camshaft in camshaft carrier.
14.Check end-float of camshaft using a DTI.
Camshaft end-float = 0.06 to 0.16 mm (0.002 to
0.006in).
15.Renew components as necessary to achieve
correct end-float.
CAUTION: Cylinder head and camshaft
carrier are machined together as an
assembly. If bearing surfaces in either
component are found to be damaged, complete
assembly must be replaced.
NOTE: The procedure for checking
camshaft bearing clearances is covered in
Td5 Engine Overhaul section - Cylinder
head - overhaul.Refit
16.Using a suitable cleaning solvent, clean mating
faces of cylinder head and camshaft carrier.
17.Blow out all oilways and waterways.
18.Ensure threaded holes in cylinder head and
camshaft carrier are clean and dry.
CAUTION: Support each end of the
cylinder head on blocks of wood. With
camshaft carrier bolted down some valves
and the injector nozzles will protrude from the
face of cylinder head.
19.Fit new adjusting screws fully into rocker arms.
Fit new lock nuts to screws but do tighten.
CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P
to 19P have a centre punch mark adjacent to the
adjusting screw slot. These screws are not
interchangeable with those fitted to Engine Serial
No. Prefixes 10P to 14P.
20.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with clean engine oil.
21.Position camshaft in cylinder head with the
timing pin hole in the vertical position.
22.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face as shown and
spread to an even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate
camshaft bearings. Assembly and bolt
tightening must be completed within 20 minutes
of applying sealant.
23.Fit camshaft carrier ensuring that it is correctly
located on dowels.
24.Fit and lightly tighten camshaft carrier bolts.
ProCarManuals.com