torque LAND ROVER DEFENDER 1999 Workshop Manual

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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INTRODUCTION
9
INFORMATION ABBREVIATIONS AND SYMBOLS USED IN THIS
MANUAL
Across flats (bolt size) AF............................................
After bottom dead centre ABDC...................................
After top dead centre ATDC.........................................
Alternating current a.c..................................................
Ampere amp................................................................
Ampere hour amp hr....................................................
Before bottom dead centre BBDC................................
Before top dead centre BTDC......................................
Bottom dead centre BDC.............................................
Brake horse power bhp................................................
British Standards BS....................................................
Carbon monoxide CO..................................................
Centimetre cm.............................................................
Centigrade (Celsius) C................................................
Cubic centimetre cm
3...................................................
Cubic inch in3...............................................................
Degree (angle) deg or° ...............................................
Degree (temperature) deg or° .....................................
Diameter dia................................................................
Direct current d.c..........................................................
Electronic Control Unit ECU........................................
Fahrenheit F.................................................................
Feet ft...........................................................................
Feet per minute ft/min..................................................
Fifth 5th........................................................................
First 1st........................................................................
Fluid ounce fl oz..........................................................
Foot pounds (torque) lbf.ft............................................
Fourth 4th.....................................................................
Gramme (force) gf........................................................
Gramme (mass) g........................................................
Gallons gal...................................................................
High tension (electrical) H.T.........................................
Internal diameter I.D....................................................
Inches of mercury in. Hg..............................................
Inches in......................................................................
Kilogramme (force) kgf.................................................
Kilogramme (mass.) kg................................................
Kilogramme centimetre (torque) kgf.cm.......................
Kilogramme per square millimetre kgf/mm
2.................
Kilogramme per square centimetre kgf/cm2.................
Kilogramme metres (torque) kgf.m..............................
Kilometres km..............................................................
Kilometres per hour km/h.............................................
Kilovolts kV...................................................................
Left-hand LH................................................................
Left-hand steering LHStg.............................................
Left-hand thread LHThd...............................................
Litres litre.....................................................................Low tension l.t..............................................................
Maximum max.............................................................
Metre m........................................................................
Millilitre ml....................................................................
Millimetre mm...............................................................
Miles per gallon mpg....................................................
Miles per hour mph......................................................
Minute (angle)’ ............................................................
Minus (of tolerance) -...................................................
Negative (electrical) -...................................................
Newton metres (torque) Nm........................................
Number No..................................................................
Ohms ohm...................................................................
Ounces (force) ozf.......................................................
Ounces (mass) oz........................................................
Outside diameter O.D..................................................
Part number Part No....................................................
Percentage %...............................................................
Pints pt.........................................................................
Plus (tolerance) +.........................................................
Positive (electrical) +....................................................
Pound (force) lbf..........................................................
Pounds inch (torque) lbf.in...........................................
Pound (mass) lb...........................................................
Pounds per square inch P.S.I......................................
Ratio :...........................................................................
Reference ref...............................................................
Revolution per minute rev/min.....................................
Right-hand RH.............................................................
Second (angle) "...........................................................
Second (numerical order) 2nd......................................
Specific gravity sp.gr....................................................
Square centimetres cm
2...............................................
Square inches in2.........................................................
Standard wire gauge s.w.g..........................................
Synchroniser/Synchromesh synchro...........................
Third 3rd.......................................................................
Top dead centre TDC..................................................
United Kingdom UK......................................................
Vehicle Identification Number VIN...............................
Volts V.........................................................................
Watts W.......................................................................
SCREW THREADS
British Standard Pipe BSP...........................................
Unified Coarse UNC....................................................
Unified Fine UNF.........................................................
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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.
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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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12ENGINE
4
REPAIR Refit
9.Position new crankshaft pulley to vice.
10.Remove 3 bolts and remove damper from
crankshaft pulley.
11.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
12.Fit crankshaft pulley.
13.FitLRT-51-003to crankshaft pulley and secure
with 2 bolts.
14.Fit new crankshaft pulley bolt and tighten to460
Nm (340 lbf.ft).
NOTE: It is recommended that a torque
multiplier is used to tighten crankshaft
pulley bolt.
15.Remove 2 bolts and removeLRT-51-003from
crankshaft pulley.
16.Fit damper to crankshaft pulley, fit bolts and
tighten to80 Nm (60 lbf.ft).
17.Fit auxiliary drive belt.
18.Fit radiator.See COOLING SYSTEM, Repair.
19.Fit underbelly panel.See CHASSIS AND
BODY, Repair.OIL SEAL - CRANKSHAFT - REAR
Service repair no - 12.21.20
Remove
1.Remove flywheel.See this Section.
2.Remove sump gasket.See this Section.
3.Remove 5 bolts securing oil seal housing to
cylinder block.
