oil filter LAND ROVER DEFENDER 1999 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DEFENDER, Model: LAND ROVER DEFENDER 1999Pages: 667, PDF Size: 8.76 MB
Page 24 of 667
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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Page 56 of 667
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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Page 58 of 667
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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Page 74 of 667
MAINTENANCE
15
MAINTENANCE FULL FLOW OIL FILTER
1.Renew full flow oil filter.See ENGINE , Repair.GEARBOX OIL
WARNING: Avoid excessive skin contact
with used gearbox oil. Used gearbox oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Renew gearbox oil.See MANUAL GEARBOX,
Adjustment.
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Page 84 of 667
12 - ENGINE
CONTENTS
Page
DESCRIPTION AND OPERATION
TD5 ENGINE 1........................................................................................................
GENERAL 12..........................................................................................................
CYLINDER BLOCK 13............................................................................................
CRANKSHAFT, SUMP AND OIL PUMP 22............................................................
CYLINDER HEAD COMPONENTS 25...................................................................
CAMSHAFT COVER COMPONENTS 30...............................................................
CAMSHAFT TIMING CHAIN COMPONENTS 30...................................................
CYLINDER BLOCK FLOW 32.................................................................................
OIL COOLER / FILTER FLOW 34...........................................................................
CYLINDER HEAD FLOW 36...................................................................................
ADJUSTMENT
ENGINE OIL PRESSURE CHECK 1......................................................................
REPAIR
CAMSHAFT 1.........................................................................................................
PULLEY - CRANKSHAFT 3....................................................................................
OIL SEAL - CRANKSHAFT - REAR 4.....................................................................
BEARING - SPIGOT - CRANKSHAFT 5.................................................................
GASKET - CYLINDER HEAD 6..............................................................................
ROCKER SHAFT ASSEMBLY 11...........................................................................
GASKET - COVER - CAMSHAFT 13......................................................................
ENGINE AND ANCILLARIES 14.............................................................................
MOUNTING - FRONT - LH 19................................................................................
MOUNTING - FRONT - RH 20................................................................................
MOUNTING - GEARBOX - REAR - LH 21..............................................................
MOUNTING - GEARBOX - REAR - RH 22.............................................................
FLYWHEEL 22........................................................................................................
FILTER - OIL 23......................................................................................................
STRAINER - OIL PICK-UP 24.................................................................................
PUMP - OIL 24........................................................................................................
GASKET - ENGINE TO SUMP 26..........................................................................
SWITCH - OIL PRESSURE 28...............................................................................
VALVE - RELIEF - OIL PRESSURE 29..................................................................
COOLER - ENGINE OIL 29....................................................................................
CENTRIFUGE ASSEMBLY 30................................................................................
ROTOR - CENTRIFUGE 32....................................................................................
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Page 88 of 667
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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Page 97 of 667
12ENGINE
12
DESCRIPTION AND OPERATION GENERAL
The Td5 diesel engine is a 2.5 litre, 5 cylinder, in-line direct injection unit having 2 valves per cylinder, operated by
a single overhead camshaft. The engine emissions on pre EU3 models comply with ECD2 (European Commission
Directive) legislative requirements. EU3 models comply with ECD3 legislative requirements. Both units employ
electronic engine management control, positive crankcase ventilation and exhaust gas recirculation to limit the
emission of pollutants. The unit is water cooled and turbo-charged and is controlled by an electronic engine
management system.
The cylinder block is a monobloc cast iron construction with an aluminium stiffening plate fitted to the bottom of the
cylinder block to improve lower structure rigidity. The cylinder head and sump are cast aluminium. An acoustic
cover is fitted over the upper engine to reduce engine generated noise.
The engine utilises the following features:
Electronic Unit Injectors (EUI’s)controlled by an Engine Management System for precise fuel delivery under
all prevailing operating conditions.
Turbochargingwhich delivers compressed air to the combustion chambers via an intercooler for improved
power output.
Fuel Cooler
Oil Cooler
Centrifuge Oil Filter
Hydraulic Lash Adjusterswith independent finger followers
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Page 98 of 667
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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Page 101 of 667
12ENGINE
16
DESCRIPTION AND OPERATION Oil cooler
1.Front oil gallery - full-flow filter to oil cooler matrix
2.Full-flow filter adaptor outlet port to oil cooler
(opens at 74°C)
3.Full-flow filter inlet port
4.Oil cooler housing
5.Full-flow filter outlet port to cylinder block
6.Coolant inlet port
7.Oil cooler banjo bolt seals (2 off)
8.Banjo bolts (2 off)
9.Banjo bolt oil holes - to oil cooler matrix
10.Rear oil gallery - full-flow filter / oil cooler outlet
to cylinder block11.Centre oil gallery - from pump to full-flow filter
12.Inlet port to centrifuge filter
13.Sealing ring - centrifuge filter housing to oil
cooler housing
14.Port - oil cooler matrix
15.Oil cooler matrix
16.Inlet port from pump via cylinder block to oil
cooler housing
17.Outlet port from oil cooler housing to cylinder
block
18.Rear view of oil cooler housing
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Page 102 of 667
ENGINE
17
DESCRIPTION AND OPERATION The engine oil cooler assembly is located on the left hand side of the engine block behind the oil centrifuge and oil
filter. The housing is bolted to the engine block by seven bolts. A matrix is included in the oil cooler housing which
acts as a heat exchanger. Coolant flow circulates through the oil cooler housing under pressure from the coolant
pump and distributes the flow evenly around the matrix fins and then along the block into three core holes for
cylinder cooling. Coolant enters the oil cooler through a pipe with a rubber hose extension at the rear side of the
engine. The coolant hose is attached to the stub pipe of the oil cooler by a spring clip.
Oil, drawn from the sump by the oil pump, passes through the oil cooler via the cylinder block. The flow of coolant
around the exterior surface of the oil cooler matrix cools a proportion of the engine oil flow as it passes through the
oil cooler.
The oil cooler is sealed to the cylinder block by a gasket which must be replaced every time the oil cooler housing
is removed.
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