Land Rover Defender 1999, Defender 2002 User Manual

Workshop Manual Werkplaatshandboek Manual d'Atelier Werkstatthandbuch Manuale d'Officina Manual de Taller Manual de Oficina

DEFENDER 1999 & 2002 MY

WORKSHOP MANUAL SUPPLEMENT

& BODY REPAIR MANUAL

This Supplement supersedes Workshop Manual VDR 100250 and should be used in conjunction with the following Manuals:

Workshop Manual - Defender 300 Tdi LRL 0097

Overhaul Manual - R380 gearbox LRL 0003 3rd edition

Overhaul Manual - LT230T Transfer gearbox LRL 0081 3rd edition

Publication Part No. LRL 0410ENG (3rd Edition)

 Land Rover 2001

mechanical, recording or other means without prior permission from Land Rover.

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

17 18 19

37 41

60 64

84 86 88

01 - INTRODUCTION

CONTENTS

INFORMATION

INTRODUCTION 1..................................................................................................

DIMENSIONS 1.......................................................................................................

REFERENCES 1.....................................................................................................

REPAIRS AND REPLACEMENTS 1.......................................................................

POISONOUS SUBSTANCES 1..............................................................................

FUEL HANDLING PRECAUTIONS 2......................................................................

SYNTHETIC RUBBER 3.........................................................................................

RECOMMENDED SEALANTS 3.............................................................................

USED ENGINE OIL 3..............................................................................................

ACCESSORIES AND CONVERSIONS 4...............................................................

WHEELS AND TYRES 4.........................................................................................

STEAM CLEANING 4..............................................................................................

SPECIFICATION 4..................................................................................................

SPECIAL SERVICE TOOLS 4................................................................................

JACKING 5..............................................................................................................

HYDRAULIC VEHICLE RAMP (FOUR POST) 6.....................................................

TWO POST VEHICLE RAMPS 6............................................................................

DYNAMOMETER TESTING 6................................................................................

TOWING 7..............................................................................................................

TRANSPORTING THE VEHICLE BY TRAILER 7..................................................

JUMP STARTING 8................................................................................................

ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL 9.............................

CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY 10....................

VEHICLE IDENTIFICATION NUMBER (VIN) 11.....................................................

LOCATION OF IDENTIFICATION NUMBERS 12...................................................

FAULT DIAGNOSTIC EQUIPMENT 13..................................................................

READING THIS SUPPLEMENT 14........................................................................

Page

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, CAUTIONS and NOTES are 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.

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.

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.

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.

INFORMATION

INTRODUCTION

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions which must be observed if fuel is to be handled safely. It also outlines the other areas of risk which must not be ignored.

This information is issued for basic guidance only, and in any case of doubt, appropriate enquiries should be made of your local Fire Officer or Fire Department.

Fuel vapour is highly flammable and in confined spaces is also very explosive and toxic and when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of fuel is very dangerous.

Always have a fire extinguisher containing FOAM CO GAS, or POWDER close at hand when handling fuel, or when dismantling fuel systems and in areas where fuel containers are stored.

WARNING: lt is imperative that the battery is not disconnected during fuel system

repairs as arcing at the battery terminal could ignite fuel vapour in the atmosphere. Always disconnect the vehicle battery BEFORE carrying out work on the fuel system. Whenever fuel is being handled, transferred or stored, or when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any leadlamps used must be flame proof and kept clear of spillage. No one should be permitted to repair components associated with fuel without first having had fuel system training.

Hot fuel handling precautions

WARNING: Before commencing any operation requiring fuel to be drained from the fuel tank, the following procedure must

be adhered to:

1. Allow sufficient time for the fuel to cool, thus

avoiding contact with hot fuels.

2. Vent the system by removing the fuel filler cap in

a well ventilated area. Refit the filler cap until the commencement of fuel drainage.

Fuel transfer

WARNING: Fuel must not be extracted or drained from any vehicle while it is standing over a pit.

The transfer of fuel from the vehicle fuel tank must be carried out in a well ventilated area. An approved transfer tank must be used according to the transfer tank manufacturer’s instructions and local regulations, including attention to grounding of tanks.

Fuel tank removal

A FUEL VAPOUR warning label must be attached to the fuel tank upon removal from the vehicle.

Fuel tank repair

Under no circumstances should a repair to any tank be attempted.

INFORMATION

INTRODUCTION

SYNTHETIC RUBBER

Many ’0’ ring seals, flexible pipes and other similar items which appear to be natural rubber are made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe, and does not present a health hazard. However, if the material is damaged by fire or excessive heat, it can break down and produce highly corrosive Hydrofluoric acid which can cause serious burns on contact with skin. Should the material be in a burnt or overheated condition handle only with seamless industrial gloves. Decontaminate and dispose of the gloves immediately after use.

If skin contact does occur, remove any contaminated clothing immediately and obtain medical assistance without delay. In the meantime, wash the affected area with copious amounts of cold water or limewater for fifteen to sixty minutes.

RECOMMENDED SEALANTS

A number of branded products are recommended in this manual for use during maintenance and repair work. These items include:

HYLOMAR GASKET AND JOINTING COMPOUND

and

HYLOSIL RTV SILICONE COMPOUND.

They should be available locally from garage equipment suppliers. If there is any problem obtaining supplies, contact the following company for advice and the address of the nearest supplier.

MARSTON LUBRICANTS LTD. Hylo House, Cale Lane, New Springs, Wigan WN2 1JR

USED ENGINE OIL

WARNING: Prolonged and repeated contact with engine or motor oil will result

in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. Used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided.

Handling precautions

1. Avoid prolonged and repeated contact with oils,

particularly used engine oils.

2. Wear protective clothing, including impervious

gloves where applicable.

3. Do not put oily rags in pockets.

4. Avoid contaminating clothes, particularly

underwear, with oil.

5. Overalls must be cleaned regularly. Discard

unwashable clothing and oil impregnated footwear.

6. First aid treatment must be obtained immediately

for open cuts and wounds.

7. Use barrier creams, before each work period, to

help the removal of oil from the skin.

8. Wash with soap and water to ensure all oil is

removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed.

9. Do not use gasoline, kerosene, diesel fuel,

petrol, thinners or solvents for washing the skin.

10. If skin disorders develop, obtain medical advice.

11. Where practicable, degrease components prior

to handling.

12. Where there is a risk of eye contact, eye

protection should be worn, for example, goggles or face shields; in addition an eye wash facility should be provided.

Disposing of used oils

Environmental protection precaution

Tel 01942 824242

It is illegal to pour used oil onto the ground, down sewers or drains, or into waterways.

Dispose of used oil through authorised waste disposal contractors. If in doubt contact your Local Authority for advice on disposal facilities.

INFORMATION

INTRODUCTION

ACCESSORIES AND CONVERSIONS

DO NOT FIT unapproved 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.

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.

STEAM CLEANING

To prevent consequential rusting, any steam cleaning within the engine bay MUST be 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.

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

INFORMATION

JACKING

The following instructions must be carried out before raising the vehicle off the ground.

1. Use a solid level ground surface.

2. Apply parking brake.

3. Select 1st gear in main gearbox.

4. Select Low range in transfer gearbox.

CAUTION: To avoid damage occurring to

the under body components of the vehicle

the following jacking procedures must be adhered to.

DO NOT POSITION JACKS OR AXLE STANDS UNDER THE FOLLOWING COMPONENTS.

Body structure Bumpers Fuel lines Brake lines Front radius arms Panhard rod Steering linkage Rear Trailing links Fuel tank Engine sump Gearbox bell housing

INTRODUCTION

Jack or support vehicle by axles only.

Vehicle jack

The jack provided with the vehicle is only intended to be used in an emergency, for changing a tyre. Do NOT use the jack for any other purpose. Refer to Owner’s Manual for vehicle jack location points and procedure. Never work under a vehicle supported by the vehicle jack.

Hydraulic jack

A hydraulic jack with a minimum 1500 kg, 3,300 lbs load capacity must be used, see illustration J6083.

CAUTION: Do not commence work on the

underside of the vehicle until suitable axle

stands have been positioned under the axle, see J6084.

Raise the front of the vehicle

1. Position cup of hydraulic arm under differential

casing.

NOTE: The differential casing is not central to the axle. Care should be taken when raising the front road wheels off the

ground as the rear axle has less sway stiffness.

2. Raise front road wheels to enable an axle stand

to be installed under left hand axle tube.

INFORMATION

INTRODUCTION

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.

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.

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.

INFORMATION

INTRODUCTION

TOWING

CAUTION: The vehicle has permanent

four-wheel drive. The following towing

instructions must be adhered to:

Towing the vehicle on all four wheels with driver operating steering and brakes.

1. Turn ignition key to position ’1’ to release

steering lock.

2. Select neutral in main gearbox and transfer

gearbox.

Rear suspended tow by breakdown vehicle

1. If the front axle is to be trailed turn ignition key to

position ’1’ to release steering lock.

2. Select neutral in main gearbox and transfer box.

CAUTION: The steering wheel and/or linkage must be secured in a straight ahead position. DO NOT use the steering

lock mechanism for this purpose.

TRANSPORTING THE VEHICLE BY TRAILER

Lashing/towing eyes are provided on front and rear of the chassis side members, see J6085, to facilitate the securing of the vehicle to a trailer or other means of transportation.

CAUTION: Underbody components must not be used as lashing points.

