oil level LAND ROVER DEFENDER 1999 Workshop Manual

04GENERAL SPECIFICATION DATA
6
INFORMATION SUSPENSION
Type Coil springs controlled by telescopic dampers front.................................................................................
and rear.
Front Transverse location of axle by Panhard rod, and fore.................................................................................
and aft location by two radius arms. Anti-roll bar fitted
as standard on 90 models with 265/75 tyres and 130
models.
Rear Fore and aft movement inhibited by two tubular trailing.................................................................................
links. Lateral location of axle by a centrally positioned
’A’frame, upperlink assembly, bolted at the apex to a
ball joint mounting. Anti-roll bar fitted as standard on
90 models with 265/75 tyres, 110 models with self
levelling unit, and 130 models.
ROAD SPRING DATA
90 (2400 Kg) Part No. Colour Code
Front - Driver’s side NRC 9446 Blue/green
Front - Passenger side NRC 9447 Blue/yellow
Rear - Driver’s side NRC 9448 Blue/red
Rear - Passenger side NRC 9449 Yellow/white
90 (2550 Kg)
Front - Driver’s side NRC 9446 Blue/green
Front - passenger side NRC 9447 Blue/yellow
Rear - Driver’s side NRC 9462 Green/yellow/red
Rear - Passenger side NRC 9463 Green/yellow/white
110 (3050 Kg)
Front - both sides NRC 8045 Yellow/yellow
Rear - both sides NRC 6904 Red/green
110 Levelled (2950 Kg)
Front - both sides NRC 8045 Yellow/yellow
Rear - both sides NRC 7000 Green/white
110 (3400 Kg)
Front - both sides NRC 8045 Yellow/yellow
Rear - both sides NRC 6904 Red/green
Rear helper springs - both sides RRC 3266 No colour code
110 (3600 Kg)
Front - Driver’s side NRC 9448 Blue/red
Front - passenger side NRC 9449 Yellow/white
Rear - both sides NRC 6904 Red/green
Rear helper springs - both sides RRC 3226 No colour code
130 (3500 Kg)
Front - driver’s side NRC 9448 Blue/red
Front - passenger side NRC 9449 Yellow/white
Rear - driver’s side NRC 6389 Red/red
Rear - passenger side NRC 6904 Red/green
Front/rear helper springs - both sides RRC 3266 No colour code
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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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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.
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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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10MAINTENANCE
12
MAINTENANCE AUXILIARY DRIVE BELT
Check
1.Check auxiliary drive belt for signs of splits,
fraying, oil contamination and wear.
NOTE: Any requirement to replace the
auxiliary drive belt should be advised to
the customer as this will incur additional
labour and/or material cost and should not be
carried out without the authorisation of the
customer.
Renew
1.Renew auxiliary drive belt.See ELECTRICAL,
Repair.
NOTE: Additional time is built into the
96,000/8 year service time to allow for
auxiliary drive belt renewal.PAS FLUID, CLUTCH FLUID AND SCREEN
WASHER LEVELS
PAS Fluid
1.Clean arear around PAS reservoir filler cap, and
remove cap.
2.Check fluid level in PAS reservoir.
3.Top-up if necessary to the correct level using
recommended fluid.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
4.Fit filler cap.
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10MAINTENANCE
16
MAINTENANCE TRANSFER BOX OIL
WARNING: Avoid excessive skin contact
with mineral oil. Mineral oils remove the
natural fats from the skin, leading to
dryness, irritation and dermatitis.
Check
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of oil filler/level
plug hole.
5.Remove all traces of sealant from threads of oil
filler/level plug.
6.Apply Loctite 290 to threads of oil filler/level plug
and tighten to25 Nm (18 lbf.ft).
7.Remove all traces of oil from main casing.
8.Fit underbelly panel.See CHASSIS AND
BODY, Repair.Renew
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Place a suitable container beneath transfer box
to catch any fluid spillage.
3.Clean area around oil filler/level and drain plugs.
4.Remove oil filler/level plug.
5.Remove oil drain plug.
6.Allow oil to drain.
7.Apply Loctite 290 to threads of oil drain plug.
8.Fit transfer box drain plug and tighten to30 Nm
(22 lbf.ft).
9.Fill transfer box with recommended oil to bottom
of oil filler/level plug hole.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
10.Remove all traces of sealant from threads of oil
filler/level plug.
11.Apply Loctite 290 to threads of oil filler/level plug
and tighten to25 Nm (18 lbf.ft).
12.Remove all traces of oil from main casing.
