shaft 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 4 of 667
CONTENTS
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE
17 EMISSION CONTROL
18 ENGINE MANAGEMENT SYSTEM
19 FUEL SYSTEM
26 COOLING SYSTEM
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
47 PROPELLER SHAFTS
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
76 CHASSIS AND BODY
77 PANEL REPAIRS
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
88 INSTRUMENTS
01
04
05
07
09
10
12
17
18
19
26
30
33
37
41
47
57
60
64
70
76
77
82
84
86
88
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INTRODUCTION
1
INFORMATION INTRODUCTION
This Workshop Manual Supplement covers vehicles
from 1999 and 2002 model year onwards. The Body
Repair Manual has also been incorporated into this
supplement. Amendments and additional pages will
be issued, when necessary, to ensure that the
supplement covers latest models.
This Supplement is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover Defender vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system should
be carried out by a Land Rover Dealer. Repairs to
such items should NEVER be attempted by untrained
individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft end of the engine is referred to as the front.
To reduce repetition, some operations covered in this
Supplement do not include reference to testing the
vehicle after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out, particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer’s specification. Torque spanner values
given in the Supplement must be strictly adhered to.
Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during
removal it must be replaced with a new one. Certain
fasteners must not be re-used. These fasteners are
specified in the Supplement.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.
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Page 13 of 667
01INTRODUCTION
6
INFORMATION 3.Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1.Position cup of hydraulic arm under differential
casing.
2.Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3.Lower jack until axle sits securely on axle
stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a’drive on’type ramp which supports vehicle
on its road wheels. If a’wheel-free’condition is
required, use a’drive on’ramp incorporating a
’wheel-free’system providing support beneath axle
casings. Alternatively, place vehicle on a firm, flat floor
and support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using ’Two Post’ ramps
that employ four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.DYNAMOMETER TESTING
The front and rear axles cannot be driven
independently.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal workshop
safety standards are applied, there is no speed
restriction during testing except any that may apply to
the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.
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Page 19 of 667
01INTRODUCTION
12
INFORMATION LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - Td5 Engine
The Td5 engine number is stamped on the LH side of
the cylinder block, below the exhaust manifold.Main gearbox R380 serial number
Stamped on a cast pad on the bottom RH side of the
gearbox.
Transfer gearbox LT230 serial number
The serial number is stamped on the LH side of the
gearbox casing below the mainshaft rear bearing
housing adjacent to the bottom cover.
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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 25 of 667
04GENERAL SPECIFICATION DATA
2
INFORMATION Gudgeon pins
Type Fully floating, offset towards piston thrust side..................................................................................
Piston rings
Type
Upper compression Barrel edge, chrome plated.................................................
Lower compression Taper faced.................................................
Oil control Bevelled ring with spring................................................................
New ring to groove clearance
Upper compression Not measured.................................................
Lower compression 0.050 - 0.082 mm (0.002 - 0.003 in).................................................
Oil control 0.050 - 0.082 mm (0.002 - 0.003 in)................................................................
Piston ring fitted gap in cylinder bore
Upper compression 0.30 - 0.45 mm (0.0118 - 0.0177 in).................................................
Lower compression 0.40 - 0.60 mm (0.0157 - 0.0236 in).................................................
Oil control 0.25 - 0.40 mm (0.0098 - 0.0157 in)................................................................
Camshaft
Drive Duplex chain.................................................................................
End float 0.6 - 0.16 mm...........................................................................
Number of bearings 6..........................................................
Tappets
Type Hydraulic lash adjusters with followers.................................................................................
Valves
Stem diameter
Exhaust 6.905±0.008 mm (0.271±0.0003 in) ...................................................................
Inlet 6.915±0.008 mm (0.272±0.0003 in) .........................................................................
Head diameter
Exhaust 31.7 mm (1.25 in)...................................................................
Inlet 34.7 mm (1.37 in).........................................................................
Seat face angle
Exhaust 45° ...................................................................
Inlet 30° .........................................................................
Valve face angle
Exhaust 44°48’±12’ ...................................................................
Inlet 29°48’±12’ .........................................................................
Valve springs
Type Parallel, single coil.................................................................................
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Page 26 of 667
GENERAL SPECIFICATION DATA
3
INFORMATION FUEL SYSTEM - Td5
Type Direct injection from pressure regulated supply with.................................................................................
cooled return flow
Pressure regulator setting 4 bar (58 lbf.in
2) ................................................
Pump Electric two stage submersible................................................................................
Pump output
Low pressure 30 l/h (6.6 gal/h) at 0.5 bar (7.25 lbf.in
2) ..........................................................
High pressure 180 l/h (39.6 gal/h) at 4 bar (58 lbf.in2) ..........................................................
Max consumption 30 l/h (6.6 gal/h).............................................................
Injectors Electronic unit injectors...........................................................................
Injector normal operating pressure 1500 bar (21750 lbf.in
2) ..................................
Filter In-line canister filter/water separator with water.................................................................................
detection
COOLING SYSTEM - Td5
Type Pressurised spill return partial flow, thermostatically.................................................................................
controlled
Cooling fans 11 blade axial flow on viscous coupling and 11 blade.....................................................................
axial flow electric
Electric cooling fan switching points
On Vehicle speeds of 50 mph (80 km/h) and below while...........................................................................
ambient temperature is 28°C (82°F) or above
Off Vehicle speeds of 62.5 mph (100 km/h) and above or...........................................................................
ambient temperatures of 25°C (77°F) and below
Coolant pump Centrifugal impeller, belt driven from crankshaft...................................................................
Thermostat Waxstat with pressure relief valve.......................................................................