Install vehicle on trailer and apply park brake. Select neutral in main gearbox.

3. Secure tow rope, chain or cable to front towing

eyes (alternative types shown).

4. Release the parking brake.

CAUTION: The brake servo and power

assisted steering system will not be

functional without the engine running. Greater pedal pressure will be required to apply the brakes, the steering system will require greater effort to turn the front road wheels. The vehicle tow connection should be used only in normal road conditions, ’snatch’ recovery should be avoided.

INFORMATION

JUMP STARTING

flames, sparks or lighted tobacco are brought near battery. When charging or using a battery in an enclosed space, always provide ventilation and shield your eyes.

Keep out of reach of children. Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also, shield eyes when working near battery to protect against possible splashing of acid solution. In case of acid contact with skin, eyes, or clothing, flush immediately with water for a minimum of fifteen minutes. If acid is swallowed, drink large quantities of milk or water, followed by milk of magnesia, a beaten egg, or vegetable oil.

SEEK MEDICAL AID IMMEDIATELY.

To Jump Start - Negative Ground Battery

INTRODUCTION

WARNING: Hydrogen and oxygen gases

are produced during normal battery

operation. This gas mixture can explode if

WARNING: To avoid any possibility of

injury use particular care when connecting

a booster battery to a discharged battery.

WARNING: Making final cable connection could cause an electrical arc which if made near battery could cause an

explosion.

3. If booster battery is installed in another vehicle,

start engine and allow to idle.

4. Start engine of vehicle with discharged battery,

following starting procedure in Owners’ Manual.

1. Position vehicles so that jump leads will reach, ensuring that vehicles DO NOT TOUCH, alternatively a fully charged slave battery may be positioned on floor adjacent to vehicle.

2. Ensuring that ignition and all electrical accessories are switched off, that parking brake is applied and neutral is selected, connect the jump leads as follows;

A. Connect one end of first jumper cable to positive (+) terminal of booster battery. B. Connect other end of first jumper cable to positive (+) terminal of discharged battery. C. Connect one end of second jumper cable to negative terminal of booster battery. D. Connect other end of second jumper cable to a good earth point on the disabled vehicle (eg. engine front lifting eye, as shown in J6086), NOT TO

NEGATIVE TERMINAL OF DISCHARGED BATTERY. Keep jumper lead away from moving

parts, pulleys, drive belts and fan blade assembly.

CAUTION: If vehicle fails to start within a maximum time of 12 seconds, switch

ignition off and investigate cause. Failing to follow this instruction could result in irrepairable damage to catalyst, if fitted.

5. Remove negative (-) jumper cable from the

engine and then terminal of booster battery.

6. Remove positive (+) jumper cable from positive

terminals of booster battery and discharged battery.

INFORMATION

ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL

INTRODUCTION

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 Cubic inch in

...................................................

...............................................................

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 Kilogramme per square centimetre kgf/cm

.................

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 Square inches in

...............................................

.........................................................

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.........................................................

INFORMATION

CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY

INTRODUCTION

NEW TERM (ACRONYM)

Accelerator pedal (AP).................................................

Air cleaner (ACL)..........................................................

Air conditioning (A/C)...................................................

Battery positive voltage (B+)........................................

Closed loop (CL)..........................................................

Closed throttle position (CTP)......................................

Canister purge valve (CANPV)....................................

Data link connector (DLC)...........................................

Diagnostic trouble code (DTC).....................................

Distributor ignition (DI).................................................

Engine control module (ECM)......................................

Engine coolant level (ECL)...........................................

Engine coolant temperature (ECT)..............................

Engine speed (RPM)....................................................

Evaporative emission system (EVAP)..........................

Engine fuel temperature sensor (EFTS)......................

4th gear, 3rd gear etc. (4GR, 3GR)..............................

Fuel pump (FP)............................................................

Fan control module (FCM)...........................................

Generator (GEN)..........................................................

Ground (GND)..............................................................

Heated oxygen sensor (H02S)....................................

Idle air control (IAC)......................................................

Idle air control valve (IACV).........................................

Ignition control module (ICM).......................................

Intake air temperature (IAT).........................................

Manifold vacuum zone (MVZ)......................................

Mass air flow sensor (MAF).........................................

Open loop (OL)............................................................

Relay module (RM)......................................................

Solid state relay module (SSRM).................................

Three way catalytic converter (TWC)..........................

Throttle body (TB)........................................................

Throttle position sensor (TP)........................................

Transmission range (TR)..............................................

Wide open throttle (WOT)............................................

OLD TERM (ACRONYM)

Throttle pedal (-)..........................................................

Air cleaner (-)...............................................................

Air conditioning (AC)....................................................

Battery plus, bat +, bat feed (B+).................................

Closed loop (-).............................................................

Closed throttle, idle position (-)....................................

Charcoal canister purge valve (-).................................

Serial link (-)................................................................

Fault code (-)...............................................................

Electronic ignition (-)....................................................

Electronic control unit (ECU)........................................

Coolant level (-)...........................................................

Coolant temperature (temp).........................................

Coolant temperature thermistor (-)..............................

Engine speed (rev/min)................................................

Evaporative loss system (ELC)...................................

Fuel temperature thermistor (-)....................................

Fourth gear, 3rd gear (-)..............................................

Fuel pump (-)...............................................................

Condenser fan timer (-)................................................

Alternator (-)................................................................

Ground, earth (B-)........................................................

Lambda (02) sensor (-)................................................

Idle speed control (ISC)................................................

Stepper motor (-).........................................................

Ignition module (-)........................................................

Intake temperature/ambient temperature (-)................

Manifold depression, vacuum (-).................................

Air flow meter (-)..........................................................

Fault code display unit (-)............................................

Open loop (-)...............................................................

Relay (-).......................................................................

Control unit (-)..............................................................

Catalyst, catalytic converter (CAT)..............................

Throttle housing (-)......................................................

Transmission gear (-)...................................................

Full throttle, wide open throttle (WOT).........................

INFORMATION

VEHICLE IDENTIFICATION NUMBER (VIN)

The Vehicle Identification Number and the recommended maximum vehicle weights are stamped on a plate riveted to the brake pedal box in the engine compartment. The VIN is also stamped on a plate visible through the LH side of the windscreen.

INTRODUCTION

a. Identification b. Maximum permitted laden weight for vehicle c. Maximum vehicle and trailer weight d. Maximum road weight-front axle e. Maximum road weight-rear axle f. Paint code g. Trim level

The number is also stamped on the RH side of the chassis to the rear of the front lashing eye, see J6089.

The Vehicle Identification Number identifies the manufacturer, model range, wheel base, body type, engine, steering, transmission, model year and place of manufacture. The following example shows the coding process.

SAL LD H M 8 7 X A

SAL = World manufacturer identifier LD = Land Rover Defender H = 110 inch, V= 90inch, K= 130 inch M = 4 door Station Wagon, A= 90 Soft Top, Hard Top,

Pick-up, B= 2 door Station Wagon, E= 2 door 130 Crew cab, F= 4 door 130 Crew cab, H= 130 High Capacity Pick-up

8= Td5 engine. 7= RH drive, 5 speed manaul, 8= LH drive, 5 speed

manual

X= 1999 MY, volume build. A= Solihull build, F= CKD, assembled locally from kit

INFORMATION

INTRODUCTION

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.

INFORMATION

INTRODUCTION

Front axle serial number

Stamped on the front of LH axle tube, inboard of radius arm mounting bracket.

Rear axle serial number

FAULT DIAGNOSTIC EQUIPMENT

TESTBOOK

For Defender models fitted with the vehicle Anti-theft Immobilisation and Alarm System, diagnostic equipment, named TestBook, is available to assist in the diagnostic and fault finding abilities of the Dealer workshop. A diagnostic connector, located under the front centre seat, or cubby box, as shown below, is provided to facilitate the procedures.

Stamped on the rear of LH axle tube, inboard of spring mounting.

If an exhaust gas recirculation (EGR) system is fitted, this too can be checked using TestBook. A diagnostic connector, also located under the front centre seat or cubby box, is provided.

Features of Testbook include :-

Fully upgradable support for the technician. Structured diagnostics to accommodate all skill levels. Touch screen operation. Direct print out of screen information and test results.

INFORMATION

READING THIS SUPPLEMENT

This Supplement is divided into sections shown on the contents page, alongside a range of icons, familiar to service technicians.

Relevant information is contained within each of these sections. These are further divided into the following sub-sections which appear at the foot of each page :-

Description and operation. Adjustment. Repair. Overhaul.

To avoid repeating information through the sections, where part of the repair operation impacts on another section, a cross reference is given to direct the reader to where the information is sited.

INTRODUCTION

For example: The maintenance section states the need to renew drive belt. A cross reference sites this information in: Section 12 Engine

- Sub-section: Repair

INFORMATION

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.......................................................................................................

BULBS 9.................................................................................................................

VEHICLE WEIGHTS AND PAYLOAD 10................................................................

TOWING WEIGHTS 11...........................................................................................

OFF-ROAD PERFORMANCE 11............................................................................

TYRE SIZE AND PRESSURES 12.........................................................................

WHEELS 12............................................................................................................

VEHICLE DIMENSIONS 13....................................................................................

GENERAL SPECIFICATION DATA

ENGINE - Td5

Type 2.5 litre in-line direct injection Diesel, turbocharged.................................................................................

