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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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10MAINTENANCE 22 MAINTENANCE SHOCK ABSORBERS 1.Check for signs of leakage from suspension dampers. 2.Check for signs of suspension damper damage.TOWING BRACKET 1.Check security of towing bracket.
MAINTENANCE 23 MAINTENANCE ENGINE AND TRANSMISSION MOUNTINGS 1.Check condition of front LH engine mounting. Tighten fixings if necessary.See ENGINE , Repair. 2.Check condition of front RH engine mounting. Tighten fixings if necessary.See ENGINE , Repair. 3.Check condition of rear LH gearbox mounting. Tighten fixings if necessary.See ENGINE , Repair. 4.Check condition of rear RH gearbox mounting. Tighten fixings if necessary.See ENGINE , Repair.ROAD TEST There are two purposes for conducting a road test. Firstly, to ensure the work completed within the dealership meets the standards required as layed down by dealership processes. Secondly, for a skilled technician to assess the general condition of the vehicle and report any conditions that the customer should be made aware of. CAUTION: Two wheel roller tests must not be carried out. Four wheel roller tests must be restricted to 3 mph (5 kph). 1.Check for correct operation of starter switch. Ensure the engine starts in a correct manner. Leave the engine running. 2.With vehicle stationary, turn steering from lock to lock. Check for smooth operation and ensure there is no undue noise from the power steering pump or drive belt. 3.Depress clutch and select all gears in turn. Check for smooth notch free engagement. 4.Drive vehicle on a short road test. Check all vehicle systems for correct operation. Pay particular attention to: Engine noise Gearbox noise Suspension noise Body noise Braking system operation Gear selection Engine performance 5.Check for correct operation of all instruments and warning devices where practical. 6.After road test, carry out a final inspection of the vehicle on vehicle ramps. 7.Check all underbonnet fluid levels and top-up if necessary.
10MAINTENANCE 24 MAINTENANCE ENDORSE SERVICE RECORD 1.Insert date and mileage of next service. 2.Insert current mileage. 3.Tick one of the boxes on the brake fluid replacement indicator. 4.Endorse service record with dealer stamp. 5.Sign and date the service record. 6.Sign and date the maintenance check sheet.REPORT ANY UNUSUAL FEATURES 1.Produce a written report detailing additional work necessary, or items which may require attention prior to the next service.
12 - ENGINE CONTENTS Page DESCRIPTION AND OPERATION TD5 ENGINE 1........................................................................................................ GENERAL 12.......................................................................................................... CYLINDER BLOCK 13............................................................................................ CRANKSHAFT, SUMP AND OIL PUMP 22............................................................ CYLINDER HEAD COMPONENTS 25................................................................... CAMSHAFT COVER COMPONENTS 30............................................................... CAMSHAFT TIMING CHAIN COMPONENTS 30................................................... CYLINDER BLOCK FLOW 32................................................................................. OIL COOLER / FILTER FLOW 34........................................................................... CYLINDER HEAD FLOW 36................................................................................... ADJUSTMENT ENGINE OIL PRESSURE CHECK 1...................................................................... REPAIR CAMSHAFT 1......................................................................................................... PULLEY - CRANKSHAFT 3.................................................................................... OIL SEAL - CRANKSHAFT - REAR 4..................................................................... BEARING - SPIGOT - CRANKSHAFT 5................................................................. GASKET - CYLINDER HEAD 6.............................................................................. ROCKER SHAFT ASSEMBLY 11........................................................................... GASKET - COVER - CAMSHAFT 13...................................................................... ENGINE AND ANCILLARIES 14............................................................................. MOUNTING - FRONT - LH 19................................................................................ MOUNTING - FRONT - RH 20................................................................................ MOUNTING - GEARBOX - REAR - LH 21.............................................................. MOUNTING - GEARBOX - REAR - RH 22............................................................. FLYWHEEL 22........................................................................................................ FILTER - OIL 23...................................................................................................... STRAINER - OIL PICK-UP 24................................................................................. PUMP - OIL 24........................................................................................................ GASKET - ENGINE TO SUMP 26.......................................................................... SWITCH - OIL PRESSURE 28............................................................................... VALVE - RELIEF - OIL PRESSURE 29.................................................................. COOLER - ENGINE OIL 29.................................................................................... CENTRIFUGE ASSEMBLY 30................................................................................ ROTOR - CENTRIFUGE 32....................................................................................
