Rover DEFENDER 300Tdi Workshop Manual Download

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INSTRUMENTS

REPAIR

FUEL GAUGE TANK UNIT - SIDE FUEL TANK

Service repair no - 88.25.31

WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when

carrying out the following instructions.

Remove

1. Disconnect battery.
2. Remove RH front seat cushion.
3. Release retaining catch and remove seat base

cover to gain access to fuel tank.

4. Disconnect electrical plug from fuel gauge unit.
5. Release locking ring and withdraw fuel gauge

unit from tank, complete with sealing ring.

Refit

6. Insert gauge unit into tank with float positioned

towards front of tank. Fit new sealing washer, if
necessary.

7. Secure gauge unit with locking ring.
8. Fit electrical plug.
9. Fit seat base cover and seat cushion.

10. Reconnect battery.

Summary of Contents for DEFENDER 300Tdi

Page 1: ...This file was downloaded from www RepairMyLandrover co uk The ONLY site you will ever need when maintaining your Landrover...

Page 2: ...ly 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...

Page 3: ...E 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 A...

Page 4: ...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 crankshaft end of the engine is ref...

Page 5: ...ttery 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 a...

Page 6: ...oil will result in the removal of natural fats from the skin leading to dryness irritation and dermatitis Used engine oil contains potentially harmful contaminants which may cause skin cancer Adequat...

Page 7: ...ved 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...

Page 8: ...ck The jack provided with the vehicle is only intended to be used in an emergency for changing a tyre Do NOT use the jack for any other purpose Refer to Owner s Manual for vehicle jack location points...

Page 9: ...MPS The manufacturer of LAND ROVER VEHICLES DOES NOT recommend using Two Post ramps that employ four adjustable support arms These are NOT considered safe for Land Rover vehicles If vehicle is install...

Page 10: ...e greater effort to turn the front road wheels The vehicle tow connection should be used only in normal road conditions snatch recovery should be avoided Rear suspended tow by breakdown vehicle 1 If t...

Page 11: ...ion and all electrical accessories are switched off that parking brake is applied and neutral is selected connect the jump leads as follows A Connect one end of first jumper cable to positive terminal...

Page 12: ...er square millimetre kgf mm2 Kilogramme per square centimetre kgf cm2 Kilogramme metres torque kgf m Kilometres km Kilometres per hour km h Kilovolts kV Left hand LH Left hand steering LHStg Left hand...

Page 13: ...Mass air flow sensor MAFS Open loop OL Relay module RM Solid state relay module SSRM Three way catalytic converter TWC Throttle body TB Throttle position sensor TPS Transmission range TR Wide open th...

Page 14: ...amped on the RH side of the chassis to the rear of the front lashing eye see J6089 The Vehicle Identification Number identifies the manufacturer model range wheel base body type engine steering transm...

Page 15: ...serial number Stamped on a cast pad on the bottom RH side of the gearbox Transfer gearbox LT230 serial number The serial number is stamped on the LH side of the gearbox casing below the mainshaft rear...

Page 16: ...s to accommodate all skill levels Touch screen operation Direct print out of screen information and test results READING THIS MANUAL This manual is divided into sections shown on the contents page alo...

Page 17: ...grooves Diametrical clearance 0 0792 0 0307 mm Connecting rods Length between centres 175 38 175 43 mm Diametrical clearance big end bearings 0 025 0 075 mm End float on crankpin 0 15 0 356 mm Piston...

Page 18: ...mm Exhaust 9 97 mm Cam lift Inlet 6 81 mm Exhaust 7 06 mm Valve head stand down Inlet 0 81 1 09 mm Exhaust 0 86 1 14 mm Valve springs Type Single coil Length free 46 28 mm Length under 21 kg load 40...

Page 19: ...fan 11 blade axial flow 433 mm diameter 1 29 1 drive ratio with viscous coupling Pump type Centrifugal impellor belt driven Thermostat opening 88 C Expansion tank cap pressure 1 06 Kgf cm2 15 Ibf in2...

Page 20: ...l turns lock to lock 3 375 Steering pump Make type Hobourn Eaton series 500 Steering geometry Steering wheel diameter 412 mm 16 22 in Toe out measurement 0 to 2 mm toe out Toe out included angle 0 to...

Page 21: ...ar Passenger side NRC 9449 Yellow white 90 2550 Kg Front Driver s side NRC 9446 Blue green Front passenger side NRC 9447 Blue yellow Rear Driver s side NRC 9462 Green yellow red Rear Passenger side NR...

Page 22: ...ameter 90 290 mm 11 42 in 110 130 298 mm 11 73 Disc thickness 90 12 5 mm 0 49 in 110 130 14 1 mm 0 56 in Wear limit 90 0 38 mm 0 015 in 110 130 1 0 mm 0 04 in per side of disc Disc run out maximum 0 1...

Page 23: ...measured between adjacent commutatator segments 0 23 to 0 35 ohms Light running rack disconnected current at 13 5 V 2 0 amps Wiper speed wet screen 60 seconds from cold Low speed 45 3 rev min High spe...

Page 24: ...r lamps 12V 5W capless Tail lamps 12V 5 21W bayonet Direction indicator lamps 12V 21W bayonet Number plate lamp 12V 5W capless Reverse lamp 12V 21W bayonet Rear fog guard lamp 12V 21W bayonet Interior...