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 cm3(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

and intercooled

Type Wet sump, pressure fed.................................................................................

Pump type Eccentric rotor, crankshaft driven integral with stiffener........................................................................

Filter type:

Primary Centrifuge filter....................................................................

Secondary Disposable canister with full flow by-pass...............................................................

Pressure at idle (cold) 3.0 bar (43.5 lbf.in2)......................................................

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.................................................................................

Clearance in cylinder bore 0.172 - 0.206 mm (measured at bottom of skirt, 90° to...............................................

Diameter 84.270 - 85.254 mm (measured 90° to gudgeon pin,..........................................................................

plate.

crown.

gudgeon pin)

and 40.00 mm from bottom of skirt.)

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)................................................................

GENERAL SPECIFICATION DATA

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.................................................................................

INFORMATION

GENERAL SPECIFICATION DATA

FUEL SYSTEM - Td5

Type Direct injection from pressure regulated supply with.................................................................................

Pressure regulator setting 4 bar (58 lbf.in2)................................................

Pump Electric two stage submersible................................................................................

Pump output

Low pressure 30 l/h (6.6 gal/h) at 0.5 bar (7.25 lbf.in2)..........................................................

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.in2)..................................

Filter In-line canister filter/water separator with water.................................................................................

COOLING SYSTEM - Td5

Type Pressurised spill return partial flow, thermostatically.................................................................................

Cooling fans 11 blade axial flow on viscous coupling and 11 blade.....................................................................

Electric cooling fan switching points

On Vehicle speeds of 50 mph (80 km/h) and below while...........................................................................

Off Vehicle speeds of 62.5 mph (100 km/h) and above or...........................................................................

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.in2).........

cooled return flow

detection

controlled

axial flow electric

ambient temperature is 28°C (82°F) or above

ambient temperatures of 25°C (77°F) and below

CLUTCH - Td5

Type Diaphragm spring, hydraulically operated with.................................................................................

Drive plate diameter 267 mm.........................................................

Pressure plate diameter 270 mm...................................................

self-centering pre-loaded release bearing

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.................................................................

Rear axle

Type Spiral bevel, fully floating shafts.................................................................................

Ratio 3.54:1.................................................................................

Front axle

GENERAL SPECIFICATION DATA

and rear drive permanently engaged via a lockable differential

Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................

Ratio 3.54:1.................................................................................

Propeller shafts

Type, front and rear Tubular 51 mm dia...........................................................

Universal joints Open type Hookes O3EHD.................................................................

floating shafts, 32° angularity of universal joint on full lock

INFORMATION

GENERAL SPECIFICATION DATA

STEERING

Power steering box

Make/type Adwest Varamatic - worm and roller box........................................................................

Ratio Variable: straight ahead 19.3:1 on lock 14.3:1.................................................................................

Steering wheel turns, lock-to-lock 3.375....................................

Steering pump

Make/type Hobourn-Eaton series 500........................................................................

Steering geometry

Steering wheel diameter 412 mm (16.22 in)..................................................

Toe-out measurement 0 to 2 mm toe out......................................................

Toe-out included angle 0° to 0° 20’.....................................................

Camber angle 0° *..................................................................

Castor angle 3° *.....................................................................

Swivel pin inclination static 7° *...............................................

* Check with vehicle on level ground, in unladen condition and five gallons of fuel. Rock the front of the vehicle up and down to allow it to take up a normal static position.

Turning circle between kerbs

90 models:

265/75 x 16 tyres 12,65 m (41.5 ft)..............................................................

All other tyres 11,70 m (38.4 ft)...................................................................

110 models:

750 x 16 tyres 13,41 m (44 ft)..................................................................

130 models:

750 x 16 tyres 15,24 m (50 ft)..................................................................

INFORMATION

SUSPENSION

Type Coil springs controlled by telescopic dampers front.................................................................................

Front Transverse location of axle by Panhard rod, and fore.................................................................................

Rear Fore and aft movement inhibited by two tubular trailing.................................................................................

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

GENERAL SPECIFICATION DATA

and rear.

and aft location by two radius arms. Anti-roll bar fitted as standard on 90 models with 265/75 tyres and 130 models.

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.

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

INFORMATION

GENERAL SPECIFICATION DATA

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 cm2(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).........................................................................

Disc run-out maximum 0,15 mm (0.006 in).....................................................

Pad area 90 - 30,5 cm2(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.................................................................................

Drum internal diameter 254 mm (10.0 in).....................................................

Width 70 mm (2.75 in)................................................................................

Pad material Ferodo 3611 non asbestos.....................................................................

Servo/master cylinder

per side of disc

the transfer gearbox output shaft

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/in2) ratio 4.0:1,......................

NOTE: * Pressure reducing valves are not fitted to all 110 specifications.

110 - 43 bar (645 Ibf/in2) ratio 2.9:1*

INFORMATION

AIR CONDITIONING

System CFC free, expansion valve system.............................................................................

Compressor Nippon Denso.....................................................................

Refrigerant R134a CFC free.......................................................................

Charge quantity 750 g ± 50 g................................................................

Refrigerant oil ND-OIL 8...................................................................

WIPER MOTORS

Tailgate wiper motor

Make/type IMOS (non-serviceable)........................................................................

Running current, wet screen at 20°C ambient 1.0 to 2.8 amps.................

Wiper speed, wet screen at 20°C ambient 37 to 43 cycles per minute.......................

Windscreen wiper motor

GENERAL SPECIFICATION DATA

Make/type Lucas 14W uprated two speed........................................................................

Armature end float 0,1 to 0,2 mm............................................................

Brush length, minimum 4,8 mm....................................................

Brush spring tension 140 to 200 g........................................................

Resistance of armature winding at 16˚C (69˚F) measured between adjacent

commutatator segments 0.23 to 0.35 ohms...................................................

Light running, rack disconnected: current at 13.5 V 2.0 amps.........

Wiper speed, wet screen, 60 seconds from cold Low speed - 45 ± 3 rev/min, High speed - 65 ± 5..............

ELECTRICAL

System 12 volt, negative ground.............................................................................

Battery

Make/type Delphi GP31........................................................................

Alternator

Type Nippon Denso.................................................................................

rev/min

Fuses

Type Autofuse (blade type) blow ratings to suit individual.................................................................................

Horns

Make/type Mixo TR99........................................................................

Starter motor

Make and type Bosch 12v.................................................................

INFORMATION

circuits

GENERAL SPECIFICATION DATA

BULBS

REPLACEMENT BULBS TYPE

Headlamps 12V 60/55W Halogen Front side lamps 12V 5W Side repeater lamps 12V 5W Tail lamps 12V 21W Cente High Mounted Stop Lamp 12V 21W Direction indicator lamps 12V 21W Number plate lamp 12V 4W Reverse lamp 12V 21W Rear fog guard lamp 12V 21W Interior roof lamps 12V 10W Instrument illumination 12V 1.2W Warning light panel 12V 1.2W Hazard warning switch 12V 1.2W

CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage to vehicle wiring and switches.

INFORMATION

VEHICLE WEIGHTS AND PAYLOAD

When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the unladen vehicle weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum values.

It is the customer’s responsibility to limit the vehicle’s payload in an appropriate manner such that neither maximum axle loads nor Gross Vehicle Weight are exceeded.

Maximum EEC kerb weight and distribution - all optional equipment

VEHICLE AXLE WEIGHTS

90 models Station Wagon Utility

Front axle 1200 Kg (2645 lb)......................................................................... 1200 Kg (2645 lb)

Rear axle 1500 kg (3307 lb).......................................................................... 1500 Kg (3307 lb)

Gross vehicle weight 2550 Kg (5291 lb)........................................................ 2400 Kg (5622 lb)

110 models Station Wagon Utility

Front axle 1200 Kg (2645 lb)......................................................................... 1200 Kg (2645 lb)

Rear axle 1750 Kg (3858 lb).......................................................................... 1850 Kg (4078 lb)

Gross vehicle weight 2950 Kg (6503 lb)........................................................ 3050 Kg (6724 lb)

GENERAL SPECIFICATION DATA

130 models Utility

Front axle 1580 Kg (3483 lb).....................................................................................................................

Rear axle 2200 Kg (4850 lb)......................................................................................................................

Gross vehicle weight 3500 Kg (7716 lb)....................................................................................................

NOTE: Axle weights are not accumulative. The individual maximum axle weights and gross vehicle weight must not be exceeded.

EEC VEHICLE KERB WEIGHTS

90 models Standard Heavy Duty

Soft top: 1770 Kg (3402 lb)............................................................................ 1993 Kg (4393 lb)

Pick-up: 1770 Kg (3402 lb)............................................................................ 1993 Kg (4393 lb)

Hard top: 1815 Kg (4001 lb).......................................................................... 1987 Kg (4380 lb)

Station wagon: 1870 Kg - 1885 Kg................................................................. 1989 Kg - 1998 Kg

(4122 lb - 4155 lb) (4385 lb - 4404 lb)

110 models

Soft top: 1885 Kg - 2080 Kg............................................................................ (4155 lb - 4585 lb)

High capacity pick-up: 1920 Kg - 2122 Kg...................................................... (4232 lb - 4678 lb)

Hard top: 1920 Kg - 2110 Kg.......................................................................... (4232 lb - 4651 lb)

Station wagon: 2055 Kg - 2229 Kg................................................................. (4530 lb - 4914 lb)

130 models

Crew cab and high capacity pick-up: 2177 Kg - 2286 Kg...........................................................................

