wheel bolts LAND ROVER DEFENDER 1999 Workshop Manual

ENGINE
5
DESCRIPTION AND OPERATION 1.Crankshaft pulley bolt
2.TV Damper to crankshaft pulley bolts (3 off)
3.TV Damper
4.Crankshaft pulley
5.Woodruff key
6.Crankshaft
7.Crankshaft to flywheel dowel
8.Spigot bush
9.Flywheel to crankshaft bolts (8 off)
10.Flywheel assembly
11.Main bearing shells (6 pairs)
12.Main bearing caps (6 off)
13.Main bearing cap bolts (12 off)
14.Thrust washer (2 off at No. 3 Main bearing)
15.Piston lubrication jets (5 off)
16.Piston lubrication jet cap head screw (5 off)
17.Stiffener plate (oil pump integral)
18.Stiffener plate / oil pump assembly to cylinder block bolts (22 off)
19.Oil pick-up pipe O-ring
20.Oil pick-up pipe inserts (2 x 6mm; 1 x 10mm)
21.Upper oil pick-up pipe
22.Oil pick-up pipe gauze
23.Lower oil pick-up pipe
24.Sump
25.Oil drain plug seal
26.Oil drain plug
27.Sump to cylinder block bolts (20 off)
28.Sump gasket
29.Oil pick-up pipe bolts (3 off)
30.Oil pump
31.Chain lubrication jet
32.Chain lubrication jet screw
33.Stiffener to cylinder block dowel (2 off)
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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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12ENGINE
24
DESCRIPTION AND OPERATION Crankshaft
1.Front end to crankshaft sprocket
2.Oil supply cross-drillings
3.Main journals4.Big-end journals
5.Rear end to flywheel
The crankshaft is constructed from cast iron and is surface-hardened. The areas between the crankshaft journals
and the adjoining webs and balance weights are compressed using the cold roll process to form journal fillets.
Cross-drillings in the crankshaft between adjoining main and big-end bearings are used to divert lubrication oil to
the big-end bearings.
A torsional vibration damper is attached to the crankshaft pulley by three bolts.
The crankshaft is carried in six main bearings, with end-float being controlled by thrust washers positioned on both
sides of No. 3 main bearing.
Main bearings
There are six main bearings used to carry the crankshaft. Each of the bearing caps are of cast iron construction
and are attached to the cylinder block by two bolts.
The bearing shells are of the split cylindrical type. The upper half bearing shells are grooved to facilitate the supply
of lubrication oil to the bearings and fit into a recess in the underside of the cylinder block. The lower half bearing
shells are smooth and fit into the bearing caps.
Steel-backed, thrust washers are included at each side of No. 3 main bearing to control crankshaft end-float. One
side of each of the thrust washers is grooved, the grooved side of each of the thrust washers is fitted facing
outward from No. 3 main bearing.
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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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ENGINE
5
REPAIR
7.Fit oil seal housing bolts and using sequence
shown, tighten to9 Nm (7 lbf.ft).
8.Fit sump gasket.See this Section.
9.Fit flywheel.See this Section.BEARING - SPIGOT - CRANKSHAFT
Service repair no - 12.21.45
Remove
1.Remove clutch assembly.See CLUTCH,
Repair.
2.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
3.Fit extractor to spigot bush.
4.Remove spigot bush from crankshaft.
Refit
5.Clean spigot bush and mating face in rear of
crankshaft.
6.Fit new spigot bush to crankshaft using a
suitable drift.
7.Fit clutch assembly.See CLUTCH, Repair.
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12ENGINE
22
REPAIR MOUNTING - GEARBOX - REAR - RH
Service repair no - 12.45.09
Remove
1.Remove LH rear gearbox mounting.See this
Section.
2.Remove 4 bolts securing mounting bracket to
transfer gearbox.
3.Remove 2 nuts, remove mounting and mounting
bracket.
Refit
4.Clean mounting and mating faces.
5.Position mounting and mounting bracket and
tighten nuts to48 Nm (35 lbf.ft)and bolts to85
Nm (63 lbf.ft).
6.Fit LH rear gearbox mounting.See this
Section.FLYWHEEL
Service repair no - 12.53.07
Remove
1.Remove clutch assembly.See CLUTCH,
Repair.
2.Remove and discard 8 bolts securing flywheel to
crankshaft and remove flywheel.
NOTE: Dowel located.
Refit
3.Clean flywheel and crankshaft mating face.
4.Position flywheel to crankshaft.
5.Fit new flywheel retaining bolts and tighten by
diagonal selection to:
Stage 1 -40 Nm (30 lbf.ft)
Stage 2 -Further 90°
CAUTION: Do not carry out stages 1 and 2
in one operation.
6.Fit clutch assembly.See CLUTCH, Repair.
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ENGINE
21
OVERHAUL
7.Using sequence shown, tighten sump bolts to25
Nm (18 lbf.ft).
8.Fit new centrifuge oil drain pipe gasket.
CAUTION: Gasket must be fitted dry.
9.Fit centrifuge oil drain pipe, fit bolts and tighten
to10 Nm (7 lbf.ft).SEAL - CRANKSHAFT - REAR
Service repair no - 12.21.20.01
Remove
1.Remove flywheel.See Repair.
2.Remove sump gasket.See this Section.
3.Remove 5 bolts securing crankshaft rear oil seal
housing to cylinder block.
4.Remove and discard crankshaft rear oil seal and
housing.
NOTE: Dowel located.