Page 25: ...5 lb 1200 Kg 2645 lb Rear axle 1750 Kg 3858 lb 1850 Kg 4078 lb Gross vehicle weight 2950 Kg 6503 lb 3050 Kg 6724 lb 130 models Front axle 1580 Kg 3483 lb Rear axle 2200 Kg 4850 lb Gross vehicle weight...

Page 26: ...and Pick up EEC kerb weight 48 Hard top and station wagon EEC kerb weight 51 5 Departure angle Soft top and Pick up EEC kerb weight 49 Hard top and Station wagon EEC kerb weight 53 Wading depth 500 mm...

Page 27: ...higher at running temperature If the vehicle has been parked in the sun or high ambient temperatures DO NOT reduce the tyre pressures move the vehicle into the shade and wait for the tyres to cool bef...

Page 28: ...wheel boxes 925 mm 36 4 in 110 models Overall length Soft top and Pick up 4438 mm 175 in High capacity pick up 4631 mm 182 in Hard top Station and County 4599 mm 181 in Overall width 1790 mm 70 5 in O...

Page 29: ...e 4600 40 120 rev min Idle speed at running temperature 720 20 rev min Die down time 4 seconds INJECTION PUMP Make type standard Bosch rotary R509 type with boost control and two speed mechanical gove...

Page 30: ...sch KBAL 90 P37 Nozzle type DSLA 145P366 Opening pressure working pressure Initial pressure 200 atmospheres Secondary 280 atmospheres TURBOCHARGER Make type Garrett T250 04 Maximum boost pressure 0 93...

Page 31: ...eats 4 Always use a recommended Service Tool where specified 5 Protect temporarily exposed screw threads by replacing nuts or fitting plastic caps SAFETY PRECAUTIONS 1 Whenever possible use a lift whe...

Page 32: ...g are correctly replaced or renewed if disturbed 3 Use marking ink to identify mating parts to ensure correct reassembly If a centre punch or scriber is used they may initiate cracks or distortion of...

Page 33: ...ing generously with lubricant appropriate to installation 6 Inspect shaft and bearing housing for discolouration or other marking suggesting that movement has taken place between bearing and seatings...

Page 34: ...g lip 6 Grease outside diameter of seal place square to housing recess and press into position using great care and if possible a bell piece to ensure that seal is not tilted In some cases it may be p...

Page 35: ...ately covered to exclude dirt 3 Clean hose externally and blow through with airline Examine carefully for cracks separation of plies security of end fittings and external damage Reject any hose found...

Page 36: ...our METRIC NUT IDENTIFICATION 1 A nut with an ISO metric thread is marked on one face or on one of the flats of the hexagon with the strength grade symbol 8 12 or 14 Some nuts with a strength 4 5 or 6...

Page 37: ...Both UNF and Metric threads to ISO standards are used See below for thread identification 2 Damaged threads must always be discarded Cleaning up threads with a die or tap impairs the strength and clos...

Page 38: ...Diesel RES 22 OL PD 2 15W 40 Engine sump or CCMC PD 2 or API CD Main Gearbox manual ATF Dexron IID Final drive units API or GL5 90 EP Swivel pin housings MIL L 2105 or MIL L 2105B 80 EP C or D Power s...

Page 39: ...Or a maximum of 60 Battery lugs Petroleum jelly Earthing surfaces NOTE Do not use Silicone Grease where paint has been removed Air Conditioning System Refrigerant Use only refrigerant R134a Compresso...

Page 40: ...Cooling system 11 50 20 20 Washer bottle 3 0 5 28 NOTE All levels must be checked by dipstick or level plugs as applicable ANTI FREEZE PERCENTAGE CONCENTRATION 50 PROTECTION LOWER TEMPERATURE LIMIT C...

Page 41: ...ndard 2869 Class A1 or A2 Using diesel fuel with a class rating lower than stated above could seriously impair vehicle performance FUEL TANK CAPACITY Side tank 90 models 54 6 litres 12 gallons 110 mod...

Page 42: ...n of all lamps horns and warning indicators CHECK OPERATION OF WIPERS Check operation of front rear wipers and washers and condition of wiper blades CHECK OPERATION OF HANDBRAKE Handbrake check adjust...

Page 43: ...tread wear and tread depth See INTRODUCTION Information wheels and tyres Check adjust tyre pressures See WHEELS AND TYRES Repair Tyres pressures INSPECT BRAKE PADS FOR WEAR CALIPERS FOR LEAKS AND COND...

Page 44: ...3 Air cleaner element 4 Engine breather filter 5 Oil filler cap 6 Oil level dipstick 7 Heater air conditioning unit 8 Windscreen washer reservoir 9 Power steering pump reservoir 10 Intercooler and hos...

Page 45: ...er element 4 Engine breather filter 5 Oil filler cap 6 Oil level dipstick 7 Heater air conditioning unit 8 Windscreen washer reservoir 9 Power steering pump reservoir 10 Intercooler and hoses 11 Radia...

Page 46: ...n to avoid excess coolant spillage from radiator 4 Fit plastic plug in radiator 5 Add a further 1 litre 1 76 pints of coolant to expansion tank and allow to settle 6 Refit expansion tank cap and therm...

Page 47: ...to casing and secure with wing nut 7 Fit end cover align mating arrows and secure with wing nut 8 Position air cleaner in mounting cradle and secure with retaining clips CLEAN ENGINE BREATHER FILTER R...