(4667 lb - 5039 lb)

EEC kerb weight = Unladen weight + Full fuel tank + 75 Kg (165 lb).

INFORMATION

GENERAL SPECIFICATION DATA

TOWING WEIGHTS

On-road Off-road

Unbraked trailers 750 Kg (1653 lb).............................................................. 500 Kg (1102 lb)

Trailers with overrun brakes 3500 Kg (7716 lb)............................................. 1000 Kg (2204 lb)

4 wheel trailers with coupled brakes * 4000 Kg (8818 lb).............................. 1000 Kg (2204 lb)

NOTE: * Only applies to vehicles modified to accept coupled brakes.

NOTE: All weight figures are subject to local restrictions.

OFF-ROAD PERFORMANCE

90 models

Max. gradient (EEC kerb weight) 45°.....................................

Approach angle:

Soft top and Pick-up (EEC kerb weight) 48°..................

Hard top and station wagon (EEC kerb weight) 51.5°......

Departure angle

Soft top and Pick-up (EEC kerb weight) 49°..................

Hard top and Station wagon (EEC kerb weight) 53°...............

Wading depth 500 mm (20 in)...................................................................

Min. ground clearance (unladen):

Soft top and pick-up 191 mm (7.5 in).................................................

Hard top and station wagon 229 mm (9.0 in).....................................

NOTE: Departure angles do not account for the addition of a tow hitch.

110 and 130 models

Max. gradient (EEC kerb weight) 45°.....................................

Approach angle (EEC kerb weight) 50°..................................

Departure angle (EEC kerb weight)

110 models 35°......................................................................

130 models 34°......................................................................

Wading depth 500 mm (20 in)...................................................................

Min. ground clearance (unladen 215 mm (8.5 in).......................................

NOTE: Departure angles do not account for the addition of a tow hitch.

INFORMATION

GENERAL SPECIFICATION DATA

TYRE SIZE AND PRESSURES

90 models Front Rear

Normal - all load conditions

205/80 R16 Radial 1,9 bar.................................................. 2,6 bar

28 Ibf/in 2,0 kgf/cm

38 Ibf/in 2,7 kgf/cm

265/75 R16 Radial (multi terrain) 1,9 bar.......................... 2,4 bar

28 Ibf/in 2,0 kgf/cm

7.50 R16 Radial 1,9 bar...................................................... 2,6 bar

28 Ibf/in 2,0 kgf/cm

110 models

Normal - all load conditions

7.50 R16 Radial 1,9 bar...................................................... 3,3 bar

28 Ibf/in 2,0 kgf/cm

130 models

Normal - all load conditions

7.50 R16 Radial 3,0 bar...................................................... 4,5 bar

44 Ibf/in 3,1 kgf/cm

WARNING: Tyre pressures must be checked with the tyres cold, as the

pressure is about 0,21 bar (3 Ibf/in2, 0,2 kgf/cm2) higher at running temperature. If the vehicle has been parked in the sun or high ambient temperatures, DO NOT reduce the tyre pressures, move the vehicle into the shade and wait for the tyres to cool before checking the

WARNING: Always use the same make and type of radial-ply tyres, front and rear. DO NOT use cross-ply tyres, or interchange

tyres from front to rear.

• If the the wheel is marked ’TUBED’, an inner tube MUST be fitted, even with a tubeless tyre.

• If the wheel is marked ’TUBELESS’, an inner tube must NOT be fitted.

pressures.

35 Ibf/in

2,5 kgf/cm

38 Ibf/in

2,7 kgf/cm

48 Ibf/in

3,4 kgf/cm

65 Ibf/in

4,6 kgf/cm

WHEELS

90 models

Steel wheel size:

Heavy duty - UK and Western Europe 6.5F X 16.............................

Other markets 5.5F X 16..................................................................

Alloy wheel size 7J X 16................................................................

110 models

Steel wheel size:

Heavy duty - UK and Western Europe 6.5F X 16.............................

Other markets 5.5F X 16..................................................................

130 models

Steel wheel size:

Heavy duty - UK and Western Europe 6.5F X 16.............................

Other markets 5.5F X 16..................................................................

INFORMATION

GENERAL SPECIFICATION DATA

VEHICLE DIMENSIONS

90 models

Overall length:

Soft top and Pick-up 3722 mm (146.5 in)................................................

Hard top and Station wagon 3883 mm (152.9 in)....................................

Overall width: 1790 mm (70.5 in)...................................................................

Overall height:

Soft top 1965 mm (77.4 in)....................................................................

Pick-up and Station wagon 1963 mm (77.3 in)......................................

Hard top 1972 mm (77.6 in)...................................................................

Wheelbase 2360 mm (92.9 in).......................................................................

Track front/rear 1486 mm (58.5 in).................................................................

Width between wheel boxes 925 mm (36.4 in)............................................

110 models

Overall length:

Soft top and Pick-up 4438 mm (175 in)................................................

High capacity pick-up 4631 mm (182 in)..............................................

Hard top/Station and County 4599 mm (181 in)...................................

Overall width: 1790 mm (70.5 in)...................................................................

Overall height: 2035 mm (80.1 in)..................................................................

Wheelbase 2794 mm (110 in).......................................................................

Track front/rear 1486 mm (58.5 in).................................................................

Width between wheel boxes:

High capacity pick-up 1090 mm (43 in)..............................................

all other models 925 mm (36.4 in).......................................................

130 models

Overall length 5132 mm (202 in)...................................................................

Overall width 1790 mm (70.5 in)....................................................................

Overall height 2035 mm (80.1 in)...................................................................

Wheelbase 3226 mm (127 in).......................................................................

Track front/rear 1486 mm (58.5 in).................................................................

Width between wheel boxes 1090 mm (43 in)............................................

INFORMATION

05 - ENGINE TUNING DATA

CONTENTS

Page

INFORMATION

ENGINE - Td5 1......................................................................................................

HEATER PLUGS - Td5 1........................................................................................

INJECTORS - Td5 1................................................................................................

TURBOCHARGER - Td5 1.....................................................................................

ENGINE - Td5

Type 2.5 Litre direct injection Diesel, turbocharged,.................................................................................

Firing order 1-2-4-5-3.....................................................................

Injection timing Controlled by ECM...............................................................

Maximum governed speed 4850 rev/min............................................

Maximum overrun speed 5460 rev/min...............................................

Idle speed 740 ± 50 rev/min.......................................................................

HEATER PLUGS - Td5

Make & type Beru 12 V......................................................................

Number of plugs Four plugs only, in cylinders 1, 2, 3 and 4...............................................................

ENGINE TUNING DATA

intercooled

INJECTORS - Td5

Injectors

Make/Type Lucas EV1..............................................................

Nominal operating pressure 1500 bar (21750 lbf.in2)....................................

TURBOCHARGER - Td5

Make & type Garrett GT 20.....................................................................

INFORMATION

07 - GENERAL FITTING REMINDERS

CONTENTS

Page

INFORMATION

GENERAL FITTING REMINDERS 1.......................................................................

PRECAUTIONS AGAINST DAMAGE 1..................................................................

SAFETY PRECAUTIONS 1....................................................................................

PREPARATION 2....................................................................................................

DISMANTLING 2.....................................................................................................

INSPECTION-GENERAL 2.....................................................................................

BALL AND ROLLER BEARINGS 3.........................................................................

OIL SEALS 4...........................................................................................................

JOINTS AND JOINT FACES 5................................................................................

FLEXIBLE HYDRAULIC PIPES, HOSES 5.............................................................

FUEL SYSTEM HOSES 6.......................................................................................

METRIC BOLT IDENTIFICATION 6........................................................................

METRIC NUT IDENTIFICATION 6..........................................................................

KEYS AND KEYWAYS 6........................................................................................

TAB WASHERS 6...................................................................................................

COTTER PINS 7.....................................................................................................

NUTS 7...................................................................................................................

LOCKING WIRE 7...................................................................................................

SCREW THREADS 7..............................................................................................

UNIFIED THREAD IDENTIFICATION 7..................................................................

GENERAL FITTING REMINDERS

WORKSHOP SAFETY IS YOUR RESPONSIBILITY!

The suggestions, cautions and warnings in the section are intended to serve as reminders for trained and experienced mechanics. This manual is not a definitive guide to automotive mechanics or workshop safety.

Shop equipment, shop environment, and the use and disposal of solvents, fluids, and chemicals are subject to government regulations which are intended to provide a level of safety. It is your responsibility to know and comply with such regulations.

PRECAUTIONS AGAINST DAMAGE

1. Always fit covers to protect fenders before

commencing work in engine compartment.

2. Cover seats and carpets, wear clean overalls

and wash hands or wear gloves before working inside vehicle.

3. Avoid spilling hydraulic fluid or battery acid on

paint work. Wash off with water immediately if this occurs. Use Polythene sheets to protect carpets and seats.

4. Always use a recommended Service Tool where

specified.

5. Protect temporarily exposed screw threads by

replacing nuts or fitting plastic caps.

SAFETY PRECAUTIONS

1. Whenever possible, use a lift when working

beneath vehicle, in preference to jacking. Chock wheels as well as applying parking brake.

WARNING: Do not use a pit when removing fuel system components.

