suspension LAND ROVER DEFENDER 1999 Workshop Manual

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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01INTRODUCTION
4
INFORMATION ACCESSORIES AND CONVERSIONS
DO NOT FITunapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitting of non-approved conversions
to the vehicle.
WHEELS AND TYRES
WARNING: DO NOT replace the road
wheels with any type other than genuine
Land Rover wheels which are designed for
multi-purpose on and off road use and have very
important relationships with the proper operation
of the suspension system and vehicle handling.
Replacement tyres must be of the make and sizes
recommended for the vehicle, and all tyres must
be the same make, ply rating and tread pattern.
STEAM CLEANING
To prevent consequential rusting, any steam cleaning
within the engine bayMUSTbe followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine coolant pipes and hose clips.
SPECIFICATION
The specification details and instructions set out in
this Supplement apply only to a range of vehicles and
not to any one. For the specification of a particular
vehicle purchasers should consult their Dealer.
The Manufacturer reserves the right to vary
specifications with or without notice, and at such times
and in such manner as it thinks fit. Major as well as
minor changes may be involved in accordance with
the Manufacturer’s policy of constant product
improvement.
Whilst every effort is made to ensure the accuracy of
the particulars contained in this Supplement, neither
the Manufacturer or Dealer, by whom this Supplement
is supplied, shall in any circumstances be held liable
for any inaccuracy or the consequences thereof.SPECIAL SERVICE TOOLS
The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified,only these tools should be used
to avoid the posibility of personal injury or
damage to the components.Also, the amount of time
which they can save can be considerable.
Special tools bulletins will be issued periodically giving
details of new tools as they are introduced.
All orders and enquiries from the United Kingdom
should be sent direct to Cartool (UK) Ltd. Overseas
orders should be placed with the local Cartool
distributor, where one exists. Countries where there is
no distributor may order direct from:
Cartool (UK) Ltd.
Unit 3,
Sterling Business Park,
Brackmills,
Northampton,
England, NN4 7EX.
The tools recommended in this Workshop Manual are
listed in an illustrated catalogue, obtainable from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle,
Merseyside, L70 1JL
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04 - GENERAL SPECIFICATION DATA
CONTENTS
Page
INFORMATION
ENGINE - Td5 1......................................................................................................
FUEL SYSTEM - Td5 3...........................................................................................
COOLING SYSTEM - Td5 3....................................................................................
CLUTCH - Td5 3.....................................................................................................
TRANSMISSION - Td5 4.........................................................................................
STEERING 5...........................................................................................................
SUSPENSION 6......................................................................................................
ROAD SPRING DATA 6..........................................................................................
SHOCK ABSORBERS 7.........................................................................................
BRAKES 7...............................................................................................................
AIR CONDITIONING 8............................................................................................
WIPER MOTORS 8.................................................................................................
ELECTRICAL 8.......................................................................................................
BULBS9 .................................................................................................................
VEHICLE WEIGHTS AND PAYLOAD 10................................................................
TOWING WEIGHTS 11...........................................................................................
OFF-ROAD PERFORMANCE 11............................................................................
TYRE SIZE AND PRESSURES 12.........................................................................
WHEELS 12............................................................................................................
VEHICLE DIMENSIONS 13....................................................................................
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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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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
6
MAINTENANCE ROAD WHEELS
Remove
1.Loosen wheel nuts. Raise vehicle for wheel free
condition and remove the wheel nuts.
2.Mark the wheel to stud relationship to ensure
that the wheels are refitted in the same
orientation.
Refit
3.Apply a thin coat of anti-seize compound to
wheel hub centre.
4.Refit wheels to original hub position.
NOTE: When refitting road wheel nuts do
not overtighten using powered tools.
Ensure the wheel nuts are correctly
torqued in the correct sequence.
5.Tighten wheel nuts.
Steel wheels -100 Nm (80 lbf/ft)
Alloy wheels -130 Nm (96 lbf/ft)
Heavy Duty wheels -170 Nm (125 lbf/ft)TYRE PRESSURES, CONDITION AND TREAD
DEPTH
1.Check for any apparent damage to tyres, paying
particular attention to side walls.
2.Look at tyre treads and check for any unusual
wear patterns which may indicate out of
specification adjustment of steering or
suspension.
NOTE: Any adjustments to steering or
suspension will be subject to additional
labour and/or material cost and should not
be carried out without the authorisation of the
customer.
3.Measure the tread depth across the width of the
tyre and around the circumference. Annotate the
maintenance check sheet with the lowest figure
obtained from each tyre.
NOTE: Any requirement to replace tyres
should be advised to the customer before
any remedial work is carried out. This will
be subject to additional labour and/or material
cost and should not be carried out without the
authorisation of the customer.
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10MAINTENANCE
20
MAINTENANCE EXHAUST SYSTEM
1.Visually check condition of exhaust system for
signs of damage.
2.Check condition of exhaust heat shields.
3.Check exhaust system is firmly secured and
check condition of exhaust mounting rubbers,
clamps and brackets.STEERING BOX AND SUSPENSION
1.Check steering box fixings. Tighten if necessary
to81 Nm (60 lbf.ft).
2.Check LH and RH front radius arm fixings.
Tighten if necessary.See FRONT
SUSPENSION, Repair.
3.Check Panhard rod fixings. Tighten if necessary.
See FRONT SUSPENSION, Repair.
4.Check all rear axle fixings. Tighten if necessary.
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10MAINTENANCE
22
MAINTENANCE SHOCK ABSORBERS
1.Check for signs of leakage from suspension
dampers.
2.Check for signs of suspension damper damage.TOWING BRACKET
1.Check security of towing bracket.
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MAINTENANCE
23
MAINTENANCE ENGINE AND TRANSMISSION MOUNTINGS
1.Check condition of front LH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
2.Check condition of front RH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
3.Check condition of rear LH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
4.Check condition of rear RH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.ROAD TEST
There are two purposes for conducting a road test.
Firstly, to ensure the work completed within the
dealership meets the standards required as layed
down by dealership processes. Secondly, for a skilled
technician to assess the general condition of the
vehicle and report any conditions that the customer
should be made aware of.
CAUTION: Two wheel roller tests must not
be carried out. Four wheel roller tests
must be restricted to 3 mph (5 kph).
1.Check for correct operation of starter switch.
Ensure the engine starts in a correct manner.
Leave the engine running.
2.With vehicle stationary, turn steering from lock to
lock. Check for smooth operation and ensure
there is no undue noise from the power steering
pump or drive belt.
3.Depress clutch and select all gears in turn.
Check for smooth notch free engagement.
4.Drive vehicle on a short road test. Check all
vehicle systems for correct operation. Pay
particular attention to:
Engine noise
Gearbox noise
Suspension noise
Body noise
Braking system operation
Gear selection
Engine performance
5.Check for correct operation of all instruments
and warning devices where practical.
6.After road test, carry out a final inspection of the
vehicle on vehicle ramps.
7.Check all underbonnet fluid levels and top-up if
necessary.
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