Page 48: ...refit cap 3 Remove cap and check fluid level Ensure fluid level is between UPPER mark and end of dipstick 4 Top up if necessary with recommended fluid See LUBRICANTS FLUIDS AND CAPACITIES Information...

Page 49: ...r cable at adjustment ferrule and linkage with injector pump and at pedal clevis pin CHECK ADJUST ENGINE IDLE SPEED Check adjust low and high engine idle speed with engine at normal running temperatur...

Page 50: ...Catalytic converter if fitted 5 Transfer box filler level plug 6 Intermediate exhaust silencer 7 Tail pipe exhaust silencer 8 Rear axle filler level plug 9 Rear axle drain plug 10 Propeller shaft univ...

Page 51: ...6 lbf ft 7 Place drain tray under oil filter 8 Unscrew filter anti clockwise using a strap wrench if necessary 9 Clean mating face of oil filter adaptor 10 Coat rubber sealing washer of new filter wit...

Page 52: ...er transfer gearbox 5 Remove filler level plug to vent gearbox and assist draining 6 Remove drain plug and allow oil to drain 7 Thoroughly clean drain plug threads and apply fresh Hylomar sealant 8 Re...

Page 53: ...ES Information Recommended lubricants and fluids 4 Clean and refit filler level plug RENEW SWIVEL PIN HOUSING OIL 1 Ensure vehicle is level and place suitable tray under swivel to be drained 2 Remove...

Page 54: ...Ball joints are lubricated for life during manufacture and require no further lubrication unless the rubber boot has been dislodged or damaged All joints should be checked at specified service interva...

Page 55: ...arried out For details of dynamometer testing See INTRODUCTION Information Dynamometer testing Check the following components 1 Engine for excessive noise 2 Clutch for slip judder or spin drag 3 Gear...

Page 56: ...raulic brake fluid seals and flexible hoses should be renewed All working surfaces of the master cylinder and caliper cylinders should be examined and renewed where necessary Air cleaner When the vehi...

Page 57: ...t of engine is fully open 2 Using a 0 20 mm 0 008 in feeler gauge adjust clearance of No 1 valve 3 Slacken locknut and turn adjusting screw clockwise to reduce clearance and anti clockwise to increase...

Page 58: ...ession tester kit LRT 19 007 into the cylinder head and clamp securely in position 8 Connect flexible hose and gauge to dummy injector as shown above 9 Crank engine for 10 20 seconds and note reading...

Page 59: ...Connect pressure test gauge LRT 12 052A as shown 4 Start and run engine to normal operating temperature 5 With engine running at idle check oil pressure which should read 1 76 bar 25 87 lbf in2 6 If p...

Page 60: ...ion system using a battery backed up alarm sounder See ELECTRICAL Repair battery 3 Remove bonnet 4 Remove cable ties securing gearbox harness to breather pipes 5 Disconnect harness from diff lock and...

Page 61: ...onnect exhaust down pipe 19 Disconnect inlet and outlet hoses from power steering pump 20 Disconnect bleed hose from thermostat housing 21 Release bleed hose from retaining clips on front timing cover...

Page 62: ...Support gearbox 33 Remove engine to bell housing fixings leaving starter motor attached to engine 34 Carefully raise engine to release from gearbox 35 Ensure all relevant connections to engine have be...

Page 63: ...nd vacuum pipe 60 Secure breather pipe clip to cylinder head 61 Connect engine harness multi plug 62 Fit heater plug feed wire 63 Connect electrical feed plug at rear of cylinder head 64 Fit heater ho...

Page 64: ...COVER PLATE AND SEAL Service repair no 12 65 01 Remove 1 Disconnect battery 2 Drain coolant See COOLING SYSTEM Repair Drain and refill cooling system 3 Remove top hose from radiator 4 Remove intercool...

Page 65: ...it intercooler to induction manifold hose 21 Fit top hose to radiator 22 Refill cooling system See COOLING SYSTEM Repair Drain and refill cooling system 23 Reconnect battery CAMSHAFT DRIVE BELT Servic...

Page 66: ...belts at an acute angle otherwise premature failure could result Belt tensioner NOTE The belt tensioner need only be removed if it is being replaced or for access purposes to remove front cover 10 Rem...

Page 67: ...24 Disengage timing pin 25 Insert pin from special tool LRT 12 045 in injection pump gear and through into pump flange 26 Slacken injection pump gear retaining bolts 27 Slacken tensioner and retensio...

Page 68: ...il 4 With lip side leading drive in seal squarely using special tool LRT 12 079 5 Fit crankshaft gear See Crankshaft gear CAMSHAFT GEAR Service repair no 12 65 24 Remove 1 Remove camshaft drive belt S...

Page 69: ...repair no 19 30 06 Remove 1 Remove camshaft drive belt See Camshaft drive belt 2 Slacken 3 bolts on front of injector pump gear 3 Remove special tool pin from gear 4 Remove 3 bolts and withdraw gear a...

Page 70: ...from mating faces Refit 11 Fit slave guide studs to locate gasket 12 Fit new gasket to cylinder block 13 Align flats on oil pump with flats on crankshaft 14 Fit front cover to block taking care not t...

Page 71: ...0 mm bead of Hylosil RTV102 to the sump flange ensuring bead is applied inboard of the bolt holes 8 Secure sump to block with 22bolts Tighten to 25 Nm 18 lbf ft 9 Refill engine oil See LUBRICANTS FLUI...