4.Remove seal housing.
Refit
5.Clean seal housing mating face on cylinder
block.
6.Position seal protector,LRT-12-061over
crankshaft boss. Fit new seal and housing
assembly and remove toolLRT-12-061.
CAUTION: Oil seal must be fitted dry.
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12ENGINE
30
OVERHAUL
22.Fit oil seal guide, from seal kit, over end of
crankshaft.
23.Fit new oil seal into timing cover using
LRT-12-156.
CAUTION: Oil seal must be fitted dry.
24.RemoveLRT-12-156and oil seal guide.
25.Fit crankshaft pulley, fit crankshaft pulley bolt.
26.FitLRT-51-003to crankshaft pulley and secure
with 2 bolts.
27.Using assistance, restrain engine and using a
torque multiplier, tighten crankshaft bolt to460
Nm (340 lbf.ft).
WARNING: DUE TO THE HIGH TORQUE
LOADING REQUIRED, IT IS ESSENTIAL
THAT ENGINE IS ADEQUATELY
RESTRAINED.
28.RemoveLRT-51-003.
29.Position damper to crankshaft pulley, fit 3 bolts
and tighten to80 Nm (60 lbf.ft).
30.Fit sump gasket.See this Section.
31.Fit cylinder head gasket.See this Section.BEARINGS - CONNECTING RODS
Service repair no - 12.17.16.01
Remove
1.Remove oil pump.See this Section.
2.Mark cylinder reference number on each
connecting rod big-end bearing cap.
3.Make suitable alignment marks between each
big-end bearing cap and connecting rod.
CAUTION: Due to the’fracture split’
method of manufacturing connecting rods
and bearing caps, incorrect fitting of cap
to connecting rod will damage mating faces and
necessitate replacement of connecting rod
assembly.
4.Rotate crankshaft clockwise until No. 1 big-end
is at BDC.
5.Remove and discard 2 bolts securing No. 1
big-end bearing cap.
6.Remove bearing cap, remove and discard
big-end bearing shell.
7.Push connecting rod up cylinder bore until rod is
clear of crankshaft journal.
CAUTION: Ensure that connecting rod
does not contact cylinder bore or oil squirt
jet and piston does not contact the valves
or EUI’s if the cylinder head is fitted.
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18ENGINE MANAGEMENT SYSTEM
26
DESCRIPTION AND OPERATION TURBOCHARGER
1.Exhaust gas from manifold
2.Studs to exhaust manifold
3.Turbocharger cast iron housing
4.Wastegate valve linkage
5.Exhaust gas out to front exhaust pipe6.Compressed air intake
7.Fresh air intake
8.Turbocharger aluminium alloy housing
9.Wastegate valve vacuum port
The Td5 engine utilises a Garrett GT20 turbocharger with an electronically controlled wastegate modulator to
improve engine performance. The turbocharger uses the engines exhaust gas to spin a turbine at very high
speed. This causes inlet air on the other side of the turbine to be drawn in through the turbocharger intake for
compression.The inlet air is carried round by the vanes of the compressor and then thrown out under centrifugal
force from the turbochargers outlet duct. This compression of air enables a greater quantity of air to be delivered
to the inlet manifold via an intercooler. Combustion is improved through better volumetric efficiency. The use of a
turbocharger improves fuel consumption and increases engine torque and power. Exhaust noise is also reduced
due to the smoothing out of exhaust pulsations.
The rear cast iron body of the turbocharger housing connects to a port on the exhaust manifold at the LH side of
the cylinder head by three studs and nuts. The interface between the exhaust manifold and the turbocharger
housing is separated by a metal gasket. The exhaust outlet of the turbocharger is located at the bottom of the
turbocharger cast iron housing. It is connected to the exhaust system front downpipe and is attached by three
studs and nuts. The interface between the turbocharger housing and the exhaust front pipe is separated by a
metal gasket.
The front casing of the turbocharger is constructed from aluminium alloy and is connected to the air inlet duct by a
metal band clip. The compressed air outlet is connected to the intercooler by a metal pipe which has rubber hose
extensions at each end attached by metal band clips.
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18ENGINE MANAGEMENT SYSTEM
28
DESCRIPTION AND OPERATION OPERATION
Engine Management
The ECM controls the operation of the engine using stored information within its memory. This guarantees
optimum performance from the engine in terms of torque delivery, fuel consumption and exhaust emissions in all
operating conditions, while still giving optimum driveability.
The ECM will receive information from its sensors under all operating conditions, especially during:
Cold starting.
Hot starting.
Idle.
Wide open throttle.
Acceleration.
Adaptive strategy.
Backup strategy for sensor failures.
