1999-2002 Land Rover Defender TD5 TDI8 Service & Repair Manual

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TABLE OF' CONTENTS SECTION Introduction mI ...................................................................................................... ................................................................................... El General Specification Data .......................... Engine Tuning Data.. .I!. ............................................................. ..................................................................................... Torque Wrench Settings.. mb .................................................................................. m I General Fitting Instructions ..................................................... ..................................................................................................... El " 1 Recommended Lubricants, Fluids and Capacities.. Maintenance El El El Engine ............................................................................................................. ,~ Cooling System .................................................................................................. ..................................................................... Fuel System (including Fuel Injection) ... ." ..I Clutch.. ............................................................................................................ O J ......................................................................... w El w Manual Gearbox and Transfer Box Propeller Shafts.. Rear Axle and Final Drive ................................................................................................ .................................................................................... .......................................................................................................... \ Steering.. Suspension ........................................................................................................ Brakes ............................................................................................................. Electrical .......................................................................................................... BOOK 2 5

BOOK ONE CONTENTS 05 Page ENGINE TUNING DATA Section Number ri - Repairsand replacement parts - Poisonous substances -Fuel handling precautions -Fuel tank draining and repair J . . - - Service tools 5 - Location of vehicle identification numbers 6 06 TORQUE WRENCH SETINGS El GENERAL SPECIFICATION DATA - V8 engine data -2.25 litre petrol engine data -2.25 litre petrol engine data - 2.25 litre dicscl cnginc data - 2.50 litre dicsel engine data - General data - all models - Tyrepressures - Replacemcnt bulbs and units - Vchiclc wcights 1 3 5 7 9 11 19 19 20 - V8 engine tuning data - 2.25 litre petrol engine tuning data - 2.5 litre petrol engine tuning data - 2.25 and 2.50 litre dicscl engine tuning data 7 :I'.. i , .. . ... ,.. .E. , 1

Book One Contents (cont’d) 07 Section GENERAL FITTING INSTRUCTIONS - Precautionsagainst damage - Safetyprecautions - Preparation and dismantling - Inspection of components - Ball and roller bearings - Oil seals - Jointsand joint faces - Flexible hydraulic pipes and hoses - Metric bolt identification - Metric nut identification - Hydraulic fittings - Keys and keyways - Tab washers, split pins, nuts and locking wire - Screw threads - Unified thread identification 1091 RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES 1 1 1 2 2 2 3 3 3 4 4 5 5: 5 6 - - Recommendcd lubricants - Anti -freeze proportions - Corrosion inhibitor - Capacities - Maintenance Schedules - Maintenance - lubrication - Maintenance - general maintenance and adjustments 2

01 fi;y :i: INTRODUCTION ... ,:.; :.?" , ... ..:I. .!I, I . ._ ...,., , . ..'. This Workshop Manual covers the Land Rover Ninety and One Ten range of vehicles. It is primarily designed to assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles. Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be completed within the time stated in the 'Repair Operation Times'. The Manual has been produced in separate books; this allows the information to be distributed throughout the specialist areas of the modern service facility. A table of contents in Book 1 lists the major components and systems together with the section and book numbers. The cover of each book details the sections contained within that book. The title page of each book carries the part numbers required to order replacement books, binders or complete Service Manuals. This can be done through the normal channels. 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 water pump end of the engine is referred to as the front. To reduce repetition, operations covered in this manual 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. 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. During the period of running-in from new, certain adjustments may vary from the specification figures given in this Manual. These adjustments will be re-set by the Distributor or Dealer at the After Sales Service, and thereafter should be maintained at the figures specified in the Manual. REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only 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 wrench setting figures given in the Repair Operation Manual must bc strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the vehicle conform to mandatory requirements existing in their country of origin. The terms of the Owners Service Statement may be invalidated by the fitting of other than Land Rover parts. A11 Land Rover parts have the full backing of the Owners Service Statement. Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts. POISONOUS SUBSTANCES Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should as far as possible be kept away from open wounds. These substances among others include antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives. FUEL HANDLING PRECAUTIONS The following information provides basic precautions which must be observed if petrol (gasoline) 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. GENERAL Petrol/gasoline vapour is highly flammable and in confined spaces is also very explosive and toxic. When petroI/gasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is potentially very dangerous. .. . .... . becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can 3

