Land Rover Defender 1999 Workshop Manual

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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

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.

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 - INTRODUCTION

CONTENTS

Page

INFORMATION

INTRODUCTION ..................................................................................................

DIMENSIONS .......................................................................................................

REFERENCES .....................................................................................................

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

POISONOUS SUBSTANCES ..............................................................................

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

SYNTHETIC RUBBER .........................................................................................

RECOMMENDED SEALANTS .............................................................................

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

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

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

STEAM CLEANING ..............................................................................................

SPECIFICATION ..................................................................................................

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

JACKING ..............................................................................................................

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

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

DYNAMOMETER TESTING ................................................................................

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

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

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 2

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.

2 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

Tel 01942 824242

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

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 3

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.

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.

SPECIAL SERVICE TOOLS

The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently, and safely. Where special tools are specified, only these tools should be used to avoid the posibility of personal injury or

damage to the components.Also, the amount of time which they can save can be considerable.

Special tools bulletins will be issued periodically giving details of new tools as they are introduced.

All orders and enquiries from the United Kingdom should be sent direct to Cartool (UK) Ltd. Overseas orders should be placed with the local Cartool distributor, where one exists. Countries where there is no distributor may order direct from:

Cartool (UK) Ltd.

Unit 3,

Sterling Business Park,

Brackmills,

Northampton,

England, NN4 7EX.

The tools recommended in this Workshop Manual are listed in an illustrated catalogue, obtainable from:

Land Rover Publications,

Character Mailing,

Heysham Road,

Bootle,

Merseyside, L70 1JL

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.

4 INFORMATION

INTRODUCTION

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

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 5

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.

6 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 7

INTRODUCTION

JUMP STARTING

WARNING: Hydrogen and oxygen gases are produced during normal battery operation. This gas mixture can explode if 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

WARNING: To avoid any possibility of injury use particular care when connecting a booster battery to a discharged battery.

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.

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.

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.

8 INFORMATION

INTRODUCTION

ABBREVIATIONS AND SYMBOLS USED IN THIS

MANUAL

Across flats (bolt size) ............................................

After bottom dead centre ...................................

ABDC

After top dead centre

Alternating current

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

ATDC

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

a.c.

Ampere ................................................................

Ampere hour ....................................................

amp amp hr

Before bottom dead centre

Before top dead centre

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

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

BBDC

BTDC

Bottom dead centre .............................................

Brake horse power ................................................

BDC bhp

British Standards ....................................................

Carbon monoxide ..................................................

Centimetre .............................................................

CO cm

Centigrade (Celsius)

Cubic centimetre

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

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

C cm 3

Cubic inch ...............................................................

Degree (angle) ...............................................

Degree (temperature) .....................................

in deg or

° deg or

Diameter ...............................................................

dia.

Direct current .........................................................

Electronic Control Unit ........................................

d.c.

ECU

Fahrenheit .................................................................

Feet ...........................................................................

F ft

Feet per minute

Fifth

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

ft/min

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

5th

First ........................................................................

Fluid ounce ..........................................................

1st fl oz

Foot pounds (torque) ............................................

Fourth .....................................................................

lbf.ft

4th

Gramme (force)

Gramme (mass)

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

gf g

Gallons ...................................................................

High tension (electrical) ........................................

gal

H.T.

Internal diameter

Inches of mercury

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

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

I.D.

in. Hg

Inches ......................................................................

Kilogramme (force) .................................................

in kgf

Kilogramme (mass.) ................................................

Kilogramme centimetre (torque) .......................

Kilogramme per square millimetre .................

kgf.cm

kgf/mm 2

Kilogramme per square centimetre .................

kgf/cm 2

Kilogramme metres (torque)

Kilometres

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

kgf.m

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

Kilometres per hour

Kilovolts

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

km/h

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

Left-hand ................................................................

Left-hand steering .............................................

LHStg

Left-hand thread

Litres

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

LHThd

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

litre

Low tension

Maximum

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

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

l.t.

max.

Metre ........................................................................

Millilitre ....................................................................

m ml

Millimetre ...............................................................

Miles per gallon ....................................................

mm mpg

Miles per hour

Minute (angle)

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

mph

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

’

Minus (of tolerance)

Negative (electrical)

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

Newton metres (torque)

Number

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

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

No.

Ohms ...................................................................

Ounces (force) .......................................................

ohm ozf

Ounces (mass) ........................................................

Outside diameter .................................................

O.D.

Part number ...................................................

Part No.

Percentage ...............................................................

Pints .........................................................................

Plus (tolerance) .........................................................

% pt

Positive (electrical) ....................................................

Pound (force) ..........................................................

