Land Rover 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 (2nd Edition)
Land Rover 2001
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic,
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
10
12
17 18 19
26
30
33
37 41
47
57
60 64
70
76
77
82
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
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
1
01
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.
2
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 manufacturers 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
2
INTRODUCTION
SYNTHETIC RUBBER
Many 0ring 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
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01
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 Manufacturers 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
4
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 Owners 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
5
01
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 ontype ramp which supports vehicle on its road wheels. If a wheel-freecondition is required, use a drive onramp incorporating a wheel-freesystem 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
6
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 1to 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 1to 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, snatchrecovery should be avoided.
INFORMATION
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01
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 OwnersManual.
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
8
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.......................................................
3
Ounces (mass) oz........................................................
3
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......................................................
2
Vehicle Identification Number VIN...............................
2
Volts V.........................................................................
Watts W.......................................................................
SCREW THREADS
British Standard Pipe BSP...........................................
Unified Coarse UNC....................................................
Unified Fine UNF.........................................................
2
2
INFORMATION
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01
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).........................
10
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
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01
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
12
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
13
01
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
14
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
1
04
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
2
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
3
04
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
4
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
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04
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 - Drivers side NRC 9446 Blue/green Front - Passenger side NRC 9447 Blue/yellow Rear - Drivers 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 Aframe, 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 - Drivers side NRC 9446 Blue/green Front - passenger side NRC 9447 Blue/yellow Rear - Drivers 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 - Drivers 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 - drivers side NRC 9448 Blue/red Front - passenger side NRC 9449 Yellow/white Rear - drivers side NRC 6389 Red/red Rear - passenger side NRC 6904 Red/green Front/rear helper springs - both sides RRC 3266 No colour code
INFORMATION
6
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
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