The ECM receives information from various sensors to determine the current operating state of the engine. The
ECM then refers this information to stored values in its memory and makes any necessary changes to optimise
air/fuel mixture and fuel injection timing. The ECM controls the air/fuel mixture and fuel injection timing via the
Electronic Unit Injectors (EUI), by the length of time the EUI’s are to inject fuel into the cylinder. This is a rolling
process and is called adaptive strategy. By using this adaptive strategy the ECM is able to control the engine to
give optimum driveability under all operating conditions.
During cold start conditions the ECM uses ECT information to allow more fuel to be injected into the cylinders.
This, combined with the glow plug timing strategy supplied by the ECM, facilitates good cold starting.
During hot start conditions, the ECM uses ECT and FT information to implement the optimum fuelling strategy to
facilitate good hot starting.
During idle and wide open throttle conditions, the ECM uses mapped information within its memory to respond to
input information from the TP sensor to implement the optimum fuelling strategy to facilitate idle and wide open
throttle.
To achieve an adaptive strategy for acceleration, the ECM uses input information from the CKP sensor, the TP
sensor, the ECT sensor, the MAP/IAT sensor, and the FT sensor. This is compared to mapped information within
its memory to implement the optimum fuelling strategy to facilitate acceleration.
Fuel Delivery / Injection Control
The fuel delivery/injection control delivers a precise amount of finely atomised fuel to mix with the air in the
combustion chamber to create a controlled explosion. To precisely control fuel delivery and control fuel injection,
the following input conditions must be met:
CKP information.
Injection timing map information.
FT information.
ECT information.
The ECM monitors the conditions required for optimum combustion of fuel in the cylinder from the various sensors
around the engine and then compares it against stored information. From this calculation, the ECM can adjust the
quantity and timing of the fuel being delivered into the cylinder. The ECM uses CKP information as follows:
To calculate engine speed.
To determine engine crankshaft position.
Engine speed and crankshaft position allows the ECM to determine fuel injection timing.
The ECM also uses ECT and FT information to allow optimum fuel delivery and injection control for all engine
coolant and fuel temperatures.
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33CLUTCH
8
DESCRIPTION AND OPERATION The dual mass flywheel is bolted on the rear of the crankshaft with eight bolts. A dowel on the crankshaft flange
ensures that the flywheel is correctly located. A ring gear is fitted on the outer diameter of the flywheel. The ring
gear is not serviceable. Thirty blind holes are drilled in the outer diameter of the flywheel adjacent to the ring gear.
The holes are positioned at 10°intervals with four 20°spaces. The holes are used by the crankshaft position
sensor for engine management.
The dual mass flywheel is used to insulate the gearbox from torsional and transient vibrations produced by the
engine. The flywheel comprises primary and secondary flywheels with the drive between the two transferred by a
torsional damper which comprises four coil springs. The springs are located in the inside diameter of the primary
flywheel. Two of the springs are of smaller diameter and fit inside the larger diameter springs.
The primary flywheel locates the ring gear and is attached to the crankshaft flange with eight bolts. The two pairs
of coil springs are located in a recess in the flywheel between two riveted retainers. A roller bearing is pressed
onto the central boss of the primary flywheel and retained with a riveted plate. The bearing provides the mounting
for the secondary flywheel.
The secondary flywheel comprises two parts; an outer flywheel which provides the friction surface for the clutch
drive plate and an inner drive plate which transfers the drive from the primary flywheel, via the coil springs, to the
outer flywheel. The two components of the secondary flywheel are secured to each other with rivets. The inner
drive plate is located between the two pairs of coil springs and can rotate on the ball bearing in either direction
against the combined compression force of the four coil springs. Under high torque loading conditions the
secondary flywheel can rotate in either direction up to 70°in relation to the primary flywheel.
The operating face of the secondary flywheel is machined to provide a smooth surface for the drive plate to
engage on. Three dowels and six studs and nuts provide for the location and attachment of the pressure plate.
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51REAR AXLE AND FINAL DRIVE
2
REPAIR Refit
15.Position axle and fit lower links. Tighten fixings
to176 Nm (130 lbf/ft).
16.If applicable, fit anti-roll bar links to axleSee
REAR SUSPENSION, Repair. Anti-roll bar
links.
17.Raise axle and locate road springs.
18.Fit coil spring retaining plates and secure with
fixing bolts.
19.Secure pivot bracket ball joint to axle bracket.
Tighten fixing to176 Nm (130 lbf/ft).
20.Align propeller shaft to differential drive flange
and tighten fixings to47 Nm (35 lbf/ft).
21.Reconnect flexible brake hose and axle breather
hose.
22.Refit shock absorbers.
23.Fit road wheels and tighten to correct torque:
Alloy wheels -130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy Duty wheels -170 Nm (125 lbf/ft)
24.Remove rear chassis support.
25.Bleed brake systemSee BRAKES, Repair.
brake system bleed.
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