AMENDMENT INSTRUCTION SHEET PDF
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AMENDMENT INSTRUCTION SHEET DEFENDER WORKSHOP MANUAL PublicationNumber LRL0097ENG Amendment Number: LD003.97 Date: 09/97 Toensurethatthismanualiskeptuptodateandthatarecordofamendmentstothismanualisavailable,an AmendmentInstructionSheetwillbeissuedwitheachsetofrevisedpages. TheTitlepageoftheManualisre-issued,andthePartNo.hasbeenraisedtothenextedition.Exceptforthe (cid:0) Contentspages,allrevisedandnewpageshavetheissuedateatthefootofeachpage,togetherwithan indicationofwhetherthepagesarerevisedornew. ThisAmendmentInstructionSheetmustbeinsertedatthefrontofthemanualtoindicatethattheamendment (cid:0) hasbeenincorporated.DonotdiscardpreviousAmendmentInstructionsheets. YourmanualisonlycompletetothisissueprovidingallpriorAmendmentsareincluded. (cid:0) Thefilinginstructionsgivesectionandpagenumbersaffected.Additionalpagesorcompletenewsectionsmay (cid:0) beissued,insertthepagesasinstructed. FILINGINSTRUCTIONS Section DiscardExisting InsertNewPages ReasonforAmendment Pages 51-RearAxleand Pages1to5 Pages1to5 Clarificationofwheelnuttorquefigures. FinalDrive-Repairs 54-FrontAxleand Pages1,and3 Pages1,and3 Clarificationofwheelnuttorquefigures. FinalDrive-Repairs 57-Steering-Repairs Page5 Page5 Clarificationofwheelnuttorquefigures. 60-FrontSuspension- Pages1,and3 Pages1,and3 Clarificationofwheelnuttorquefigures. Repairs 64-RearSuspension- Page1 Page1 Clarificationofwheelnuttorquefigures. Repairs 70-Brakes-Repairs Pages7,11,and Pages7,11,and Clarificationofwheelnuttorquefigures. 13 13 74-WheelsandTyres Page5 Pages5,and7 Clarificationofwheelnuttorquefigures. -Repairs Workshop manual 01 04 DEFENDER 300Tdi 05 07 09 10 This manual covers vehicles from 12 1996 model year 17 01 INTRODUCTION 19 04 GENERALSPECIFICATIONDATA 05 ENGINETUNINGDATA 07 GENERALFITTINGREMINDERS 09 LUBRICANTS,FLUIDSANDCAPACITIES 26 10 MAINTENANCE 12 ENGINETdi 19 FUELSYSTEMTdi 26 COOLINGSYSTEMTdi 30 30 MANIFOLDANDEXHAUSTSYSTEM 33 CLUTCH 37 MANUALGEARBOX 41 TRANSFERGEARBOX 33 47 PROPELLERSHAFTS 51 REARAXLEANDFINALDRIVE 54 FRONTAXLEANDFINALDRIVE 57 STEERING 37 60 FRONTSUSPENSION 41 64 REARSUSPENSION 70 BRAKES 74 WHEELSANDTYRES 47 76 CHASSISANDBODY 51 80 HEATINGANDVENTILATION 54 82 AIRCONDITIONING 84 WIPERSANDWASHERS 86 ELECTRICAL 57 88 INSTRUMENTS 60 64 74 70 PublicationPartNo.LRL0097ENG PublishedbyRoverTechnicalCommunication (cid:211) 1996RoverGroupLimited 75 76 80 82 84 86 88 INTRODUCTION INTRODUCTION REFERENCES Thisworkshopmanualcoversvehiclesfrom1996 Referencestotheleftorrighthandsideinthemanual modelyearonwards.Amendmentsandadditional aremadewhenviewingthevehiclefromtherear. pageswillbeissuedtoensurethatthemanualcovers Withtheengineandgearboxassemblyremoved,the latestmodels.Amendmentsandadditionswillbe crankshaftendoftheengineisreferredtoasthefront. identifiedbytheadditionofadatedfooteratthe bottomofthepage. Toreducerepetition,someoperationscoveredinthis Manualdonotincludereferencetotestingthevehicle ThisWorkshopManualisdesignedtoassistskilled afterrepair. techniciansintheefficientrepairandmaintenanceof LandRoverDefender300Tdivehicles. Itisessentialthatworkisinspectedandtestedafter completionandifnecessaryaroadtestofthevehicle Individualswhoundertaketheirownrepairsshould iscarriedout,particularlywheresafetyrelateditems havesomeskillandtraining,andlimitrepairsto areconcerned. componentswhichcouldnotaffectthesafetyofthe vehicleoritspassengers.Anyrepairsrequiredto