2. Never rely on a jack alone to support vehicle.

Use axle stands carefully placed at jacking points to provide rigid support.

3. Ensure that a suitable form of fire extinguisher is

conveniently located.

4. Check that any lifting equipment used has

adequate capacity and is fully serviceable.

5. Disconnect battery.

WARNING: Do not disconnect any pipes in air conditioning system, unless trained

and instructed to do so. A refrigerant is used which can cause blindness if allowed to contact eyes.

6. Ensure that adequate ventilation is provided

when volatile degreasing agents are being used.

7. Do not apply heat in an attempt to free stiff

fixings; as well as causing damage to protective coatings, there is a risk of damage to electronic equipment and brake linings from stray heat.

INFORMATION

GENERAL FITTING REMINDERS

PREPARATION

1. Clean components and surrounding area prior to

removal.

2. Blank off any openings exposed by component

removal using greaseproof paper and masking tape.

3. Immediately seal fuel, oil or hydraulic lines when

separated, using plastic caps or plugs, to prevent loss of fluid and entry of dirt.

4. Close open ends of oilways, exposed by

component removal, with tapered hardwood plugs or readily visible plastic plugs.

5. Immediately a component is removed, place it in

a suitable container; use a separate container for each component and its associated parts.

6. Before dismantling a component, clean it

thoroughly with a recommended cleaning agent; check that agent is suitable for all materials of component.

7. Clean bench and provide marking materials,

labels, containers and locking wire before dismantling a component.

INSPECTION-GENERAL

1. Never inspect a component for wear or

dimensional check unless it is absolutely clean; a slight smear of grease can conceal an incipient failure.

2. When a component is to be checked

dimensionally against figures quoted for it, use correct equipment (surface plates, micrometers, dial gauges, etc.) in serviceable condition. Makeshift checking equipment can be dangerous.

3. Reject a component if its dimensions are outside

limits quoted, or if damage is apparent. A part may, however, be refitted if its critical dimension is exactly limit size, and is otherwise satisfactory.

4. Use ’Plastigauge’ 12 Type PG-1 for checking

bearing surface clearances. Directions for its use, and a scale giving bearing clearances in 0,0025 mm steps are provided with it.

DISMANTLING

1. Observe scrupulous cleanliness when

dismantling components, particularly when brake, fuel or hydraulic system parts are being worked on. A particle of dirt or a cloth fragment could cause a dangerous malfunction if trapped in these systems.

2. Blow out all tapped holes, crevices, oilways and

fluid passages with an air line. Ensure that any O-rings used for sealing are correctly replaced or renewed, if disturbed.

3. Use marking ink to identify mating parts, to

ensure correct reassembly. If a centre punch or scriber is used they may initiate cracks or distortion of components.

4. Wire together mating parts where necessary to

prevent accidental interchange (e.g. roller bearing components).

5. Wire labels on to all parts which are to be

renewed, and to parts requiring further inspection before being passed for reassembly; place these parts in separate containers from those containing parts for rebuild.

6. Do not discard a part due for renewal until it has

been compared with the new part, to ensure that its correct replacement has been obtained.

INFORMATION

GENERAL FITTING REMINDERS

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.

INFORMATION

OIL SEALS

replacement seal.

1. Always fit new oil seals when rebuilding an

assembly.

2. Carefully examine seal before fitting to ensure

that it is clean and undamaged.

3. Coat the sealing lips with clean grease; pack

dust excluder seals with grease, and heavily grease duplex seals in cavity between sealing lips.

4. Ensure that seal spring, if provided, is correctly

fitted.

GENERAL FITTING REMINDERS

NOTE: Ensure that the seal running track is free from pits, scores, corrosion and general damage prior to fitting

7. If correct service tool is not available, use a

suitable drift approximately 0,4 mm (0.015 in) smaller than outside diameter of seal. Use a hammer VERY GENTLY on drift if a press is not suitable.

8. Press or drift seal in to depth of housing if

housing is shouldered, or flush with face of housing where no shoulder is provided. Ensure that the seal does not enter the housing in a tilted position.

5. Place lip of seal towards fluid to be sealed and

slide into position on shaft, using fitting sleeve when possible to protect sealing lip from damage by sharp corners, threads or splines. If fitting sleeve is not available, use plastic tube or tape to prevent damage to sealing lip.

6. Grease outside diameter of seal, place square to

housing recess and press into position, using great care and if possible a ’bell piece’ to ensure that seal is not tilted. In some cases it may be preferable to fit seal to housing before fitting to shaft. Never let weight of unsupported shaft rest in seal.

NOTE: Most cases of failure or leakage of

oil seals are due to careless fitting, and

resulting damage to both seals and sealing surfaces. Care in fitting is essential if good results are to be obtained. NEVER use a seal which has been improperly stored or handled, such as hung on a hook or nail.

INFORMATION

GENERAL FITTING REMINDERS

JOINTS AND JOINT FACES

1. Always use correct gaskets where they are

specified.

2. Use jointing compound only when

recommended. Otherwise fit joints dry.

3. When jointing compound is used, apply in a thin

uniform film to metal surfaces; take great care to prevent it from entering oilways, pipes or blind tapped holes.

4. Remove all traces of old jointing materials prior

to reassembly. Do not use a tool which could damage joint faces.

5. Inspect joint faces for scratches or burrs and

remove with a fine file or oil stone; do not allow removed material or dirt to enter tapped holes or enclosed parts.

6. Blow out any pipes, channels or crevices with

compressed air, fit new ’O’ rings or seals displaced by air blast.

FLEXIBLE HYDRAULIC PIPES, HOSES

1. Before removing any brake or power steering

hose, clean end fittings and area surrounding them as thoroughly as possible.

2. Obtain appropriate plugs or caps before

detaching hose end fittings, so that ports can be immediately covered to exclude dirt.

3. Clean hose externally and blow through with

airline. Examine carefully for cracks, separation of plies, security of end fittings and external damage. Reject any hose found faulty.

4. When refitting hose, ensure that no unnecessary

bends are introduced, and that hose is not twisted before or during tightening of union nuts.

5. Containers for hydraulic fluid must be kept

absolutely clean.

6. Do not store brake fluid in an unsealed

container. It will absorb water, and fluid in this condition would be dangerous to use due to a lowering of its boiling point.

7. Do not allow brake fluid to be contaminated with

mineral oil, or use a container which has previously contained mineral oil.

8. Do not re-use brake fluid bled from system.

9. Always use clean brake fluid to clean hydraulic

components.

10. Fit a cap to seal a hydraulic union and a plug to

its socket after removal to prevent ingress of dirt.

11. Absolute cleanliness must be observed with

hydraulic components at all times.

12. After any work on hydraulic systems, inspect

carefully for leaks underneath the vehicle while a second operator applies maximum pressure to the brakes (engine running) and operates the steering.

INFORMATION

GENERAL FITTING REMINDERS

FUEL SYSTEM HOSES

CAUTION: All fuel hoses are made up of two laminations, an armoured rubber outer

sleeve and an inner viton core. If any of the fuel system hoses have been disconnected, it is imperative that the internal bore is inspected to ensure that the viton lining has not become separated from the amoured outer sleeve. A new hose must be fitted if separation is evident.

METRIC BOLT IDENTIFICATION

METRIC NUT IDENTIFICATION

1. A nut with an ISO metric thread is marked on

one face or on one of the flats of the hexagon with the strength grade symbol 8, 12 or 14. Some nuts with a strength 4, 5 or 6 are also marked and some have the metric symbol M on the flat opposite the strength grade marking.

2. A clock face system is used as an alternative

method of indicating the strength grade. The external chamfers or a face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate the strength grade.

3. A dot is used to locate the 12 O’clock position

and a dash to indicate the strength grade. If the grade is above 12, two dots identify the 12 O’clock position.

1. An ISO metric bolt or screw, made of steel and

larger than 6 mm in diameter can be identified by either of the symbols ISO M or M embossed or indented on top of the head.

2. In addition to marks to identify the manufacture,

the head is also marked with symbols to indicate the strength grade, e.g. 8.8, 12.9 or 14.9, where the first figure gives the minimum tensile strength of the bolt material in tens of kgf/mm2.

3. Zinc plated ISO metric bolts and nuts are

chromate passivated, a gold-bronze colour.

INFORMATION

KEYS AND KEYWAYS

1. Remove burrs from edges of keyways with a fine

file and clean thoroughly before attempting to refit key.

2. Clean and inspect key closely; keys are suitable

for refitting only if indistinguishable from new, as any indentation may indicate the onset of wear.

TAB WASHERS

1. Fit new washers in all places where they are

used. Always fit a new tab washer.

2. Ensure that the new tab washer is of the same

design as that replaced.

GENERAL FITTING REMINDERS

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.

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.

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.

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.

INFORMATION

09 - LUBRICANTS, FLUIDS AND CAPACITIES

CONTENTS

Page

INFORMATION

RECOMMENDED LUBRICANTS AND FLUIDS 1..................................................

LUBRICATION PRACTICE 2..................................................................................

CAPACITIES 3........................................................................................................

ANTI-FREEZE 3......................................................................................................

RECOMMENDED FUEL 3......................................................................................