Thermostat opening temperature
Initial opening 82°C (179°F) ..........................................................
Fully open 96°C (204°F) ...............................................................
Expansion tank cap relief valve operating pressure 1.4 bar (20.3 lbf.in
2) .........
CLUTCH - Td5
Type Diaphragm spring, hydraulically operated with.................................................................................
self-centering pre-loaded release bearing
Drive plate diameter 267 mm.........................................................
Pressure plate diameter 270 mm...................................................
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Page 27 of 667
04GENERAL SPECIFICATION DATA
4
INFORMATION TRANSMISSION - Td5
Main gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward, 1 reverse, all synchromesh.............................................................................
Transfer box
Type LT230TE Two speed reduction on main gearbox output. Front.................................................................
and rear drive permanently engaged via a lockable
differential
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts, 32°angularity of universal joint on full
lock
Ratio 3.54:1.................................................................................
Propeller shafts
Type, front and rear Tubular 51 mm dia...........................................................
Universal joints Open type Hookes O3EHD.................................................................
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GENERAL SPECIFICATION DATA
7
INFORMATION SHOCK ABSORBERS
Type Telescopic, double-acting non-adjustable.................................................................................
Bore diameter 35.47mm...................................................................
BRAKES
Front brake
Caliper AP Lockheed, four opposed pistons..............................................................................
Operation Hydraulic, self adjusting.........................................................................
Disc 90 - Solid, outboard, 110/130 - Ventilated, outboard..................................................................................
Disc diameter 298 mm (11.73 in)...................................................................
Disc thickness 90 - 14,1 mm (0.56in), 110/130 - 24mm (0.95 in)..................................................................
Wear limit 1 mm (0.04in) per side of disc.........................................................................
Disc run-out maximum 0,15mm (0.006 in).....................................................
Pad area 58 cm
2(9.0 in2) ..........................................................................
Total swept area 801,3 cm2(124.2 in2) ...............................................................
Pad material Ferodo 3440 non asbestos.....................................................................
Pad minimum thickness 3 mm (0.12in)...................................................
Rear brake
Caliper AP Lockheed opposed piston..............................................................................
Operation Hydraulic, self adjusting.........................................................................
Disc Solid, outboard..................................................................................
Disc diameter 90 - 290 mm (11.42 in), 110/130 - 298 mm (11.73)...................................................................
Disc thickness 90 - 12,5 mm (0.49 in), 110/130 - 14,1 mm (0.56 in)..................................................................
Wear limit 90 - 0,38 mm (0.015 in), 110/130 - 1,0 mm (0.04 in).........................................................................
per side of disc
Disc run-out maximum 0,15 mm (0.006 in).....................................................
Pad area 90 - 30,5 cm
2(4.37 in2), 110/130 - 36,2 cm2(5.61 in2) ..........................................................................
Total swept area 90 - 694 cm2(106.98 in2) ...............................................................
Pad material Ferodo 3440 non asbestos.....................................................................
Pad minimum thickness UP TO 02MY - 3 mm (0.12 in)...................................................
Pad minimum thickness From 02MY - 2 mm (0.08 in)...................................................
Parking brake
Type Mechanical, cable operated drum brake on the rear of.................................................................................
the transfer gearbox output shaft
Drum internal diameter 254 mm (10.0 in).....................................................
Width 70 mm (2.75 in)................................................................................
Pad material Ferodo 3611 non asbestos.....................................................................
Servo/master cylinder
Manufacturer Lucas....................................................................
Servo type LSC 80........................................................................
Master cylinder type 25,4 mm (1.0 in) diameter, tandem.........................................................
Pressure reducing valve, failure conscious Cut-in pressure, 90 - 24 bar (360 Ibf/in
2) ratio 4.0:1, ......................
110 - 43 bar (645 Ibf/in2) ratio 2.9:1*
NOTE: * Pressure reducing valves are not fitted to all 110 specifications.
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Page 46 of 667
GENERAL FITTING REMINDERS
3
INFORMATION BALL AND ROLLER BEARINGS
CAUTION: Never refit a ball or roller
bearing without first ensuring that it is in a
fully serviceable condition.
1.Remove all traces of lubricant from bearing
under inspection by washing in a suitable
degreaser; maintain absolute cleanliness
throughout operations.
2.Inspect visually for markings of any form on
rolling elements, raceways, outer surface of
outer rings or inner surface of inner rings. Reject
any bearings found to be marked, since any
marking in these areas indicates onset of wear.
3.Holding inner race between finger and thumb of
one hand, spin outer race and check that it
revolves absolutely smoothly. Repeat, holding
outer race and spinning inner race.
4.Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation, and reject
bearing if action is not perfectly smooth.
5.Lubricate bearing generously with lubricant
appropriate to installation.
6.Inspect shaft and bearing housing for
discolouration or other marking suggesting that
movement has taken place between bearing and
seatings. (This is particularly to be expected if
related markings were found in operation 2).
7.Ensure that shaft and housing are clean and free
from burrs before fitting bearing.8.If one bearing assembly of a pair shows an
imperfection it is generally advisable to replace
both with new bearings; an exception could be
made if the faulty bearing had covered a low
mileage, and it could be established that
damage was confined to it only.
9.When fitting bearing to shaft, apply force only to
inner ring of bearing, and only to outer ring when
fitting into housing, as shown above.
10.In the case of grease lubricated bearings (e.g.
hub bearings) fill space between bearing and
outer seal with recommended grade of grease
before fitting seal.
11.Always mark components of separable bearings
(e.g. taper roller bearings) in dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring, always fit a complete new
bearing assembly.
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