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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
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30MANIFOLD AND EXHAUST SYSTEM 6 REPAIR Refit 7.Clean exhaust manifold and mating face. 8.Fit exhaust manifold with new gasket and tighten nuts to25 Nm (18 lbf.ft). 9. Models with A/C:Position compressor and tighten bolts to25 Nm (18 lbf.ft). 10. All Models:Position EGR valve pipe, fit new allen screws and tighten to10 Nm (7 lbf.ft). 11.Fit turbocharger.See FUEL SYSTEM, Repair. 12. Models with A/C:Fit auxiliary drive belt.See ELECTRICAL, Repair.
33 - CLUTCH CONTENTS Page DESCRIPTION AND OPERATION CLUTCH COMPONENTS 2.................................................................................... HYDRAULIC OPERATION 4.................................................................................. DESCRIPTION 6..................................................................................................... OPERATION 12...................................................................................................... ADJUSTMENT HYDRAULIC SYSTEM - BLEED 1.......................................................................... REPAIR CLUTCH ASSEMBLY 1.......................................................................................... BEARING - CLUTCH RELEASE 2.......................................................................... CLUTCH - MASTER CYLINDER LH DRIVE 2........................................................ CYLINDER - CLUTCH SLAVE 4.............................................................................
CLUTCH 1 DESCRIPTION AND OPERATION This page is intentionally left blank
33CLUTCH 2 DESCRIPTION AND OPERATION CLUTCH COMPONENTS
CLUTCH 3 DESCRIPTION AND OPERATION 1.Brake/clutch reservoir 2.Connecting hose 3.Bolt - 2 off 4.Master cylinder 5.Clutch pedal 6.Gearbox housing 7.Primary driveshaft 8.Bolt - 2 off 9.Slave cylinder 10.Bleed nipple 11.Pressure plate 12.Drive plate 13.Dual mass flywheel 14.Metal hydraulic pipe 15.Ball spigot 16.Clutch release bearing sleeve 17.Bolt - 2 off 18.Pivot washer 19.Release lever 20.Release bearing 21.Retaining clip 22.Bolt 23.Plastic hydraulic pipe
33CLUTCH 4 DESCRIPTION AND OPERATION HYDRAULIC OPERATION
CLUTCH 5 DESCRIPTION AND OPERATION 1.Brake/clutch reservoir 2.Fluid supply pipe 3.Hydraulic feed pipe 4.Damper 5.Master cylinder 6.Piston 7.Clutch pedal 8.Primary driveshaft 9.Engine crankshaft 10.Drive plate 11.Dual mass flywheel 12.Ring gear 13.Leaf spring 14.Cover - pressure plate 15.Diaphragm 16.Release bearing 17.Ball spigot 18.Release bearing sleeve 19.Release lever 20.Slave cylinder 21.Piston 22.Bleed nipple
33CLUTCH 6 DESCRIPTION AND OPERATION DESCRIPTION General The clutch system is a diaphragm type clutch operated by a hydraulic cylinder. The drive plate is of the rigid centre type with no integral damping springs. The flywheel is of the dual mass type with damping springs integral with the flywheel. The clutch requires no adjustment to compensate for wear. Hydraulic Clutch The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir. The master and slave cylinders are connected to each other hydraulically by plastic and metal pipes. The plastic section of the pipe allows ease of pipe routing and also absorbs engine movements and vibrations. The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic feed pipe to the slave cylinder and the fluid reservoir. The bore is also connected to a damper which prevents engine pulses being transferred hydraulically to the clutch pedal. A piston is fitted in the bore and has an external rod which is attached to the clutch pedal with a pin. Two coil springs on the clutch pedal reduce the effort required to depress the pedal. The master cylinder is mounted on the bulkhead and secured with two bolts. The cylinder is connected to the shared brake/clutch reservoir on the brake servo by a braided connecting hose. The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield is fitted to protect the underside of the slave cylinder from heat generated from the exhaust system. The slave cylinder comprises a cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed pipe from the master cylinder. A second port is fitted witha bleed nipple used for removing air from the hydraulic system after servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is positively retained on the release lever with a clip. Clutch Mechanism The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing. A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the clutch release lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and secures the lever on the spigot. A small bolt retains the spring clip in position. The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely around the ball. The clutch release bearing locates on the clutch release lever and release bearing sleeve. The bearing is retained on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on the carrier. The bearing and carrier are not serviceable individually.
CLUTCH 7 DESCRIPTION AND OPERATION Dual Mass Flywheel 1.Ring gear 2.Primary flywheel 3.Inner drive plate 4.Spring housing 5.Secondary flywheel 6.Rivet 7.Ball bearing8.Dowel location hole 9.Mounting hole 10.Inner spring 11.Outer spring 12.Crankshaft position sensing holes 13.Pressure plate locating dowel