LUBRICANTS, FLUIDS AND CAPACITIES

RECOMMENDED LUBRICANTS AND FLUIDS

All climates and conditions

AMBIENT TEMPERATURE °C

COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 40 50

Td5 ACEA A1 5W/30, 5W/40

Engine sump and B1 5W/50

Manual gearbox Texaco MTF94

Final drive units Molytex EP90 EP90

Swivel pin housings Texaco EP00 EP00

Power steering ATF Dexron IID,

or III Texaco cold climate PAS fluid 14315

Transfer box Texaco Multigear 75W-90R LT230TE

INFORMATION

LUBRICANTS, FLUIDS AND CAPACITIES

Propeller shaft Front and Rear Lubrication nipples (hubs, ball joints etc.) Seat slides Door lock striker

Brake and clutch reservoirs

Engine coolant Use Texaco XLC long life coolant. Use one part anti-freeze to one part water for

Battery lugs, Petroleum jelly. Earthing surfaces NOTE: Do not use Silicone Grease where paint has been removed

Air Conditioning System Refrigerant Use only refrigerant R134a

Compressor Oil ND-OIL 8

NLGI - 2 Multi-purpose Lithium based GREASE

Brake fluids having a minimum boiling point of 260° C (500° F) and complying with FMVSS 116 DOT4

protection down to -36° C (-33° F).

IMPORTANT: Coolant solution must not fall below 50% anti-freeze otherwise damage to engine is liable to occur. Maximun concentration is 60%.

LUBRICATION PRACTICE

Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and ultimately to damaged components.

Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always adhere to the recommended servicing intervals.

WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must

not be consumed and must be kept away from open wounds. These substances, among others,

include anti-freeze, windscreen washer additives, lubricants and various adhesives.

INFORMATION

LUBRICANTS, FLUIDS AND CAPACITIES

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).

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.

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.

INFORMATION

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..................................................

10 - MAINTENANCE

CONTENTS

Page

ROAD TEST 23......................................................................................................

ENDORSE SERVICE RECORD 24........................................................................

REPORT ANY UNUSUAL FEATURES 24.............................................................

UNDERBONNET VIEW - Td5

MAINTENANCE

LHD shown

1. Engine oil dipstick

2. Coolant expansion tank

3. Air cleaner

4. Brake/clutch fluid reservoir filler cap

5. Windscreen washer reservior

6. Auxiliary drive belt

7. Engine oil filler cap

8. PAS fluid reservoir

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.

LAMPS, 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.

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

mountings

MAINTENANCE

WIPERS AND WASHERS

1. Operate screen washer and switch on wipers.

Check washer jets are correctly aimed and check for smooth smearless operation across screen of wiper blades at all speeds, including intermittent.

2. Repeat operation for rear screen

wipers/washers.

3. Check all wiper blades for condition and signs of

splits or damage.

HANDBRAKE

1. With the vehicle stationary, apply handbrake and

check for correct operation. See BRAKES, Adjustment.

2. Release handbrake and check for correct

operation.

NOTE: Any adjustment required as a result of the checking process will be subject to

additional labour and/or material cost and should not be carried out without the authorisation of the customer.

Adjust handbrake (First 12,000 miles/12 months only

4. Check security of wiper arms.

1. Adjust handbrake cable. See BRAKES,

Adjustment.

NOTE: Additional time is built into the first

12,000/12 months service time to allow for

handbrake cable adjustment.

MAINTENANCE

BATTERY CONDITION - Td5

Remove

1. Remove drivers seat base.

2. Release clip securing battery cover.

3. Remove battery cover.

NOTE: The vehicle may be fitted with an alarm and immobilisation system. To

prevent the alarm from sounding, it is important that the following procedure is used when disconnecting the battery.

4. Turn the ignition switch to position ’II’, and then

to position ’0’.

5. Remove the ignition key.

6. Disconnect the vehicle -ve terminal within 15

seconds.

NOTE: Always disconnect the -ve terminal

first. When replacing, connect the +ve

terminal first.

Check

NOTE: If the indicator shows clear or yellow, tap the indicator with the handle of

a screwdriver to disperse any air bubbles. If the indicator colour remains unchanged, the battery will need replacing.

Refit

7. Clean and grease battery terminals and leads

with petroleum jelly.

8. Connect leads to battery (+ve first) and tighten

clamp bolts.

9. Fit battery cover and secure with clip.

10. Fit drivers seat base.

The battery fitted to Td5 models is designed to be maintenance free, so topping-up is not possible. On the top of the battery is a battery indicator. When the indicator shows:

• GREEN - The battery is in a good state of charge.

• DARK (turning to black) - The battery needs

charging.

• CLEAR (or light yellow) - The battery needs replacing. Do not charge the battery or jump start the vehicle in this condition.

• If the green dot is missing, the battery needs charging.

MAINTENANCE

HANDSET BATTERY

Remove

NOTE: Do not remove a battery until you are ready to install the replacement. Always fit a Land Rover STC4080 or a

Panasonic CR2032 replacement battery.

1. Unlock the vehicle and disarm the alarm system.

2. Turn the ignition switch to position ’II’, then turn

to position ’0’ and remove the key.

3. Carefully prise the handset apart, starting from

the keyring end. Avoid damaging the seal between the two halves of the case.

CAUTION: Do not allow moisture to get inside the handset.

4. Slide the battery out of its clip, taking care to

avoid touching the circuit board or the contact surfaces of the clip.

5. Press and hold one of the buttons for at least 5

seconds to drain any residual power from the handset.

HEADLAMP ALIGNMENT

1. Check alignment of headlamps. See

ELECTRICAL, Adjustment.

Refit

6. Fit the new battery, ensuring that correct polarity

is maintained (+ve side facing up). Finger marks will adversely affect battery life. Avoid touching the flat surfaces of the battery, and wipe clean before fitment.

7. Reassemble the two halves of the handset.

Operate the Padlock symbol button at least 4 times within range of the vehicle to resynchronise the hanset.

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.

MAINTENANCE

BRAKE PADS, CALIPERS AND DISCS

1. With front road wheels removed, check brake

pad thickness and ensure that both pads are wearing evenly.

2. Check brake discs for signs of cracking,

excessive scoring or oil contamination.

NOTE: Any requirement to replace brake pads or brake disc 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.

3. Check for any signs of brake fluid leakage from

caliper seals, hoses or unions.

4. Using brake cleaner, remove excessive deposits

of brake dust from pads, calipers and disc shields.

ROAD WHEEL SPEED SENSOR HARNESS - Td5

1. Check each sensor harness is correctly and

securely routed.

2. Inspect each harness for chafing or damage.

NOTE: Any requirement to replace a road wheel speed sensor 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.

MAINTENANCE

FUEL FILTER ELEMENT

1. Renew fuel filter element. See FUEL SYSTEM,

Repair.

FUEL FILTER SEDIMENTER - Td5

WARNING: Fuel vapour is highly

flammable and in contained speces is also

explosive and toxic. Always have a fire extinguisher containing FOAM, CO2, GAS OR POWDER close at hand when handling or draining fuel.

1. Disconnect battery negative lead.

2. Position suitable container beneath fuel filter

3. Disconnect multiplug from sedimenter

4. Rotate sedimenter anti-clockwise until water

flows from drain tube.

5. Allow to drain until diesel fuel flows from drain

tube.

6. Rotate sedimenter fully clockwise.

7. Connect multiplug.

8. Reconnect battery negative lead.

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.

MAINTENANCE

DOOR LOCKS AND HINGES

Front, rear and tail doors

1. Open each door in turn and lubricate door

hinges and check strap using recommended lubricant.

2. Lubricate door lock, striker and private lock using

PTFE lubricant. Remove excessive lubricant, particularly from door striker area, to avoid customer complaint.

3. Check tightness of accessible door lock and

striker fixings

4. Open and close door to check for smooth,

noise-free operation. Ensure door closes securely.

5. Check for smooth operation of private lock.

Bonnet

1. With bonnet open, lubricate hinges, striker, lock

and safety catch using a suitable lubricant.

ENGINE COOLANT

1. Renew engine coolant. See COOLING

SYSTEM, Adjustment.

MAINTENANCE

BRAKE FLUID

1. Renew brake fluid. See BRAKES,

Adjustment.

AIR FILTER ELEMENT AND DUMP VALVE

1. Replace air cleaner element. See FUEL

SYSTEM, Repair.

2. Remove all dirt from dump valve.

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.

MAINTENANCE

Clutch Fluid

1. Clean area around clutch fluid reservoir cap, and

remove cap.

2. Check fluid level in clutch fluid reservoir.

3. Top-up if necessary to the correct level using

recommended fluid. See LUBRICANTS, FLUIDS AND CAPACITIES, Information.

4. Fit filler cap.

STEERING BOX

Check

1. Check steering box for fluid leaks.

Adjust

1. Check there is no backlash in steering box with

the road wheels in the straight ahead position. Adjust if necessary. See STEERING,

Adjustment.

Screen Washer Fluid

1. Clean area around washer fluid filler cap.

2. Check washer fluid level in reservoir.

3. Top-up if necessary to the correct level using

recommended fluid. See LUBRICANTS, FLUIDS AND CAPACITIES, Information.

4. Fit filler cap.

MAINTENANCE

ENGINE OIL

WARNING: Avoid excessive skin contact

with used engine oil. Used engine oil

contains potentially harmful contaminants which may cause skin cancer or other serious skin disorders.

1. Remove underbelly panel. See CHASSIS AND

BODY, Repair.