Page 72: ...es of flywheel and crankshaft are clean 8 Locate flywheel on crankshaft remove lifting bolts and secure flywheel with new patched retaining bolts progressively tighten to 147 Nm 108 lbf ft 9 Check the...

Page 73: ...integral O ring seal and gasket was fitted on earlier engines They must be replaced with the current housing and gasket 3 shown below 1 Disconnect battery 2 Remove gearbox See MANUAL GEARBOX Repair R...

Page 74: ...r having a good slide fit in the bore of the bush Pack the bore with grease and insert the steel rod into the end of the bore give a sharp blow with a hammer and the grease should drive out the bush I...

Page 75: ...om of flywheel housing to engine mounting brackets 8 Remove inner bolts and lift off flywheel housing Refit 9 Clean rear face of housing and mating face on block ensuring all old sealant is removed 10...

Page 76: ...E CONTROL VALVE Service repair no 12 60 69 Remove 1 Clean adaptor housing 2 Disconnect oil cooler feed pipe from thermostat extension housing and plug to prevent ingress of dirt 3 Remove 2 bolts and c...

Page 77: ...il cooler pipes CYLINDER HEAD GASKET Service repair no 12 29 02 Remove 1 Disconnect battery 2 Remove bonnet 3 Drain coolant See COOLING SYSTEM Repair Drain and refill cooling system 4 Remove air clean...

Page 78: ...ts and lift rocker shaft assembly from cylinder head 21 Remove push rods and store as an identified set to allow refitment to same location 22 Remove valve stem caps 23 Evenly slacken and then remove...

Page 79: ...illustrated 35 Repeat 60 tightening procedure again strictly in sequence illustrated 36 Tighten the 10 longer bolts M12 x 140mm a further 20 again following the sequence illustrated NOTE Repositioning...

Page 80: ...r top hose at thermostat 57 Fit heater plugs See FUEL SYSTEM Repair Heater plugs 58 Fit fuel injectors See FUEL SYSTEM Repair Fuel injectors 59 Fit crankcase ventilation valve and side breather hose 6...

Page 81: ...emove engine oil sump See Engine oil sump 2 Unscrew relief valve retaining plug from base of front cover 3 Withdraw valve spring and plunger and check for wear Valve spring free length 68 00 mm 2 68 i...

Page 82: ...cover 25 Drain plug oil sump 35 Tappet guide 14 Breather side cover assembly 25 Baffle plate to breather side cover 4 Vacuum pump 25 Fuel lift pump 25 Flywheel housing 45 Flywheel housing clutch cove...

Page 83: ...bolt 5 50 Rocker cover stud 8 Rocker cover fixing nut 10 Breather cyclone to rocker cover 9 Tappet adjusting nut 16 Front cover to cylinder block 25 Front cover plate to front cover 25 Static idler t...

Page 84: ...Spill rail to injectors banjo bolt 10 Spill rail to injection pump banjo bolt 25 Boost pipe injection pump banjo bolt 10 Plug rear of injection pump 29 PAS pump to mounting plate 25 PAS pump mounting...

Page 85: ...SPECIFICATIONS TORQUE METRIC Nm M5 6 M6 9 M8 25 M10 45 M12 90 M14 105 M16 180 UNC UNF 1 4 9 5 16 24 3 8 39 7 16 78 1 2 90 5 8 136 NOTE Torque values above are to be used as a guide where no torque is...

Page 86: ...the fuel tank is located at the rear of the vehicle between the chassis longitudenal sections as shown in J6192 As an option a twin tank system fitted with a combined change over tap and 3 way fuel su...

Page 87: ...se box and is linked independently to the fuel injection pump throttle lever Air intake The air cleaner is mounted on the RH side of the engine and is connected by hoses to the cold air intake duct an...

Page 88: ...ion pump 4 Fuel injection pump 5 Fuel lift pump 6 Spill return pipe injection pump to tank 7 Supply pipe sedimentor to fuel pump 8 Fuel tank 9 Supply pipe fuel tank to sedimentor 10 Fuel filler pipe 1...

Page 89: ...pill return 10 Fuel filler cap 11 Side fuel tank 12 Supply pipe side tank to sedimentor 13 Sedimentor if fitted side tank 14 Supply pipe sedimentor to fuel tank change over tap 15 Change over tap side...

Page 90: ...ange over tap spill return 11 Supply pipe side tank to sedimentor 12 Fuel filler pipe 13 Breather pipe 14 Sedimentor if fitted side tank 15 Supply pipe sedimentor to fuel tank change over tap 16 Chang...

Page 91: ...uel supply rear tank 4 To fuel lift pump 5 Change over tap spill return 6 Spill return side tank 7 Spill return rear tank 8 Spill return injection pump to change over tap 9 Control rod operating lever...

Page 92: ...TEM COMPONENT LOCATION 1 Fuel filter bleed screw 2 Fuel filter 3 Turbocharger 4 Actuator 5 Air cleaner 6 Fuel injector 7 Heater plug 8 Heater plug controller 9 Coolant temperature transmitter 10 Fuel...

Page 93: ...Vacuum spill pipe modulator to air cleaner hose 4 Vacuum pipe brake servo hose to modulator valve 5 T piece connector 6 Vacuum pipe vacuum pump to brake servo 7 EGR valve 8 Vacuum pipe modulator valve...