safetycriticalitemssuchassteering,brakes, suspensionorsupplementaryrestraintsystemshould REPAIRSANDREPLACEMENTS becarriedoutbyaLandRoverDealer.Repairsto suchitemsshouldNEVERbeattemptedbyuntrained Whenreplacementpartsarerequireditisessential individuals. thatLandRoverpartsareused. Attentionisparticularlydrawntothefollowingpoints WARNINGS,CAUTIONSandNOTESaregiven concerningrepairsandthefittingofreplacementparts throughoutthisManualinthefollowingform: andaccessories:Safetyfeaturesembodiedinthe vehiclemaybeimpairedifotherthanLandRover WARNING:Procedureswhichmustbe partsarefitted.Incertainterritories,legislation followedpreciselytoavoidthepossibility prohibitsthefittingofpartsnottothevehicle ofpersonalinjury. manufacturer’sspecification.Torquespannervalues givenintheWorkshopManualmustbestrictly CAUTION:Thiscallsattentionto adheredto.Lockingdevices,wherespecified,mustbe procedureswhichmustbefollowedto fitted.Iftheefficiencyofalockingdeviceisimpaired avoiddamagetocomponents. duringremovalitmustbereplacedwithanewone. Certainfastenersmustnotbere-used.These NOTE:Thiscallsattentiontomethods fastenersarespecifiedintheWorkshopManual. whichmakeajobeasierorgiveshelpful information. POISONOUSSUBSTANCES DIMENSIONS Manyliquidsandothersubstancesusedare poisonousandthereforemustnotbeconsumed.Itis Thedimensionsquotedaretodesignengineering alsoadvisabletokeepallsubstancesawayfromopen specification.Alternativeunitequivalents,shownin wounds.Thesesubstancesamongothersinclude bracketsfollowingthedimensions,havebeen anti-freeze,brakefluid,fuel,windscreenwasher convertedfromtheoriginalspecification. additives,airconditioningrefrigerant,lubricantsand variousadhesives. INFORMATION 1 01 INTRODUCTION FUELHANDLINGPRECAUTIONS Hotfuelhandlingprecautions Thefollowinginformationprovidesbasicprecautions WARNING:Beforecommencingany whichmustbeobservediffuelistobehandledsafely. operationrequiringfueltobedrainedfrom Italsooutlinestheotherareasofriskwhichmustnot thefueltank,thefollowingproceduremust beignored. beadheredto: Thisinformationisissuedforbasicguidanceonly,and 1. Allowsufficienttimeforthefueltocool,thus inanycaseofdoubt,appropriateenquiriesshouldbe avoidingcontactwithhotfuels. madeofyourlocalFireOfficerorFireDepartment. 2. Ventthesystembyremovingthefuelfillercapin awellventilatedarea.Refitthefillercapuntilthe Fuelvapourishighlyflammableandinconfined commencementoffueldrainage. spacesisalsoveryexplosiveandtoxicandwhen dilutedwithairbecomesareadilyignitablemixture. Fueltransfer Thevapourisheavierthanairandwillalwaysfallto thelowestlevel.Itcanreadilybedistributed WARNING:Fuelmustnotbeextractedor throughoutaworkshopbyaircurrent,consequently, drainedfromanyvehiclewhileitis evenasmallspillageoffuelisverydangerous. standingoverapit. AlwayshaveafireextinguishercontainingFOAMCO2 Thetransferoffuelfromthevehiclefueltankmustbe GAS,orPOWDERcloseathandwhenhandlingfuel, carriedoutinawellventilatedarea.Anapproved orwhendismantlingfuelsystemsandinareaswhere transfertankmustbeusedaccordingtothetransfer fuelcontainersarestored. tankmanufacturer’sinstructionsandlocalregulations, includingattentiontogroundingoftanks. WARNING:ltisimperativethatthebattery isnotdisconnectedduringfuelsystem Fueltankremoval repairsasarcingatthebatteryterminal couldignitefuelvapourintheatmosphere. AFUELVAPOURwarninglabelmustbeattachedto AlwaysdisconnectthevehiclebatteryBEFORE thefueltankuponremovalfromthevehicle. carryingoutworkonthefuelsystem. Wheneverfuelisbeinghandled,transferredor Fueltankrepair stored,orwhenfuelsystemsarebeingdismantled allformsofignitionmustbeextinguishedor Undernocircumstancesshouldarepairtoanytank removed,anyleadlampsusedmustbeflameproof beattempted. andkeptclearofspillage. Nooneshouldbepermittedtorepaircomponents associatedwithfuelwithoutfirsthavinghadfuel systemtraining. 