2. Position suitable container beneath sump.

3. Clean arear around drain plug.

CENTRIFUGE ROTOR - Td5

1. Renew centrifuge rotor. See ENGINE , Repair.

4. Remove oil drain plug, discard sealing washer.

5. Allow oil to drain.

6. Fit new sealing washer to oil drain plug.

7. Fit engine drain plug and tighten to 23 Nm (17

lbf.ft).

8. Fill engine with recommended grade of oil to correct mark on dipstick. See LUBRICANTS,

FLUIDS AND CAPACITIES, Information.

9. Fit underbelly panel. See CHASSIS AND BODY, Repair.

MAINTENANCE

FULL FLOW OIL FILTER

1. Renew full flow oil filter. See ENGINE , Repair.

GEARBOX OIL

WARNING: Avoid excessive skin contact with used gearbox oil. Used gearbox oil

contains potentially harmful contaminants which may cause skin cancer or other serious skin disorders.

1. Renew gearbox oil. See MANUAL GEARBOX,

Adjustment.

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

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 to 30 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 to 25 Nm (18 lbf.ft).

12. Remove all traces of oil from main casing.

13. Fit underbelly panel. See CHASSIS AND

BODY, Repair.

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 to 25 Nm (18 lbf.ft).

7. Remove all traces of oil from main casing.

8. Fit underbelly panel. See CHASSIS AND

BODY, Repair.

MAINTENANCE

FRONT AND REAR AXLE OIL

Renew

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.

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.

MAINTENANCE

PROPELLER SHAFTS

1. Clean area around front universal joint grease

nipple.

2. Apply recommended grease to the grease nipple. See LUBRICANTS, FLUIDS AND

CAPACITIES, Information.

CLUTCH PIPES AND UNIONS

Check

1. Check route of clutch pipe from master cylinder

to slave cylinder. Ensure that pipe is correctly retained and shows no signs of fluid leakage or chafing.

2. Check unions for signs of fluid leakage.

MAINTENANCE

PAS PIPES AND UNIONS

Check

1. Check PAS pipes for correct, secure routing and

signs of chafing.

2. Check for signs of fluid leakage from PAS pump, hoses, and hose unions.

ENGINE, GEARBOX, TRANSFER BOX AND AXLES

Check

1. Check for oil leaks from engine, gearbox, tansfer

box, and front and rear axles. Pay particular attention to areas around oil seals.

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

to 81 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.

MAINTENANCE

STEERING BALL JOINTS

MAINTENANCE

1. Check for wear in joints by moving ball joint up

and down vigorously. If free movement is apparent, fit a new joint assembly.

2. Check condition of steering ball joints paying

particular attention to dust covers.

NOTE: Any requirement to replace the steering ball joints 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.

NOTE: Ball joints are lubricated for life during manufacture and require no further

lubrication unless the rubber boot has been dislodged or damaged. All joints should be checked at specified service intervals, but more frequently if vehicle is used under arduous conditions.

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.

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.

MAINTENANCE

ENDORSE SERVICE RECORD

1. Insert date and mileage of next service.

2. Insert current mileage.

3. Tick one of the boxes on the brake fluid

replacement indicator.

4. Endorse service record with dealer stamp.

5. Sign and date the service record.

6. Sign and date the maintenance check sheet.

REPORT ANY UNUSUAL FEATURES

1. Produce a written report detailing additional work

necessary, or items which may require attention prior to the next service.

MAINTENANCE

12 - ENGINE

CONTENTS

Page

DESCRIPTION AND OPERATION

TD5 ENGINE 1........................................................................................................

GENERAL 12..........................................................................................................

CYLINDER BLOCK 13............................................................................................

CRANKSHAFT, SUMP AND OIL PUMP 22............................................................

CYLINDER HEAD COMPONENTS 25...................................................................

CAMSHAFT COVER COMPONENTS 30...............................................................

CAMSHAFT TIMING CHAIN COMPONENTS 30...................................................

CYLINDER BLOCK FLOW 32.................................................................................

OIL COOLER / FILTER FLOW 34...........................................................................

CYLINDER HEAD FLOW 36...................................................................................

ADJUSTMENT

ENGINE OIL PRESSURE CHECK 1......................................................................

REPAIR

CAMSHAFT 1.........................................................................................................

PULLEY - CRANKSHAFT 3....................................................................................

OIL SEAL - CRANKSHAFT - REAR 4.....................................................................

BEARING - SPIGOT - CRANKSHAFT 5.................................................................

GASKET - CYLINDER HEAD 6..............................................................................

ROCKER SHAFT ASSEMBLY 11...........................................................................

GASKET - COVER - CAMSHAFT 13......................................................................

ENGINE AND ANCILLARIES 14.............................................................................

MOUNTING - FRONT - LH 19................................................................................

MOUNTING - FRONT - RH 20................................................................................

MOUNTING - GEARBOX - REAR - LH 21..............................................................

MOUNTING - GEARBOX - REAR - RH 22.............................................................

FLYWHEEL 22........................................................................................................

FILTER - OIL 23......................................................................................................

STRAINER - OIL PICK-UP 24.................................................................................

PUMP - OIL 24........................................................................................................

GASKET - ENGINE TO SUMP 26..........................................................................

SWITCH - OIL PRESSURE 28...............................................................................

VALVE - RELIEF - OIL PRESSURE 29..................................................................

COOLER - ENGINE OIL 29....................................................................................

CENTRIFUGE ASSEMBLY 30................................................................................

ROTOR - CENTRIFUGE 32....................................................................................

12 - ENGINE

CONTENTS

Page

OIL SEAL - TIMING COVER 32..............................................................................

TIMING CHAIN AND SPROCKETS 33...................................................................

OVERHAUL

GASKET - INLET MANIFOLD 1..............................................................................

GASKET - EXHAUST MANIFOLD 2.......................................................................

GASKET - CYLINDER HEAD 3..............................................................................

CYLINDER HEAD GASKET SELECTION 7...........................................................

CYLINDER HEAD - OVERHAUL 8.........................................................................

GASKET - ENGINE SUMP 20................................................................................

SEAL - CRANKSHAFT - REAR 21.........................................................................

STARTER RING GEAR 22.....................................................................................

PUMP - OIL 23........................................................................................................

TIMING CHAIN AND SPROCKETS 26...................................................................

BEARINGS - CONNECTING RODS 30..................................................................

PISTONS, CONNECTING RODS AND CYLINDER BORES 32.............................

CRANKSHAFT 36...................................................................................................

TD5 ENGINE

ENGINE

DESCRIPTION AND OPERATION

Cylinder block components

ENGINE

DESCRIPTION AND OPERATION

1. Oil dipstick tube

2. Screw - oil dipstick tube to camshaft carrier

3. Oil dipstick

4. 2nd piston ring

5. Piston

6. Small-end bush

7. Connecting rod

8. Big-end bearing cap

9. Connecting rod bolt (2 off per connecting rod)

10. Top piston ring

11. Oil control ring

12. Circlips (2 off per gudgeon pin)

13. Gudgeon pin

14. Big-end bearing shells

15. Dowels to cylinder head (2 off)

16. Gearbox shim plate

17. Rear crankshaft seal and housing

18. Screws - crankshaft seal flange to engine block (5 off)

19. Bolts - Gearbox shim plate to cylinder block (2 off)

20. Main oil gallery plug (rear)

21. Oil filter adaptor gasket

22. Oil filter adaptor thermostat

23. Oil filter adaptor assembly

24. Oil filter adaptor insert

25. Oil filter adaptor to cylinder block bolts (3 off)

26. Oil filter

27. Oil pressure switch

28. Oil cooler banjo bolts (2 off)

29. O-rings - oil cooler banjo bolts (2 off)

30. Oil cooler to cylinder block bolts (7 off)

31. Centrifuge assembly

32. Centrifuge to cylinder block bolts (3 off)

33. Centrifuge oil drain pipe

34. Oil drain pipe to sump gasket

35. Centrifuge to oil drain pipe gasket

36. Oil cooler plugs (3 off)

37. Oil cooler assembly

38. Oil cooler matrix ’O’ rings (2 off)

39. Oil cooler matrix

40. Oil cooler gasket

41. Coolant and PAS pump assembly bracket

42. Bracket bolts (5 off + 1 stud/nut)

43. Cylinder block

44. Dowels - timing chain cover (2 off)

45. Oil gallery delivery plug

46. Cross drilling plug

47. Coolant jacket plug

48. Core plugs (3 off)

ENGINE

DESCRIPTION AND OPERATION

Crankshaft, sump and oil pump

ENGINE

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)

