AMENDMENT INSTRUCTION SHEET - land rover resource

450 Pages·2011·7.46 MB·English

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
Tel[phone]
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