+ lbf

Pounds inch (torque)

Pound (mass)

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

lbf.in

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

Pounds per square inch

Ratio

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

P.S.I.

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

Reference ..............................................................

Revolution per minute .....................................

ref.

rev/min

Right-hand .............................................................

Second (angle)

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

Second (numerical order) ......................................

2nd

Specific gravity ...................................................

Square centimetres sp.gr.

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

cm 2

Square inches .........................................................

in 2

Standard wire gauge .........................................

Synchroniser/Synchromesh ..........................

s.w.g.

synchro.

Third .......................................................................

Top dead centre ..................................................

3rd

TDC

United Kingdom ......................................................

Vehicle Identification Number ...............................

VIN

Volts

Watts

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

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

SCREW THREADS

British Standard Pipe

Unified Coarse

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

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

BSP

UNC

Unified Fine .........................................................

UNF

INFORMATION 9

INTRODUCTION

CROSS REFERENCE OF EMISSION SYSTEM

TERMINOLOGY

NEW TERM (ACRONYM)

Accelerator pedal

Air cleaner

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

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

(AP)

(ACL)

Air conditioning ...................................................

Battery positive voltage ........................................

(A/C)

(B+)

Closed loop ..........................................................

Closed throttle position ......................................

(CL)

(CTP)

Canister purge valve

Data link connector

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

(CANPV)

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

(DLC)

Diagnostic trouble code

Distributor ignition

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

(DTC)

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

(DI)

Engine control module

Engine coolant level

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

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

(ECM)

(ECL)

Engine coolant temperature ..............................

Engine speed ....................................................

(ECT)

(RPM)

Evaporative emission system ..........................

Engine fuel temperature sensor ......................

(EVAP)

(EFTS)

4th gear, 3rd gear etc.

Fuel pump

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

(4GR, 3GR)

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

(FP)

Fan control module

Generator

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

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

(FCM)

(GEN)

Ground ..............................................................

(GND)

Heated oxygen sensor

Idle air control

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

(H02S)

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

(IAC)

Idle air control valve .........................................

Ignition control module .......................................

(IACV)

(ICM)

Intake air temperature .........................................

Manifold vacuum zone ......................................

(IAT)

(MVZ)

Mass air flow sensor

Open loop

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

(MAF)

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

(OL)

Relay module ......................................................

Solid state relay module .................................

(RM)

(SSRM)

Three way catalytic converter

Throttle body

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

(TWC)

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

(TB)

Throttle position sensor

Transmission range ..............................................

Wide open throttle

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

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

(TP)

(TR)

(WOT)

OLD TERM (ACRONYM)

Throttle pedal

Air cleaner

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

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

(-)

Air conditioning ....................................................

Battery plus, bat +, bat feed

Closed loop

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

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

(AC)

(B+)

(-)

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

Fuel temperature thermistor

(ELC)

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

(-)

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 11

INTRODUCTION

LOCATION OF IDENTIFICATION NUMBERS

Engine serial number - Td5 Engine

Main gearbox R380 serial number

The Td5 engine number is stamped on the LH side of the cylinder block, below the exhaust manifold.

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.

12 INFORMATION

Front axle serial number

INTRODUCTION

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

Rear axle serial number

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.

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

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

INTRODUCTION

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.

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

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

GENERAL SPECIFICATION DATA

ENGINE - Td5

Type .................................................................................

Number of cylinders

Bore

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

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

Stroke ...............................................................................

Capacity ...........................................................................

Firing order .......................................................................

Compression ratio ............................................................

Direction of rotation ..........................................................

Dimensions

Length .....................................................................

Width .......................................................................

Height ......................................................................

Emissions standard :-

Engine Serial No. Prefixes 10P to 14P - EU2 Model ........

Engine Serial No. Prefixes 15P to 19P - EU3 Model ........

2.5 litre in-line direct injection Diesel, turbocharged and intercooled

5 in-line, No. 1 cylinder at front of engine

84.450 mm (3.3248 in)

88.950 mm (3.5020 in)

2498 cm 3 (152.5 in 3 )

1 - 2 - 4 - 5 - 3

19.5:1

Clockwise viewed from the front of the engine.

766 mm (30.1 in)

708 mm (27.8 in)

788 mm (31.0 in)

ECD 2

ECD 3

Lubrication

Type .................................................................................

Pump type ........................................................................

Wet sump, pressure fed

Eccentric rotor, crankshaft driven integral with stiffener plate.

Filter type:

Primary ....................................................................

Secondary ...............................................................

Pressure at idle (cold) ......................................................

Pressure at 3500 rev/min (hot) .........................................

Relief valve opening pressure ..........................................

Low oil pressure switch opening pressure .......................