Page 94: ...response to throttle variations injection timing varying with engine speed Any excess fuel delivered to the injection pump is passed back to the tank via the spill return line Fuel is injected in a fi...

Page 95: ...ry Engine speed is measured by monitoring the waveform present on one phase of the generator Throttle position is measured via a sensor mounted on the fuel injection pump throttle lever Closed loop co...

Page 96: ...f engine and disconnect throttle position sensor multi plug 3 Connect an Ohmmeter across pins 1 and 3 of multi plug Ohmmeter should read between 1K and 1 05K ohms 4 Connect Ohmmeter across pins 1 and...

Page 97: ...ne speed or anti clockwise to decrease the speed Run engine at an increased speed for a few seconds then check idle speed again 6 When correct speed has been achieved hold adjuster screw steady while...

Page 98: ...aft clockwise until centre pin engages timing slot in flywheel 4 Remove injection pump access plate complete with gasket from front cover plate 5 Fit locking pin LRT 12 045 2 to injection pump gear If...

Page 99: ...y between 2 500 and 3 000 rev min Under these circumstances boost pressure should read 0 95 1 09 Kgf cm2 13 5 15 5 lb in2 PRIMING THE FUEL SYSTEM Service repair no 19 50 01 NOTE If the fuel system has...

Page 100: ...owing 1 Slacken fuel inlet pipe banjo bolt at injection pump 2 Operate hand priming lever on fuel lift pump until fuel free from air emerges from injection pump 3 Tighten banjo bolt whilst fuel is sti...

Page 101: ...remove the undertray and or integral access panels See CHASSIS AND BODY Repair Front undertray or See CHASSIS AND BODY Repair Rear undertray 5 Carefully rotate crankshaft clockwise until centre pin en...

Page 102: ...hrottle position sensor multi plug if fitted 26 Connect throttle cable and where applicable hand throttle cable 27 Remove pump gear retaining tool LRT 12 045 28 Carefully turn the pump hub nut in a cl...

Page 103: ...ss of dirt and foriegn matter 5 Remove retaining nut and release each injector clamp plate from cylinder head 6 Remove injector and discard copper washer Refit 7 Ensure injectors and seating in cylind...

Page 104: ...ecure with bolts Tighten to 25 Nm 18 lbf ft 8 Connect inlet and outlet pipes using new nuts and olives 9 Refit injector pipes Tighten union nuts to 28 Nm 21 lbf ft FUEL SEDIMENTOR Service repair no 19...

Page 105: ...banjo bolts and detach fuel pipes 7 Remove filter assembly from vehicle Unscrew filter element if necessary 8 Plug fuel pipe ends to prevent ingress of dirt Refit 9 Position filter assembly and fit fu...

Page 106: ...connect battery 2 Remove fuel filler cap 3 Remove fuel tank drain plug allow fuel to drain into a clean container and refit plug 4 Remove RH seat cushion 5 Release retaining catch and remove seat base...

Page 107: ...1 NOTE This fuel tank is used on 110 130 5 door vehicles fitted with a twin tank option WARNING Before any attempt is made to start the removal procedure it is vital that the FUEL HANDLING PRECAUTIONS...

Page 108: ...into a clean container and refit plug 4 Slacken retaining clips and disconnect fuel filler hose from rear tank 5 Disconnect breather hose from filler tube 6 Disconnect electrical plug and fuel supply...

Page 109: ...ge tank unit rear fuel tank 110 130 Refit 16 If applicable locate stone guard under tank 17 Raise rear tank into position and connect spill return pipe to the elbow with the nut and olive 18 Continue...

Page 110: ...lease fuel tap from chassis mounted support bracket 12 Remove fuel tap complete with operating rod and lever 13 Plug all connections to prevent ingress of dirt 14 Dismantle spill return and fuel tap c...

Page 111: ...g Refit 7 Clean heater plug and seating 8 Coat threads of heater plug with suitable anti seize compound operational to a temperature of 1000 C 9 Fit heater plug tighten to 23 Nm 17 lbf ft 10 Connect w...

Page 112: ...Slacken hose clip and detach outlet hose 2 Release clips and open air cleaner retaining straps 3 Lift up air cleaner slacken hose clip and detach inlet hose 4 Remove air cleaner Refit 5 Position air c...

Page 113: ...ction pump throttle lever Use new split pin to secure clevis 13 Adjust throttle cable See Adjustment Throttle cable THROTTLE PEDAL Service repair no 19 20 01 Remove 1 Remove throttle cable from pedal...

Page 114: ...tery TURBOCHARGER OIL FEED PIPE Service repair no 19 42 14 Remove 1 Disconnect battery 2 Remove exhaust front pipe See MANIFOLD AND EXHAUST SYSTEM Repair Exhaust front pipe 3 Remove banjo bolt securin...

Page 115: ...ve drain pipe and discard gasket 6 Plug connections to prevent ingress of dirt Refit 7 Ensure mating surfaces of oil pipe turbocharger and engine block are clean 8 Using new gasket fit oil drain pipe...

Page 116: ...disconnect bottom hose from intercooler 8 Manoeuvre intercooler upwards and remove from vehicle 9 Check condition of foam pads fitted to top and bottom of intercooler and renew if necessary 10 Check c...