13.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
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MAINTENANCE
17
MAINTENANCE FRONT AND REAR AXLE OIL
Renew
A- Front and rear axle, 90 models, front, 110/130
models.
B- Rear axle, 110/130 models.
WARNING: Avoid excessive skin contact
with used axle oil. Used axle oil contains
potentially harmful contaminants which
may cause skin cancer or other serious skin
disorders.1.Ensure vehicle is level and place suitable tray
under axle to be drained.
2.Using 13mm square drive wrench, remove drain
and filler/level plugs from axle and allow oil to
drain completely.
3.Clean and refit drain plug.
4.Inject new oil, until it runs out from filler/level
hole. Allow excess oil to drain and wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
5.Clean and refit filler/level plug.
Check
1.Ensure vehicle is level.
2.Using 13 mm square drive wrench, remove
filler/level plug.
3.If necessary inject new oiluntil oil runs out from
filler/level hole. Allow excess oil to drain and
wipe clean.See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
4.Clean and refit filler/level plug.
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ENGINE
33
DESCRIPTION AND OPERATION 1.Oil squirt jets (5 off)
2.Main oil delivery gallery
3.Inflow from oil cooler housing
4.Flow to oil cooler / filters (from oil pump via cylinder block)
5.Sump
6.Oil pick-up pipe
7.Flow from oil pump (relief-valve in housing)
8.Oil pump
9.Cross-drilling supply to main and crankshaft bearings
10.To cylinder head
Oil from the sump is drawn up through a two-piece plastic pick-up which contains a mesh to siphon any relatively
large pieces of material which could cause damage to the pump. The head of the pick-up is centrally immersed in
the sump oil and oil is delivered to the inlet side of the eccentric rotor pump through a gallery in the stiffener plate.
Pressurised oil from the pump is passed through to the cylinder block where it is delivered to the centrifuge filter
and full-flow filter via a port in the RH cylinder block which interfaces with a port in the centre gallery of the oil
cooler housing. The oil pump contains an oil pressure relief valve which opens to allow oil to be recirculated back
around the pump if the oil pressure increases to a high enough level.
10% of the oil flow from the pump is diverted through the centrifuge filter and returned to the sump via the
centrifuge filter drain tube. The remaining 90% of the oil passes through the standard full-flow filter to the main oil
gallery in the cylinder block.
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ENGINE
35
DESCRIPTION AND OPERATION 1.To cylinder block main gallery (from rear of oil cooler housing)
2.Oil cooler housing
3.Oil pressure switch
4.Full-flow filter
5.Centrifuge filter
6.Return to sump
7.Flow from oil pump (via cylinder block)
8.Oil cooler matrix
When the engine temperature is below 74°C, the thermostat in the full-flow filter adaptor housing is closed and a
proportion of the oil flow to the main oil gallery is diverted to the oil cooler to supply an oil feed to the turbocharger
bearings. Oil passes through the oil cooler to the front gallery in the oil cooler housing where there is a tapping to
connect the feed pipe to the turbocharger. Oil used by the turbocharger bearings is returned to the sump through
an oil drain pipe which connects to a port in the LH side of the cylinder block.
The remainder of the oil flow leaving the full-flow filter outlet is passed into the cylinder block via a port at the rear
of oil cooler rear gallery.
When the oil temperature rises above 74°C the thermostat in the full-flow filter housing begins to open to allow a
proportion of the oil from the full-flow filter to pass through the oil cooler before it reaches the main oil gallery in the
cylinder block. In this instance, oil supply to the turbocharger bearings is fed directly from the full-flow filter without
first passing through the oil cooler. Between 74°C and 88°C the thermostat valve plunger opens by about 9 mm
(0.3 in) to allow proportionally more oil to flow through the oil cooler before being passed to the cylinder block main
oil delivery gallery. Above 88°C the thermostat valve continues to open by about 1mm (0.03 in) for every 10°C
increase in temperature until the valve is fully open, when all the oil flow to the cylinder block is forced to pass to
the cylinder block via the oil cooler.
An oil pressure switch is located in a port in the rear gallery of the oil cooler housing to sense the oil pressure level
before flow enters the main oil gallery in the engine block. A warning lamp in the instrument cluster is switched on
if the oil pressure is detected as being too low.
Drillings from the cylinder block main oil gallery direct oil to the crankshaft main bearings and cross drillings in the
crankshaft direct oil to the big-end bearings. An additional five drillings in the cylinder block supply oil at reduced
pressure to the oil squirt jets for piston cooling and gudgeon pin lubrication.
Oil supply from the cylinder block is then passed to the cylinder head galleries through a non-return valve which is
included as an integral item in the lower face of the cylinder head.
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