Centrifuge filter

Disposable canister with full flow by-pass

3.0 bar (43.5 lbf.in

2 )

1.5 - 3.0 bar (21.75 - 43.5 lbf.in

2 )

4.0 bar (58 lbf.in

2 )

0.2 - 0.6 bar (3.0 - 8.8 lbf.in

2 )

Crankshaft

Main bearing journal diameter ..........................................

Crankpin journal diameter ................................................

Crankshaft end float .........................................................

61.9875 - 62.0125 mm

53.99 - 54.01 mm

0.020 - 0.250 mm

Main bearings

Number and type ..............................................................

6 half shells (5 main, 1 thrust)

Pistons

Type .................................................................................

Clearance in cylinder bore

Diameter

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

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

Graphite compound skirt with combustion chamber in crown.

0.172 - 0.206 mm (measured at bottom of skirt, 90

° to gudgeon pin)

84.270 - 85.254 mm (measured 90

° to gudgeon pin, and 40.00 mm from bottom of skirt.)

INFORMATION 1

GENERAL SPECIFICATION DATA

Gudgeon pins

Type .................................................................................

Fully floating, offset towards piston thrust side.

Piston rings

Type

Upper compression .................................................

Lower compression .................................................

Oil control ................................................................

Barrel edge, chrome plated

Taper faced

Bevelled ring with spring

New ring to groove clearance

Upper compression .................................................

Lower compression .................................................

Oil control ................................................................

Not measured

0.050 - 0.082 mm (0.002 - 0.003 in)

Piston ring fitted gap in cylinder bore

Upper compression .................................................

Lower compression .................................................

Oil control ................................................................

0.30 - 0.45 mm (0.0118 - 0.0177 in)

0.40 - 0.60 mm (0.0157 - 0.0236 in)

0.25 - 0.40 mm (0.0098 - 0.0157 in)

Camshaft

Drive .................................................................................

End float ...........................................................................

Number of bearings ..........................................................

Duplex chain

0.6 - 0.16 mm

Tappets

Type .................................................................................

Hydraulic lash adjusters with followers

Valves

Stem diameter

Exhaust ...................................................................

Inlet .........................................................................

Head diameter

Exhaust ...................................................................

Inlet .........................................................................

Seat face angle

Exhaust ...................................................................

Inlet .........................................................................

Valve face angle

Exhaust ...................................................................

Inlet .........................................................................

6.905

0.008 mm (0.271

0.0003 in)

6.915

0.008 mm (0.272

0.0003 in)

31.7 mm (1.25 in)

34.7 mm (1.37 in)

48’

12’

48’

12’

Valve springs

Type .................................................................................

Parallel, single coil

2 INFORMATION

GENERAL SPECIFICATION DATA

FUEL SYSTEM - Td5

Type .................................................................................

Pressure regulator setting ................................................

Pump ................................................................................

Pump output

Low pressure ..........................................................

High pressure ..........................................................

Max consumption .............................................................

Injectors ...........................................................................

Injector normal operating pressure ..................................

Filter .................................................................................

Direct injection from pressure regulated supply with cooled return flow

4 bar (58 lbf.in

2 )

Electric two stage submersible

30 l/h (6.6 gal/h) at 0.5 bar (7.25 lbf.in

2 )

180 l/h (39.6 gal/h) at 4 bar (58 lbf.in

2 )

30 l/h (6.6 gal/h)

Electronic unit injectors

1500 bar (21750 lbf.in

2 )

In-line canister filter/water separator with water detection

COOLING SYSTEM - Td5

Type .................................................................................

Cooling fans .....................................................................

Pressurised spill return partial flow, thermostatically controlled

11 blade axial flow on viscous coupling and 11 blade axial flow electric

Electric cooling fan switching points

On ...........................................................................

Off ...........................................................................

Coolant pump

Thermostat

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

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

Thermostat opening temperature

Initial opening ..........................................................

Fully open ...............................................................

Expansion tank cap relief valve operating pressure .........

Vehicle speeds of 50 mph (80 km/h) and below while ambient temperature is 28

C (82

F) or above

Vehicle speeds of 62.5 mph (100 km/h) and above or ambient temperatures of 25

C (77

F) and below

Centrifugal impeller, belt driven from crankshaft

Waxstat with pressure relief valve

C (179

C (204

1.4 bar (20.3 lbf.in

2 )

CLUTCH - Td5

Type .................................................................................

Drive plate diameter .........................................................

Pressure plate diameter ...................................................

Diaphragm spring, hydraulically operated with self-centering pre-loaded release bearing

267 mm

270 mm

INFORMATION 3

GENERAL SPECIFICATION DATA

TRANSMISSION - Td5

Main gearbox

Type R380 .......................................................................

Speeds .............................................................................