12 - ENGINE CONTENTS Page OIL SEAL - TIMING COVER 32.............................................................................. TIMING CHAIN AND SPROCKETS 33................................................................... OVERHAUL GASKET - INLET MANIFOLD 1.............................................................................. GASKET - EXHAUST MANIFOLD 2....................................................................... GASKET - CYLINDER HEAD 3.............................................................................. CYLINDER HEAD GASKET SELECTION 7........................................................... CYLINDER HEAD - OVERHAUL 8......................................................................... GASKET - ENGINE SUMP 20................................................................................ SEAL - CRANKSHAFT - REAR 21......................................................................... STARTER RING GEAR 22..................................................................................... PUMP - OIL 23........................................................................................................ TIMING CHAIN AND SPROCKETS 26................................................................... BEARINGS - CONNECTING RODS 30.................................................................. PISTONS, CONNECTING RODS AND CYLINDER BORES 32............................. CRANKSHAFT 36...................................................................................................
12ENGINE 2 DESCRIPTION AND OPERATION Cylinder block components
ENGINE 3 DESCRIPTION AND OPERATION 1.Oil dipstick tube 2.Screw - oil dipstick tube to camshaft carrier 3.Oil dipstick 4.2nd piston ring 5.Piston 6.Small-end bush 7.Connecting rod 8.Big-end bearing cap 9.Connecting rod bolt (2 off per connecting rod) 10.Top piston ring 11.Oil control ring 12.Circlips (2 off per gudgeon pin) 13.Gudgeon pin 14.Big-end bearing shells 15.Dowels to cylinder head (2 off) 16.Gearbox shim plate 17.Rear crankshaft seal and housing 18.Screws - crankshaft seal flange to engine block (5 off) 19.Bolts - Gearbox shim plate to cylinder block (2 off) 20.Main oil gallery plug (rear) 21.Oil filter adaptor gasket 22.Oil filter adaptor thermostat 23.Oil filter adaptor assembly 24.Oil filter adaptor insert 25.Oil filter adaptor to cylinder block bolts (3 off) 26.Oil filter 27.Oil pressure switch 28.Oil cooler banjo bolts (2 off) 29.O-rings - oil cooler banjo bolts (2 off) 30.Oil cooler to cylinder block bolts (7 off) 31.Centrifuge assembly 32.Centrifuge to cylinder block bolts (3 off) 33.Centrifuge oil drain pipe 34.Oil drain pipe to sump gasket 35.Centrifuge to oil drain pipe gasket 36.Oil cooler plugs (3 off) 37.Oil cooler assembly 38.Oil cooler matrix ’O’ rings (2 off) 39.Oil cooler matrix 40.Oil cooler gasket 41.Coolant and PAS pump assembly bracket 42.Bracket bolts (5 off + 1 stud/nut) 43.Cylinder block 44.Dowels - timing chain cover (2 off) 45.Oil gallery delivery plug 46.Cross drilling plug 47.Coolant jacket plug 48.Core plugs (3 off)
12ENGINE 4 DESCRIPTION AND OPERATION Crankshaft, sump and oil pump
ENGINE 5 DESCRIPTION AND OPERATION 1.Crankshaft pulley bolt 2.TV Damper to crankshaft pulley bolts (3 off) 3.TV Damper 4.Crankshaft pulley 5.Woodruff key 6.Crankshaft 7.Crankshaft to flywheel dowel 8.Spigot bush 9.Flywheel to crankshaft bolts (8 off) 10.Flywheel assembly 11.Main bearing shells (6 pairs) 12.Main bearing caps (6 off) 13.Main bearing cap bolts (12 off) 14.Thrust washer (2 off at No. 3 Main bearing) 15.Piston lubrication jets (5 off) 16.Piston lubrication jet cap head screw (5 off) 17.Stiffener plate (oil pump integral) 18.Stiffener plate / oil pump assembly to cylinder block bolts (22 off) 19.Oil pick-up pipe O-ring 20.Oil pick-up pipe inserts (2 x 6mm; 1 x 10mm) 21.Upper oil pick-up pipe 22.Oil pick-up pipe gauze 23.Lower oil pick-up pipe 24.Sump 25.Oil drain plug seal 26.Oil drain plug 27.Sump to cylinder block bolts (20 off) 28.Sump gasket 29.Oil pick-up pipe bolts (3 off) 30.Oil pump 31.Chain lubrication jet 32.Chain lubrication jet screw 33.Stiffener to cylinder block dowel (2 off)