2 INFORMATION INTRODUCTION SYNTHETICRUBBER USEDENGINEOIL Many’0’ringseals,flexiblepipesandothersimilar WARNING:Prolongedandrepeated itemswhichappeartobenaturalrubberaremadeof contactwithengineormotoroilwillresult syntheticmaterialscalledFluoroelastomers.Under intheremovalofnaturalfatsfromthe normaloperatingconditionsthismaterialissafe,and skin,leadingtodryness,irritationanddermatitis. doesnotpresentahealthhazard.However,ifthe Usedengineoilcontainspotentiallyharmful materialisdamagedbyfireorexcessiveheat,itcan contaminantswhichmaycauseskincancer. breakdownandproducehighlycorrosiveHydrofluoric Adequatemeansofskinprotectionandwashing acidwhichcancauseseriousburnsoncontactwith facilitiesshouldbeprovided. skin.Shouldthematerialbeinaburntoroverheated conditionhandleonlywithseamlessindustrialgloves. Handlingprecautions Decontaminateanddisposeoftheglovesimmediately afteruse. 1. Avoidprolongedandrepeatedcontactwithoils, particularlyusedengineoils. Ifskincontactdoesoccur,removeanycontaminated 2. Wearprotectiveclothing,includingimpervious clothingimmediatelyandobtainmedicalassistance gloveswhereapplicable. withoutdelay.Inthemeantime,washtheaffected 3. Donotputoilyragsinpockets. areawithcopiousamountsofcoldwaterorlimewater 4. Avoidcontaminatingclothes,particularly forfifteentosixtyminutes. underwear,withoil. 5. Overallsmustbecleanedregularly.Discard unwashableclothingandoilimpregnated footwear. 6. Firstaidtreatmentmustbeobtainedimmediately RECOMMENDEDSEALANTS foropencutsandwounds. 7. Usebarriercreams,beforeeachworkperiod,to Anumberofbrandedproductsarerecommendedin helptheremovalofoilfromtheskin. thismanualforuseduringmaintenanceandrepair 8. Washwithsoapandwatertoensurealloilis work. removed(skincleansersandnailbrusheswill Theseitemsinclude: help).Preparationscontaininglanolinreplacethe HYLOMARGASKETANDJOINTINGCOMPOUND naturalskinoilswhichhavebeenremoved. and 9. Donotusegasoline,kerosene,dieselfuel, HYLOSILRTVSILICONECOMPOUND. petrol,thinnersorsolventsforwashingtheskin. 10. Ifskindisordersdevelop,obtainmedicaladvice. Theyshouldbeavailablelocallyfromgarage 11. Wherepracticable,degreasecomponentsprior equipmentsuppliers.Ifthereisanyproblemobtaining tohandling. supplies,contactthefollowingcompanyforadvice 12. Wherethereisariskofeyecontact,eye andtheaddressofthenearestsupplier. protectionshouldbeworn,forexample,goggles orfaceshields;inadditionaneyewashfacility MARSTONLUBRICANTSLTD. shouldbeprovided. HyloHouse, CaleLane, Disposingofusedoils NewSprings, WiganWN21JR Environmentalprotectionprecaution Tel01942824242 Itisillegaltopourusedoilontotheground,down sewersordrains,orintowaterways. Disposeofusedoilthroughauthorisedwastedisposal contractors.IfindoubtcontactyourLocalAuthorityfor adviceondisposalfacilities. INFORMATION 3 01 INTRODUCTION ACCESSORIESANDCONVERSIONS SPECIALSERVICETOOLS DONOTFITunapprovedaccessoriesorconversions, Theuseofapprovedspecialservicetoolsis astheycouldaffectthesafetyofthevehicle. important.Theyareessentialifserviceoperationsare LandRoverwillnotacceptliabilityfordeath,personal tobecarriedoutefficiently,andsafely.Wherespecial injury,ordamagetopropertywhichmayoccurasa toolsarespecified,onlythesetoolsshouldbeused