Single helical constant mesh

5 forward, 1 reverse, all synchromesh

Transfer box

Type LT230TE .................................................................

Two speed reduction on main gearbox output. Front and rear drive permanently engaged via a lockable differential

Rear axle

Type .................................................................................

Ratio .................................................................................

Spiral bevel, fully floating shafts

3.54:1

Front axle

Type .................................................................................

Ratio .................................................................................

Spiral bevel, enclosed constant velocity joints, fully floating shafts, 32

° angularity of universal joint on full lock

3.54:1

Propeller shafts

Type, front and rear ..........................................................

Universal joints .................................................................

Tubular 51 mm dia.

Open type Hookes O3EHD

4 INFORMATION

GENERAL SPECIFICATION DATA

STEERING

Power steering box

Make/type ........................................................................

Ratio .................................................................................

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

Adwest Varamatic - worm and roller box

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

3.375

Steering pump

Make/type ........................................................................

Hobourn-Eaton series 500

Steering geometry

Steering wheel diameter ..................................................

Toe-out measurement ......................................................

Toe-out included angle .....................................................

Camber angle ..................................................................

Castor angle .....................................................................

Swivel pin inclination static ...............................................

412 mm (16.22 in)

0 to 2 mm toe out

° to 0

20’

* 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 ..............................................................

All other tyres ...................................................................

12,65 m (41.5 ft)

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 5

GENERAL SPECIFICATION DATA

SUSPENSION

Type

Front .................................................................................

Rear

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

Coil springs controlled by telescopic dampers front and rear.

Transverse location of axle by Panhard rod, and fore and aft location by two radius arms. Anti-roll bar fitted as standard on 90 models with 265/75 tyres and 130 models.

Fore and aft movement inhibited by two tubular trailing links. Lateral location of axle by a centrally positioned

’A’ frame, upperlink assembly, bolted at the apex to a ball joint mounting. Anti-roll bar fitted as standard on

90 models with 265/75 tyres, 110 models with self levelling unit, and 130 models.

ROAD SPRING DATA

90 (2400 Kg)

Front - Driver’s side

Front - Passenger side

Rear - Driver’s side

Rear - Passenger side

90 (2550 Kg)

Front - Driver’s side

Front - passenger side

Rear - Driver’s side

Rear - Passenger side

110 (3050 Kg)

Front - both sides

Rear - both sides

110 Levelled (2950 Kg)

Front - both sides

Rear - both sides

110 (3400 Kg)

Front - both sides

Rear - both sides

Rear helper springs - both sides

110 (3600 Kg)

Front - Driver’s side

Front - passenger side

Rear - both sides

Rear helper springs - both sides

130 (3500 Kg)

Front - driver’s side

Front - passenger side

Rear - driver’s side

Rear - passenger side

Front/rear helper springs - both sides

NRC 8045

NRC 6904

RRC 3266

NRC 9448

NRC 9449

NRC 6904

RRC 3226

NRC 9448

NRC 9449

NRC 6389

NRC 6904

RRC 3266

Part No.

NRC 9446

NRC 9447

NRC 9448

NRC 9449

NRC 9446

NRC 9447

NRC 9462

NRC 9463

NRC 8045

NRC 6904

NRC 8045

NRC 7000

Colour Code

Blue/green

Blue/yellow

Blue/red

Yellow/white

Blue/green

Blue/yellow

Green/yellow/red

Green/yellow/white

Yellow/yellow

Red/green

Yellow/yellow

Green/white

Yellow/yellow

Red/green

No colour code

Blue/red

Yellow/white

Red/green

No colour code

Blue/red

Yellow/white

Red/red

Red/green

No colour code

6 INFORMATION

GENERAL SPECIFICATION DATA

SHOCK ABSORBERS

Type .................................................................................

Bore diameter ...................................................................

Telescopic, double-acting non-adjustable

35.47mm

BRAKES

Front brake

Caliper ..............................................................................

Operation

Disc

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

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

Disc diameter ...................................................................

Disc thickness ..................................................................

Wear limit .........................................................................

Disc run-out maximum .....................................................

Pad area ..........................................................................

Total swept area ...............................................................

Pad material .....................................................................

Pad minimum thickness ...................................................

AP Lockheed, four opposed pistons

Hydraulic, self adjusting

90 - Solid, outboard, 110/130 - Ventilated, outboard

298 mm (11.73 in)

90 - 14,1 mm (0.56in), 110/130 - 24mm (0.95 in)

1 mm (0.04in) per side of disc

0,15mm (0.006 in)

58 cm 2 (9.0 in 2 )

801,3 cm 2 (124.2 in 2 )

Ferodo 3440 non asbestos

3 mm (0.12in)

Rear brake