Page 117: ...tube and exhaust manifold Tighten bolts to 25 Nm 18 lbf ft 8 Fit vacuum pipe and multi plug to EGR valve EGR VALVE MODULATOR Service repair no 17 45 04 Remove 1 Disconnect multi plug from modulator 2...

Page 118: ...justment EGR throttle sensor EGR CONTROL UNIT Service repair no 17 45 07 Remove 1 Raise centre seat or cubby box See CHASSIS AND BODY Repair Cubby box to gain access to EGR control unit harness 2 Disc...

Page 119: ...n integral part of the radiator Pre formed pipes hoses are used to link the components within the separate systems as shown below Engine cooling system 1 Radiator 2 Thermostat housing 3 Radiator botto...

Page 120: ...ncorporating a viscous coupling is driven by an independent pulley secured to the front cover plate The thermostat housing bolted to the front of the cylinder head is fitted with a vent valve that pur...

Page 121: ...re is reached the thermostat opens closing off the by pass hose 9 Coolant is then circulated via the top hose 6 and through the radiator where it is cooled and drawn from the radiator bottom hose 3 by...

Page 122: ...sm bi metal coil 7 Fluid seal 8 Bearing input member 9 Fluid chamber 10 Fluid reservoir When this clearance is filled with viscous fluid a shearing action caused by the speed differential between the...

Page 123: ...ousing plug to assist drainage 5 Similarly when coolant is below top of radiator remove radiator plug 6 Fit radiator bottom hose and fully tighten hose clip Refill CAUTION It is important that the cor...

Page 124: ...ub adaptor thread 3 Remove viscous coupling and fan from vehicle NOTE If air conditioning is fitted the fan cowl will also need removing See Fan cowl with the viscous fan unit 4 If required remove 4 s...

Page 125: ...and viscous fan unit together to enable clearance of the compressor Refit 9 Position fan cowl 10 Fit viscous fan unit See Viscous coupling and fan 11 Fit expansion tank hose into fan cowl clips 12 Se...

Page 126: ...move power steering pump pulley 12 Remove 8 bolts securing water pump noting location of 3 through bolts into cylinder block 13 Withdraw pump and gasket from auxiliary mounting bracket 14 Clean all ga...

Page 127: ...et above water pump 15 Disconnect bottom hose heater return hose at water pump and heater rail 16 Disconnect by pass hose from water pump and thermostat housing 17 Remove 5 bolts one with nut and sing...

Page 128: ...ant level is below thermostat housing 2 Disconnect top hose from outlet elbow 3 Disconnect electrical connections to water temperature switch 4 Unscrew 2 bolts and remove outlet elbow 5 Withdraw therm...

Page 129: ...oler assembly from vehicle 10 Remove 2 bolts from both sides and detach radiator top cover from side covers 11 Lift and remove radiator from intercooler and RH side frame 12 Check condition of locatin...

Page 130: ...clips and disconnect both hoses from base of expansion tank 3 Remove 3 bolts securing expansion tank to inside wing and mounting bracket 4 Remove expansion tank Refit 5 Fit expansion tank to inside wi...

Page 131: ...to ensure leak proof jointing between the various sections which are supported by flexible rubber mountings Catalytic convertor When fitted the catalytic converter is integral with the front pipe ass...

Page 132: ...d by the engine react with the catalytic element and exhaust temperature to convert the toxic gas into Nitrogen N2 Carbon dioxide CO2 and water vapour Exhaust system 110 130 1 Gasket 2 Front pipe 3 Fr...

Page 133: ...Nm 18 lbf ft 12 Fit manifold heat shield 13 Fit hose intercooler to induction manifold 14 Fit rocker cover insulation 15 Reconnect battery INDUCTION EXHAUST MANIFOLD GASKET Service repair no 30 15 15...

Page 134: ...turbocharger inlet hose 3 Disconnect boost pressure pipe at turbocharger 4 Remove intercooler bottom hose 5 Place suitable container under engine and disconnect turbocharger oil feed and return pipes...

Page 135: ...dertray or See CHASSIS AND BODY Repair Rear undertray 6 Remove flange nuts securing front pipe to intermediate silencer assembly and separate flanges 7 Release front pipe at manifold and remove gasket...

Page 136: ...e intermediate pipe to front pipe Tighten nuts to 30 Nm 22 lbf ft 10 Secure intermediate pipe to tail pipe Tighten nuts to 30 Nm 22 lbf ft 11 Lower vehicle INTERMEDIATE PIPE 110 130 Service repair no...

Page 137: ...intermediate pipe Tighten nuts to 30 Nm 22 lbf ft 8 Lower vehicle TAILPIPE 110 130 Service repair no 30 10 22 Remove 1 Raise vehicle on ramp 2 Remove 2 flange nuts securing tail pipe to intermediate...

Page 138: ...ing Clutch components 1 Crankshaft and flywheel 2 Friction plate 3 Clutch cover 4 Diaphragm spring 5 Pressure plate 6 Fulcrum posts 9 for diaphragm spring 7 Bearing rings 2 for diaphragm spring 8 Retr...

Page 139: ...gm spring 4 pivots on the bearing rings 7 and fulcrum posts 6 causing the pressure plate 5 to release the clamping force on the friction plate and linings 2 As the the clamping force is removed from t...

Page 140: ...immediately engaged without making a grinding noise This indicates the clutch is not making a clean break However if the clutch pedal is held depressed for several seconds the friction plate will eve...