directresultofthefittingofnon-approvedconversions toavoidthepossibilityofpersonalinjuryor tothevehicle. damagetothecomponents.Also,theamountof timewhichtheysavecanbeconsiderable. Specialtoolsbulletinswillbeissuedperiodicallygiving detailsofnewtoolsastheyareintroduced. WHEELSANDTYRES AllordersandenquiriesfromtheUnitedKingdom WARNING:DONOTreplacetheroad shouldbesentdirecttoV.L.Churchill.Overseas wheelswithanytypeotherthangenuine ordersshouldbeplacedwiththelocalV.L.Churchill LandRoverwheelswhicharedesignedfor distributor,whereoneexists.Countrieswherethereis multi-purposeonandoffroaduseandhavevery nodistributormayorderdirectfrom: importantrelationshipswiththeproperoperation V.L.ChurchillLimited, ofthesuspensionsystemandvehiclehandling. POBox3, Replacementtyresmustbeofthemakeandsizes Daventry,Northants, recommendedforthevehicle,andalltyresmust England,NN114NF. bethesamemake,plyratingandtreadpattern. ThetoolsrecommendedinthisWorkshopManualare listedinamulti-languageillustratedcatalogue, obtainablefrom: STEAMCLEANING Messers.V.L.Churchillattheaboveaddress, orfrom: Topreventconsequentialrusting,anysteamcleaning LandRoverPublications, withintheenginebayMUSTbefollowedbycareful CharacterMailing, re-waxingofthemetalliccomponentsaffected. HeyshamRoad, Particularattentionmustbegiventothesteering Bootle, column,enginecoolantpipesandhoseclips. Merseyside,L701JL SPECIFICATION COPYRIGHT Thespecificationdetailsandinstructionssetoutin (cid:211) 1996RoverGroupLimited thisManualapplyonlytoarangeofvehiclesandnot toanyone.Forthespecificationofaparticularvehicle Allrightsreserved.Nopartofthispublicationmaybe purchasersshouldconsulttheirDealer. produced,storedinaretrievalsystemortransmitted TheManufacturerreservestherighttovary inanyform,electronic,mechanical,recordingorother specificationswithorwithoutnotice,andatsuchtimes meanswithoutpriorwrittenpermissionofRover andinsuchmannerasitthinksfit.Majoraswellas Group. minorchangesmaybeinvolvedinaccordancewith theManufacturer’spolicyofconstantproduct improvement. Whilsteveryeffortismadetoensuretheaccuracyof theparticularscontainedinthisManual,neitherthe ManufacturerorDealer,bywhomthisManualis supplied,shallinanycircumstancesbeheldliablefor anyinaccuracyortheconsequencesthereof. 4 INFORMATION INTRODUCTION JACKING Thefollowinginstructionsmustbecarriedoutbefore raisingthevehicleofftheground. 1. Useasolidlevelgroundsurface. 2. Applyparkingbrake. 3. Select1stgearinmaingearbox. 4. SelectLowrangeintransfergearbox. CAUTION:Toavoiddamageoccurringto theunderbodycomponentsofthevehicle thefollowingjackingproceduresmustbe adheredto. DONOTPOSITIONJACKSORAXLESTANDS UNDERTHEFOLLOWINGCOMPONENTS. Bodystructure Bumpers Fuellines Brakelines Frontradiusarms Panhardrod Steeringlinkage RearTrailinglinks Fueltank Enginesump Gearboxbellhousing Jackorsupportvehiclebyaxlesonly. Vehiclejack Thejackprovidedwiththevehicleisonlyintendedto beusedinanemergency,forchangingatyre.Do NOTusethejackforanyotherpurpose.Referto Owner’sManualforvehiclejacklocationpointsand Raisethefrontofthevehicle procedure.Neverworkunderavehiclesupportedby thevehiclejack. 1. Positioncupofhydraulicarmunderdifferential casing. Hydraulicjack NOTE:Thedifferentialcasingisnot Ahydraulicjackwithaminimum1500kg,3,300lbs centraltotheaxle.Careshouldbetaken loadcapacitymustbeused,seeJ6083. whenraisingthefrontroadwheelsoffthe groundastherearaxlehaslessswaystiffness. CAUTION:Donotcommenceworkonthe undersideofthevehicleuntilsuitableaxle 2. Raisefrontroadwheelstoenableanaxlestand standshavebeenpositionedunderthe tobeinstalledunderlefthandaxletube. axle,seeJ6084. INFORMATION 5 01 INTRODUCTION 3. Positionanaxlestandunderrighthandaxle DYNAMOMETERTESTING tube,carefullylowerjackuntilaxlesitssecurely onbothaxlestands,removetrolleyjack. Thefrontandrearaxlescannotbedriven 4. Beforecommencingworkonundersideof independently. vehiclere-checksecurityofvehicleonstands. 