ENGINE

DESCRIPTION AND OPERATION

Cylinder head components

ENGINE

DESCRIPTION AND OPERATION

1. Camshaft carrier

2. Dowel - rocker shaft to camshaft carrier (1 off)

3. Cylinder head bolts (12 off)

4. Rocker shaft to camshaft carrier bolts (6 off)

5. Rocker shaft

6. Circlips (10 off)

7. EUI Rocker arms (5 off)

8. Camshaft carrier to cylinder head screws (13 off)

9. Finger follower (10 off)

10. Valve spring collets (20 off)

11. Lash adjuster (10 off)

12. Valve spring retainer (10 off)

13. Valve spring (10 off)

14. Valve stem seal (10 off)

15. Valve guide (10 off)

16. Valve seat insert (10 off)

17. Inlet valve (5 off)

18. Exhaust valve (5 off)

19. Camshaft

20. Camshaft bore seal (rear)

21. Coolant jacket core plug

22. Cylinder head block

23. Water jacket threaded plug

24. Engine lifting bracket (LH)

25. Engine lifting bracket bolts (2 off)

26. Coolant outlet elbow to cylinder head bolts (3 off)

27. Coolant outlet elbow

28. Coolant outlet elbow gasket

29. Cylinder head gasket

30. Non-return valve (not removable, integral in cylinder head)

31. Camshaft bore end cap (front)

32. End cap seal

33. Cylinder head to cam carrier dowel (2 off)

34. Engine lifting bracket (RH)

35. Engine lifting bracket bolts (2 off)

ENGINE

DESCRIPTION AND OPERATION

Camshaft cover and engine cover

ENGINE

DESCRIPTION AND OPERATION

1. Acoustic cover

2. Oil filler flap

3. Rear acoustic cover

4. Rear acoustic cover inserts (2 off)

5. Rear acoustic cover grommets (2 off)

6. Rear acoustic cover screws (2 off)

7. Acoustic cover grommets (3 off)

8. Acoustic cover bolts (3 off)

9. Camshaft cover isolators (13 off)

10. Camshaft cover flange screws (13 off)

11. Breather hose clip

12. Breather hose

13. Breather hose to breather valve clip

14. Breather valve

15. Camshaft cover gasket

16. Oil separator plate

17. Oil separator plate gasket

18. Camshaft cover

19. Acoustic cover to camshaft cover seal

20. Oil filler cap and seal

ENGINE

DESCRIPTION AND OPERATION

Camshaft timing chain components

ENGINE

DESCRIPTION AND OPERATION

1. Vacuum pump stub pipe

2. Cylinder head to timing chain cover bolt

3. Cylinder head to timing chain cover nut

4. Cylinder head to timing chain cover stud

5. Tensioner assembly pivot screw

6. Tensioner adjuster

7. Tensioner arm assembly

8. Duplex timing chain - crankshaft to camshaft sprocket

9. Camshaft sprocket bolts (3 off)

10. Camshaft sprocket

11. Fixed chain guide

12. Fixed guide pin

13. Fixed chain guide to cylinder block screws

14. Oil pump drive chain

15. Oil pump sprocket

16. Oil pump sprocket screw

17. Crankshaft sprockets

18. Bearing to viscous fan shaft

19. Viscous fan to cover bearing

20. Circlip

21. Hub - viscous fan to bearing flange

22. Timing chain cover

23. Timing chain cover to crankshaft seal

24. Timing chain to cylinder head screws (8 off)

ENGINE

DESCRIPTION AND OPERATION

GENERAL

The Td5 diesel engine is a 2.5 litre, 5 cylinder, in-line direct injection unit having 2 valves per cylinder, operated by a single overhead camshaft. The engine emissions on pre EU3 models comply with ECD2 (European Commission Directive) legislative requirements. EU3 models comply with ECD3 legislative requirements. Both units employ electronic engine management control, positive crankcase ventilation and exhaust gas recirculation to limit the emission of pollutants. The unit is water cooled and turbo-charged and is controlled by an electronic engine management system.

The cylinder block is a monobloc cast iron construction with an aluminium stiffening plate fitted to the bottom of the cylinder block to improve lower structure rigidity. The cylinder head and sump are cast aluminium. An acoustic cover is fitted over the upper engine to reduce engine generated noise.

The engine utilises the following features:

• Electronic Unit Injectors (EUI’s) controlled by an Engine Management System for precise fuel delivery under

all prevailing operating conditions.

• Turbocharging which delivers compressed air to the combustion chambers via an intercooler for improved

power output.

• Fuel Cooler

• Oil Cooler

• Centrifuge Oil Filter

• Hydraulic Lash Adjusters with independent finger followers

ENGINE

DESCRIPTION AND OPERATION

ENGINE

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.

DESCRIPTION AND OPERATION

Connecting rods

ENGINE

1. Small-end oil holes

2. Small-end bushing

The connecting rods are machined, H-section steel forgings which feature a fracture-split at the big-end between the connecting rod and the bearing cap. The connecting rod features a serrated fracture across the big-end at right angles to the length of the connecting rod, this forms a unique mating surface between the connecting rod and the fractured end which is used as the big-end cap. The use of a fracture split in the big-end of the connecting rod ensures a perfect match for assembly on the crankshaft bearing journals and provides the connecting rod with strong resistance to lateral movement.

The end-cap fixing bolts are offset to ensure that the cap is fitted to the connecting rod in the correct orientation. If the end-cap is fitted incorrectly and the end-cap bolts tightened, the connecting rod must be replaced, since the matching serrations will have been damaged.

The big-end bearing shells are plain split halves without location tags. On EU2 vehicles the two halves of the bearing shells are of different construction. The upper half bearing shell fitted to the connecting rod is treated using the sputtering process to improve its resistance to wear. The connecting rod bearing shell can be identified by having a slighter darker colouration than the big-end bearing cap shell, and the back face of the connecting rod bearing shell has a shinier finish than the front face.

On EU3 vehicles both bearing shells are of the same construction as the connecting rod bearing shell.

The small-end of the connecting rod has a bushed solid eye which is free to move on the gudgeon pin, the bushing is a hand push, interference fit. The steel bushing has two slots machined in its upper surface for providing oil lubrication to the moving surface of the gudgeon pin. The oil slots must be correctly aligned to the oil slots provided in the small end of the connecting rod. The small-end lubrication is supplied by squirt feed from the piston lubrication jets.

3. Connecting rod

4. Serrated fracture

DESCRIPTION AND OPERATION

Pistons

ENGINE

1. Bowl in piston head

2. Piston ring grooves

The five pistons have graphite compound coated aluminium alloy skirts which are gravity die cast and machined. Each of the pistons has phosphated, shaped gudgeon pin bores and a swirl chamber (bowl-in-piston) machined in the head which partly contains the inlet air that is compressed during the combustion process and helps provide turbulence for efficient air / fuel mixture to promote complete combustion. The recesses in the piston crowns also provide clearance for the valve heads.

CAUTION: Pre EU3 and EU3 pistons are not interchangeable due to the EU3 piston combustion bowl being offset.

The pistons are attached to the small-end of the connecting rods by fully floating gudgeon pins which are retained in the piston gudgeon pin bushings by circlips.

The pistons and gudgeon pins are gallery cooled, oil being supplied under pressure from the piston lubrication jets when the pistons are close to bottom dead centre.

Piston rings

Each piston is fitted with two compression rings and an oil control ring. The top compression ring is located in a steel insert ring carrier which helps to provide a minimal reaction to compression forces.

The top ring is barrel-edged and chrome-plated, the 2nd compression ring is taper-faced and the oil control ring is chrome-plated and features a bevelled ring with spring.

3. Graphite coated aluminium alloy skirt

4. Gudgeon pin bore

DESCRIPTION AND OPERATION

Land Rover Defender 1999, Defender 2002 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

REFERENCES

REPAIRS AND REPLACEMENTS

DIMENSIONS

POISONOUS SUBSTANCES

INFORMATION

FUEL HANDLING PRECAUTIONS

SYNTHETIC RUBBER

RECOMMENDED SEALANTS

USED ENGINE OIL

ACCESSORIES AND CONVERSIONS

WHEELS AND TYRES

SPECIAL SERVICE TOOLS

STEAM CLEANING

SPECIFICATION

JACKING

HYDRAULIC VEHICLE RAMP (FOUR POST)

DYNAMOMETER TESTING

TWO POST VEHICLE RAMPS

TOWING

TRANSPORTING THE VEHICLE BY TRAILER

JUMP STARTING

ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL

CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY

VEHICLE IDENTIFICATION NUMBER (VIN)

LOCATION OF IDENTIFICATION NUMBERS

FAULT DIAGNOSTIC EQUIPMENT

READING THIS SUPPLEMENT

ENGINE - Td5

INFORMATION

FUEL SYSTEM - Td5

COOLING SYSTEM - Td5

CLUTCH - Td5

TRANSMISSION - Td5

STEERING

SUSPENSION

ROAD SPRING DATA

SHOCK ABSORBERS

BRAKES

AIR CONDITIONING

WIPER MOTORS

ELECTRICAL

BULBS

VEHICLE WEIGHTS AND PAYLOAD

TOWING WEIGHTS

OFF-ROAD PERFORMANCE

TYRE SIZE AND PRESSURES

WHEELS

VEHICLE DIMENSIONS

ENGINE - Td5

HEATER PLUGS - Td5

INJECTORS - Td5

TURBOCHARGER - Td5

INFORMATION

OIL SEALS 4...........................................................................................................

GENERAL FITTING REMINDERS

PRECAUTIONS AGAINST DAMAGE

SAFETY PRECAUTIONS

INFORMATION

PREPARATION

INSPECTION-GENERAL

DISMANTLING

BALL AND ROLLER BEARINGS

JOINTS AND JOINT FACES

FLEXIBLE HYDRAULIC PIPES, HOSES

FUEL SYSTEM HOSES

METRIC BOLT IDENTIFICATION

METRIC NUT IDENTIFICATION

KEYS AND KEYWAYS

TAB WASHERS

COTTER PINS

SCREW THREADS

NUTS

LOCKING WIRE

UNIFIED THREAD IDENTIFICATION

RECOMMENDED LUBRICANTS AND FLUIDS