Land Rover Defender 300Tdi.Manual de taller.pdf

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AMENDMENT INSTRUCTION SHEET
DEFENDER WORKSHOP MANUAL
Publication Number LRL0097ENG
Amendment Number: LD003.97
Date: 09/97
To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an
Amendment Instruction Sheet will be issued with each set of revised pages.
The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the
Contents pages, all revised and new pages have the issue date at the foot of each page, together with an
indication of whether the pages are revised or new.
This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment
has been incorporated. Do not discard previous Amendment Instruction sheets.
Your manual is only complete to this issue providing all prior Amendments are included.
The filing instructions give section and page numbers affected. Additional pages or complete new sections may
be issued, insert the pages as instructed.
FILING INSTRUCTIONS
Section
Discard Existing
Pages
Insert New Pages Reason for Amendment
51 - Rear Axle and
Final Drive - Repairs
Pages 1 to 5
Pages 1 to 5
Clarification of wheel nut torque figures.
54 - Front Axle and
Final Drive - Repairs
Pages 1, and 3
Pages 1, and 3
Clarification of wheel nut torque figures.
57 - Steering - Repairs Page 5
Page 5
Clarification of wheel nut torque figures.
60 - Front Suspension -
Repairs
Pages 1, and 3
Pages 1, and 3
Clarification of wheel nut torque figures.
64 - Rear Suspension -
Repairs
Page 1
Page 1
Clarification of wheel nut torque figures.
70 - Brakes - Repairs
Pages 7, 11, and
13
Pages 7, 11, and
13
Clarification of wheel nut torque figures.
74 - Wheels and Tyres
- Repairs
Page 5
Pages 5, and 7
Clarification of wheel nut torque figures.
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Workshop manual
DEFENDER 300Tdi
01
04
05
07
09
10
This manual covers vehicles from
1996 model year
12
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
19 FUEL SYSTEM Tdi
26 COOLING SYSTEM Tdi
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS AND TYRES
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
88 INSTRUMENTS
17
19
26
30
33
37
41
47
51
54
57
60
64
74
70
Publication Part No. LRL 0097 ENG
Published by Rover Technical Communication
Ó
75
76
80
82
84
86
88
1996 Rover Group Limited
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INTRODUCTION
INTRODUCTION
REFERENCES
This workshop manual covers vehicles from 1996
model year onwards. Amendments and additional
pages will be issued to ensure that the manual covers
latest models. Amendments and additions will be
identified by the addition of a dated footer at the
bottom of the page.
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
crankshaft end of the engine is referred to as the front.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover Defender 300Tdi vehicles.
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.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system should
be carried out by a Land Rover Dealer. Repairs to
such items should NEVER be attempted by untrained
individuals.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that 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 spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
WARNINGS, CAUTIONS and NOTES are given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
POISONOUS SUBSTANCES
DIMENSIONS
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.
INFORMATION
1
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01
INTRODUCTION
FUEL HANDLING PRECAUTIONS
Hot fuel handling precautions
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
1. Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2. Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic and when
diluted with air becomes a readily ignitable mixture.
The vapour is heavier than air and will always fall to
the lowest level. It can readily be distributed
throughout a workshop by air current, consequently,
even a small spillage of fuel is very dangerous.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
Always have a fire extinguisher containing FOAM CO 2
GAS, or POWDER close at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer’s instructions and local regulations,
including attention to grounding of tanks.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.
Fuel tank removal
A FUEL VAPOUR warning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.
2
INFORMATION
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