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12ENGINE
22
OVERHAUL Refit
1.Clean crankshaft rear oil seal housing mating
face on cylinder block, ensure bolt and dowel
holes are clean and dry. Remove all traces of oil
from oil seal running surface on crankshaft.
2.Position seal protectorLRT-12-061over
crankshaft boss. Fit new seal and housing,
removeLRT-12-061.
CAUTION: Oil seal must be fitted dry.
3.Fit oil seal housing bolts and using sequence
shown, tighten to9 Nm (7 lbf.ft).
4.Fit sump gasket.See this Section.
5.Fit flywheel.See Repair.STARTER RING GEAR
Service repair no - 12.53.19
Remove.
1.Remove flywheel.See Repair.
2.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
3.Apply a cold chisel to root of teeth, break ring
gear and remove from flywheel.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
Refit
1.Heat ring gear evenly to 350°C, indicated by
light blue colour.
2.Locate ring gear on flywheel and press on to
flange.
WARNING: Handle hot ring gear with care.
3.Allow ring gear to air cool.
4.Fit flywheel.See Repair.
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19FUEL SYSTEM
2
DESCRIPTION AND OPERATION DESCRIPTION
General
The fuel delivery system comprises a fuel tank, fuel pump, fuel pressure regulator, five injectors and a fuel filter.
The system is controlled by the ECM, which energises the fuel pump relay and controls the operation and timing
of each injector solenoid.
Unlike other Diesel engines, the Td5 has no injection pump. The diesel direct injection system receives fuel at
pressure from a two stage fuel pump located in the fuel tank. The system incorporates a fuel return to the fuel
pump, via a fuel cooler attached to the inlet manifold, and a fuel filter. A fuel pressure regulator is located in a
housing on the rear of the cylinder head. The regulator maintains the fuel delivered to the injectors at a constant
pressure and returns excess fuel back to the fuel filter and pump via the fuel cooler.
A fuel filter is positioned on the chassis longitudinal, below the RH rear wheel arch. The fuel feed and return to and
from the engine passes through the filter. The filter also incorporates a water sensor, which illuminates a warning
lamp in the instrument pack.
A moulded fuel tank is located at the rear underside of the vehicle between the chassis longitudinals. The tank
provides the attachment for the fuel pump and the fuel gauge sender unit, which is located inside the tank.
Fuel Tank and Breather
The fuel tank and breather system is a major part of the fuel delivery system. The fuel tank and breathers are
located at the rear of the vehicle between the chassis longitudinals.
Fuel Tank
The moulded fuel tank is made from High Molecular Weight (HMW) High Density Polyethylene (HDPE), and is
manufactured using a proportion of recycled plastic.
The tank is held in position by a metal cradle which is secured to the chassis cross members by four bolts, two
holding the front of the cradle in position, two holding the rear. The fuel tank has a useable capacity of 75 litres
(16.5 gallons).
An aperture in the top surface of the tank allows for the fitment of the fuel pump and fuel gauge sender unit, which
is retained with a locking ring. A reflective metallic covering is attached to the tank with three scrivets to shield the
tank from heat generated by the exhaust system.
Fuel Tank Breather System
The fuel tank filler tube incorporates a tank vent which allows air and fuel vapour displaced from the tank when
filling to vent to atmosphere via the filler neck.
A breather spout within the tank controls the tank’Full’height. When fuel covers the spout it prevents fuel vapour
and air from escaping from the tank. This causes the fuel to’back-up’in the filler tube and shuts off the filler gun.
The position of the spout ensures that when the filler gun shuts off, a vapour space of approximately 10% of the
tanks total capacity remains. The vapour space ensures that the Roll Over Value (ROV) is always above the fuel
level and vapour can escape and allow the tank to breathe.
The ROV is welded to the top surface of the tank. It is connected by a tube to the filler tube, which in turn is
connected to the atmospheric vent pipe. The ROV allows fuel vapour to pass through it during normal vehicle
operation. In the event of the vehicle being overturned the valve shuts off, sealing the tank and preventing fuel
from spilling from the atmospheric vent pipe.
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33CLUTCH
6
DESCRIPTION AND OPERATION DESCRIPTION
General
The clutch system is a diaphragm type clutch operated by a hydraulic cylinder. The drive plate is of the rigid centre
type with no integral damping springs. The flywheel is of the dual mass type with damping springs integral with the
flywheel. The clutch requires no adjustment to compensate for wear.
Hydraulic Clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir. The master and slave
cylinders are connected to each other hydraulically by plastic and metal pipes. The plastic section of the pipe
allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the fluid reservoir. The bore is also connected to a damper which prevents
engine pulses being transferred hydraulically to the clutch pedal. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coil springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead and secured with two bolts. The cylinder is connected to the
shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat
shield is fitted to protect the underside of the slave cylinder from heat generated from the exhaust system. The
slave cylinder comprises a cylinder with a piston and a rod. A port in the cylinder body provides the attachment for
the hydraulic feed pipe from the master cylinder. A second port is fitted witha bleed nipple used for removing air
from the hydraulic system after servicing. The piston rod locates on a clutch release lever located in the gearbox
housing. The rod is positively retained on the release lever with a clip.
Clutch Mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A
spigot with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the
clutch release lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located
on the ball, the pivot washer seats against the rear face of the release lever. A spring clip is located on the lever
and the pivot washer and secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned
centrally on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever
to pivot freely around the ball.
The clutch release bearing locates on the clutch release lever and release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever
on the carrier. The bearing and carrier are not serviceable individually.
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