Page 141: ...ect worn release bearing Knocking rattling from clutch or gearbox in neutral which is reduced or disappears when the clutch is depressed Suspect worn weak release lever retainer or clutch unit Noise f...

Page 142: ...140 mm 5 50 in without floor mat 4 Adjust pedal stop as necessary to obtain correct setting 5 Adjust master cylinder push rod to obtain approximately 1 5 mm 1 16 in free play between push rod and mas...

Page 143: ...0 to support clutch driven plate locate pressure plate on flywheel dowels If fitting original pressure plate align assembly marks 7 Secure pressure plate cover fixings evenly working in a diagonal seq...

Page 144: ...les aside and lift out pedal bracket complete with master cylinder turn through 90 to ensure pedal clears aperture in bulkhead 8 Remove 6 screws and detach pedal box top cover and gasket 9 Remove nut...

Page 145: ...shes 6 Examine components for wear and damage renew as necessary NOTE If new pedal pivot bushes are required they must be reamed to 16 mm 0 625 in Refit 7 If removed fit trunnion bush and trunnion to...

Page 146: ...retainer staple 12 Fit clutch slave cylinder See Slave cylinder 13 Fit gearbox See MANUAL GEARBOX Repair R380 Gearbox SLAVE CYLINDER Service repair no 33 35 01 NOTE All hose and pipe connections and...

Page 147: ...ainer 8 Withdraw spring and retainer 9 Withdraw valve spacer and spring washer from valve stem 10 Remove valve seal Inspection 11 Clean all components in new hydraulic fluid and allow to dry 12 Examin...

Page 148: ...h master cylinder to vehicle See Repair Master cylinder SLAVE CYLINDER OVERHAUL Service repair no 33 35 07 Dismantle 1 Remove slave cylinder See Repair Slave cylinder 2 Withdraw dust cover 3 Expel pis...

Page 149: ...c fluid 12 Fit seal into piston groove with lip of seal towards fluid inlet end of cylinder 13 Locate spring over front end of piston 14 Fit assembly spring first into cylinder ensuring seal lip does...

Page 150: ...e has a single rail selector and spool type interlock The main and transfer gearboxes ventilate through nylon pipes which terminate high up in the engine compartment to prevent water entry when the ve...

Page 151: ...ving 1 Check lubricant specification and level if low do not top up at this stage 2 In situ lubricate gear mechanism and check selector adjustments See Adjustment Gear change lever bias spring adjust...

Page 152: ...x in one or more gears when being driven 1 Check lubricant specification and level if low do not top up at this stage 2 Drain lubricant and check for contamination or metal particles Suspect worn roll...

Page 153: ...f gear lever cross pin 9 Apply a slight load to gear lever in a LH direction and adjust RH screw downward until RH spring leg just makes contact with cross pin 10 Repeat procedure for LH adjustment sc...

Page 154: ...setting remove lever and gaiter from lower lever 5 Remove insulation pad from tunnel aperture 6 Remove tunnel carpet 7 Remove retaining screws and release fuse box cover 8 Remove 2 screws and release...

Page 155: ...Tighten stop screw locknut 16 Check that all other gears are selectable 17 Remove gear lever 18 Manouvre tunnel cover into position and secure with 16 screws 19 Fit fuse box and cover 20 Fit tunnel c...

Page 156: ...ents When under chassis remove and refit procedures are required it may be necessary to remove the undertray See CHASSIS AND BODY Repair Front undertray or See CHASSIS AND BODY Repair Rear undertray 1...

Page 157: ...ntake hose at induction manifold If EGR system is fitted slacken 2 retaining clips and disconnect intake hose at intercooler 16 Slacken retaining clip and disconnect hose at turbocharger 17 Remove bol...

Page 158: ...Intermediate pipe 90 or See MANIFOLD AND EXHAUST SYSTEM Repair Intermediate pipe 110 130 29 Temporarily support transmission 30 Remove nut securing gearbox LH mounting rubber to chassis crossmember 31...

Page 159: ...07 to a suitable hydraulic hoist 42 Raise hoist and secure to gearbox with 3 bolts in location provided 43 Lower hoist sufficiently to allow transfer lever to clear transmission tunnel aperture 44 Dis...

Page 160: ...ever to high low shaft position washer fit bolt and new Nyloc nut Tighten to 2 Nm 1 5 lbf ft 65 Position breather pipes secure pipe unions using new sealing washers Tighten unions to 15 Nm 11 lbf ft F...

Page 161: ...t 89 Fit front propeller shaft to transfer box Tighten nuts to 47 Nm 33 lbf ft 90 Refill main gearbox and transfer box See SECTION 10 Maintenance Under vehicle maintenance 91 Feed transmission brake c...

Page 162: ...d to the correct torque Nm Slave cylinder to bell housing 25 Breather 15 Bell housing to cylinder block 40 High low level to shaft 2 Transfer box to gearbox 45 NOTE Torque values below apply to all sc...

Page 163: ...ate gears pass the drive to high and low speed gears on the rear output shaft The rear output shaft passes through the speedo drive housing which also forms the mounting for the transmission brake A w...

Page 164: ...FAULT DIAGNOSIS TRANSFER GEARBOX OIL SEAL LOCATIONS 1 Input seal 2 Cover plate joints 3 Front output seal 4 Front and rear housing joint faces 5 Rear output seal 6 Power take off cover plate joint 7 B...