lo1 I Always have a fire extinguisher containing FOAM CO? GAS, or POWDER close at hand when handling or draining 0 fuel, or when dismantling fuel systems and in areas whcre fuel containers are stored. Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work on a fuel system. Whenever petroVgasoline is being handled, drained or stored, or when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any hcad-lamps used must be flameproof and kept clear of spillage. NO ONE SHOULD BE PERMITTED TO REPAIR COMPONENTS ASSOCIATED WITH PETROL/ GASOLINE WITHOUT FIRST HAVING HAD SPECIALIST TRAINING. FUEL TANK DRAINING WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST IT IS STANDING OVER A PIT. Draining or extracting petrol/gasoline from vehicle fuel tank must be carried out in a well ventilated area. The receptacle used to contain the petroVgasoline must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations. WHEN PETROWGASOLINE HAS BEEN EXTRACTED OR DRAINED FROM A FUEL TANK THE PRECAUTIONS GOVERNING NAKED LIGHTS AND IGNITION SOURCES SHOULD BE MAINTAINED. FUEL TANK REMOVAL On vehicles where the fuel line is secured to the fuel tank outlet by a spring steel clip, it is recommended that such clips are released before the fuel line is disconnected or the fuel tank unit is removed. This procedure will avoid the possibility of residual petrol fumes in the fuel tank being ignited when the clips are released. As an added precaution fuel tanks should have a PETROUGASOLINE VAPOUR warning label attached to them as soon as they are removed from the vehicle. fi-- k. FUEL TANK REPAIR Under no circumstances should a repair to any tank involving heat treatment be carried out without first rendering the tank SAFE, by using one of the following methods: STEAMING: With the filler cap and tank unit removed, empty the tank. Steam the tank for at least two hours with low pressure steam. Position the tank so that condensation can drain away freely, ensuring that any sediment and sludge not volatised by the steam, is washed out during the steaming process. BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely in boiling water containing an effective alkaline degreasing agent or a detergent, with the water filling and also surrounding the tank for at least two hours. After steaming or boiling a signed and dated label to this effect should be attached to the tank SPECIFICATION Purchasers arc advised that the specification details set out in this Manual apply to a rangc of vehicles and not to any one. For the specification of a particular vehicle, purchasers should consult their Distributor or Dealer. The Manufacturers reserve thc right to vary their specifications with or without notice, and at such times and in such manner as they think 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 Manual, neither the Manufacturer nor the Distributor or Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thercof. COPYRIGHT @Land Rover Limited 1984 All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, photocopying, recording or other means without prior written permission of Land Rover Limited, Service Department, Solihull, England. 4

- 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. The amount of time which they save can be considerable. Every special tool is designed with the close co-operation of Land Rover Ltd., and no tool is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried out using existing tools or standard equipment. The user is therefore assured that the tool is necessary and that it will perform accurately, efficiently and safely. 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 V. L. Churchill. Overseas orders should be placed with the local V. L. Churchill distributor, where one exists. Countfies where there is no distributor may order direct from V. L. Churchill Limited. P.O. Box 3, Daventry, Northamptonshire, England NNll 4NF. The tools recommended in this Workshop Manual are listed in a multi-language, illustrated catalogue obtainable from Messrs. V. L. Churchill at the above address under publication number 2217/2/84 or from Land Rover Ltd., under part number LSM0052TC from thc following address, Land Rover Limited, Service Department, Lode Lane, Solihull, West Midlands, England B92 8NW. 5

LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS VEHICLE IDENTIFICATION NUMBER (VIN) The Vehicle Identification Number and the recommended maximum vehicle weights are stamped on a plate riveted to the top of the brake pedal box in the engine compartment. The number is also stamped on the right-hand side of the chassis forward of the spring mounting turret. Always quote this number when writing to Land Rover Limited. Key to Vehicle Identification Number Plate A Type approval B VIN (minimum of 17 digits) C Maximum permitted laden weight for vehicle D Maximum vehicle and trailer weight E Maximum road weight - front axle F Maximum road weight - rear axle I I I fAND &IR TOO1 ST037 I ENGINE SERIAL NUMBER - VS ENGINE The V8 engine serial number is stamped on a cast pad on the cylinder block between numbers 3 and 5 cylinders. 6 ST ENGINE SERIAL NUMBER - 4 CYLINDER ENGINES The 4 cylinder engine number is stamped on a machined surface at the front left-hand side of the On later engines the number is stamped above the rear side cover, as the second illustration shows. 6” engine adjacent to the exhaust manifold front flange. -. -

LOCATION OF VEHICLE IDENTIFICATION AND UNIT NUMBERS ST663M 01 FRONT AXLE Stamped on top of the left-hand axle tube. REAR AXLE Stamped on rear of left-hand axle tube. MAIN GEARBOX LT77 - 4 CYLINDER VEHICLES Stamped on a pad on the right-hand side of the gearbox immediately below the oil filler level plug. U ST665M TRANSFER GEARBOX LT230R - 4 CYLINDER VEHICLES Stamped on the casing on the left-hand side of the gearbox below the mainshaft rear bearing housing adjacent to the bottom cover. Y ST664M TRANSFER GEARBOX LT230T - 4 CYLINDER AND V8 VEHICLES FROM SERIAL NUMBER SUFFIX ‘B’ ONWARD MAIN GEARBOX LT85 FIVE SPEED - V8 VEHICLES Stamped on the right-hand side of the front bearing plate. STl546M 7

GENERAL SPECIFICATION DATA ENGINE Type ................................................................. Number of cylinders ............................................. Bore ................................................................. Stroke ............................................................... Capacity ............................................................ Valve operation.. ................................................. Maximum power- B.H.P ..................................... Maximum power - KW.. ...................................... Maximum torque ................................................. 04 V8 Eight, two banks of four 88,90 mm (3.500 in) 71,12 mm (2.800 in) 3528 cc (215 in') Overhead by push-rod ._ '13 } at 4000rpm 84.6 251 Nm (185 lb ft) at 2500 rpm Crankshaft Main journal diameter ....................................... Minimum regrind diameter .............................. Crankpin journal diameter. Minimum regrind diameter .............................. Crankshaft end thrust ........................................ Crankshaft end-float .......................................... 58,409 - 58,422 mm (2.2996 - 2.3001 in) 57,393 - 57,406 mm (2.2596 - 2.2601 in) 50,800 - 50,812 mm (2.0000 - 2.0005 in) 49,784 - 49,797 mm (1.9600 - 1.9605in) Taken on thrust washers of centre main bearing 0,lO - 0,20 mm (0.004 - 0.008 in) .. ................................. Main bearings Number and type .............................................. 5, Vandervell shells 0,010 - 0,048 mm (0.0004 - 0.0019 in) 0,254 mm, 0,508 mm (0.010 in, 0.020 in) Material ......................................................... Lead-indium Diametrical clearance ........................................ Undersizes ...................................................... Connecting rods Type.. ............................................................ Horizontally split big end, pIain small end Length between centres ...................................... 143,81 - 143,71 mm (5.662 - 5.658 in) Big end bearings Type and material ............................................. Diametrical clearance ....................................... 0,015 - 0,055 mm (0.0006 - 0.0022 in) End-float on crankpin ....................................... 0,15 - 0,36 mm (0.006 - 0.014 in) Undersizes ...................................................... Vandervell VP lead-indium 0,254 mm, 0,508 mm (0.010 in, 0.020 in) Gudgeon pins Length ........................................................... 72,67 - 72,79 mm (2.861 - 2.866 in) Fit-in connecting rod ......................................... Clearance in piston ............................................ 0,002 - 0,007 mm (0.0001 - 0.0003 in) Diameter ........................................................ 22,215 - 22,22 mm (0.8746 - 0.8749 in) Press fit Pistons Clearance in bore measlured at hottom of skirt at right angles to gudgeon pin .................................. 0,018 - 0,033 mm (0.0007 - 0.0013 in) 1

1999-2002 Land Rover Defender TD5 TDI8 Service & Repair Manual

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