5. Reverseprocedurewhenremovingvehiclefrom WARNING:DONOTattempttodrive stands. individualwheelswithvehiclesupported onfloorjacksorstands. Raiserearofvehicle Fourwheeldynamometers 1. Positioncupofhydraulicarmunderdifferential casing. Providedthatfrontandreardynamometerrollersare 2. Raisevehicletoenableaxlestandstobe rotatingatidenticalspeedsandthatnormalworkshop installedunderleftandrighthandaxletubes. safetystandardsareapplied,thereisnospeed 3. Lowerjackuntilaxlesitssecurelyonaxle restrictionduringtestingexceptanythatmayapplyto stands,removetrolleyjack. thetyres. 4. Beforecommencingworkonundersideof vehiclere-checksecurityofvehicleonstands. Twowheeldynamometers 5. Reverseprocedurewhenremovingvehiclefrom stands. IMPORTANT:Useafourwheeldynamometerfor braketestingifpossible. Ifbraketestingonasingleaxlerigisnecessaryit mustbecarriedoutwithpropellershafttorearaxle HYDRAULICVEHICLERAMP(FOURPOST) removed,ANDneutralselectedinBOTHmain gearboxandtransfergearbox.Whencheckingbrakes, Useonlya’driveon’typerampwhichsupportsvehicle runengineatidlespeedtomaintainservovacuum. onitsroadwheels.Ifa’wheel-free’conditionis Ifcheckingengineperformance,thetransferboxmust required,usea’driveon’rampincorporatinga beinhighrangeandpropellershafttostationaryaxle ’wheel-free’systemprovidingsupportbeneathaxle mustberemoved. casings.Alternatively,placevehicleonafirm,flatfloor andsupportonaxlestands. TWOPOSTVEHICLERAMPS ThemanufacturerofLANDROVERVEHICLES DOESNOTrecommendusing’TwoPost’ramps thatemployfouradjustablesupportarms.These areNOTconsideredsafeforLandRovervehicles. IfvehicleisinstalledonaTwoPostramp responsibilityforsafetyofvehicleandpersonnel performingserviceoperationsisinthehandsof theServiceProvider. 6 INFORMATION INTRODUCTION TOWING Rearsuspendedtowbybreakdownvehicle CAUTION:Thevehiclehaspermanent 1. Ifthefrontaxleistobetrailedturnignitionkeyto four-wheeldrive.Thefollowingtowing position’1’toreleasesteeringlock. instructionsmustbeadheredto: 2. Selectneutralinmaingearboxandtransferbox. Towingthevehicleonallfourwheelswithdriver CAUTION:Thesteeringwheeland/or operatingsteeringandbrakes. linkagemustbesecuredinastraight aheadposition.DONOTusethesteering 1. Turnignitionkeytoposition’1’torelease lockmechanismforthispurpose. steeringlock. 2. Selectneutralinmaingearboxandtransfer gearbox. TRANSPORTINGTHEVEHICLEBYTRAILER Lashing/towingeyesareprovidedonfrontandrearof thechassissidemembers,seeJ6085,tofacilitatethe securingofthevehicletoatrailerorothermeansof transportation. CAUTION:Underbodycomponentsmust notbeusedaslashingpoints. Installvehicleontrailerandapplyparkbrake.Select neutralinmaingearbox. 3. Securetowrope,chainorcabletofronttowing eyes(alternativetypesshown). 4. Releasetheparkingbrake. CAUTION:Thebrakeservoandpower assistedsteeringsystemwillnotbe functionalwithouttheenginerunning. Greaterpedalpressurewillberequiredtoapply thebrakes,thesteeringsystemwillrequire greaterefforttoturnthefrontroadwheels. Thevehicletowconnectionshouldbeusedonly innormalroadconditions,’snatch’recovery shouldbeavoided. INFORMATION 7
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