Page 165: ...t to both joint faces 4 Apply thread sealant to bolts which come into contact with gearbox oil 5 Refit cover plate CAUTION Care must be taken not to overtighten fixings Leak between main and transfer...

Page 166: ...dertray See CHASSIS AND BODY Repair Front undertray or See CHASSIS AND BODY Repair Rear undertray 1 Position vehicle on a ramp 2 Select LOW range gear and leave vehicle in neutral 3 Disconnect battery...

Page 167: ...17 Remove intermediate silencer See MANIFOLD AND EXHAUST SYSTEM Repair Intermediate pipe 90 or See MANIFOLD AND EXHAUST SYSTEM Repair Intermediate pipe 110 130 18 Mark rear propeller shaft drive flan...

Page 168: ...e nut securing transfer box RH mounting rubber to chassis crossmember 29 Remove 4 nuts and bolts securing chassis crossmember to chassis longitudinal 30 With assistance and using a body jack between c...

Page 169: ...ounting brackets to gearbox and tighten fixings to 55 Nm 41 lbf ft 49 With assistance and using a body jack between chassis longitudinals jack chassis sufficiently to enable fitment of crossmember 50...

Page 170: ...ating rod 67 Fit breather pipe banjo union to high low cross shaft housing 68 Fit cntre access panel to seat base If fitted secure EGR and alarm system diagnostic connector mounting bracket to front o...

Page 171: ...sing 25 Finger housing to front output housing 25 Bearing housing to transfer case 25 Brake drum to coupling flange 25 Bearing housing cover to transfer gearbox 45 Rear output speedometer housing to t...

Page 172: ...accommodate the variation in distance between the axles and transmission The splines are pre packed with lubricant and protected by a rubber gaiter A grease nipple is also fitted for servicing requir...

Page 173: ...are correctly aligned NOTE In the event that both shafts are satisfactory but the vibration harshness is still present the transfer box operation and balance of the road wheels should be checked For t...

Page 174: ...D BODY Repair Front undertray or See CHASSIS AND BODY Repair Rear undertray Service repair no 47 15 11 12 Overhaul 4 Thoroughly examine universal joint for signs of damage or wear Replace if necessary...

Page 175: ...up 16 Insert opposite bearing cup into flange yoke 17 Press both cups into place 18 Press each cup into its respective yoke up to lower land of circlip grooves Damage may be caused to cups and seals i...

Page 176: ...oil and the hub bearings with grease The hub bearings are fitted with inner and outer seals The outer seals prevent the differential oil mixing with the hub grease and the inner seals prevent dirt in...

Page 177: ...110 130 1 Axle casing 2 Ventilation pipe 3 Axle shaft 4 Wheel studs and hub 5 Wheel bearing stub axle 6 Wheel bearings 7 Inner hub seal 8 Outer hub axle shaft seal 9 Hub lock plate thrust washer and...

Page 178: ...on system as a blockage can cause internal pressure to force oil past the seals See Description and Operation for illustrations of oil seal locations When investigating hub seal leaks check the grease...

Page 179: ...xible brake hose at RH chassis side member and breather hose at banjo connection on axle casing 7 Disconnect lower links at axle 8 Mark differential and propeller shaft flanges with identification mar...

Page 180: ...th fixing bolts 19 Secure pivot bracket ball joint to axle bracket Tighten fixing to 176 Nm 130 lbf ft 20 Align propeller shaft to differential drive flange and tighten fixings to 47 Nm 35 lbf ft 21 R...

Page 181: ...e 5 bolts and withdraw axle shaft 4 Remove joint washer 5 Bend back lock washer tabs 6 Remove locknut and lock washer 7 Remove hub adjusting nut 8 Remove spacing washer 9 Remove hub and brake disc ass...

Page 182: ...Fit locknut Tighten to 50 Nm 37 lbf ft 16 Tab over lock washer to secure adjusting nut and locknut 17 Using a new joint washer fit axle shaft to hub Tighten bolts to 65 Nm 48 lbf ft 18 Fit brake calip...

Page 183: ...emove circlip from driveshaft 5 Remove 5 bolts and withdraw driving member and joint washer 6 Bend back lock washer tabs 7 Remove locknut and lock washer 8 Remove hub adjusting nut 9 Remove spacing wa...

Page 184: ...17 Tab over lock washer to secure adjusting nut and locknut 18 Fit a new joint washer to driving member and fit member to hub Tighten bolts to 65 Nm 48 lbf ft 19 Fit circlip and dust cap 20 Fit brake...

Page 185: ...ntial unit NOTE The differential unit can only be serviced as a complete assembly with matching drive pinion For advice ring Land Rover Service Department Refit 7 Ensure mating faces are clean and app...

Page 186: ...ct refitting 8 Remove fixings and withdraw differential bearing caps 9 Clean out and examine spreader tool pegholes provided in gear casing face ensure that holes are free from dirt and burrs and dama...

Page 187: ...quarely on differential machined surface and end bars butt against edges of casing 17 Tighten adjusting nuts by hand only until all slack is taken up 18 Continue to tighten both nuts alternately with...

Page 188: ...sing LTR 51 003 to prevent coupling flange from rotating remove flange locknut and plain washer 30 Support drive pinion and remove coupling flange by tapping with a hide hammer 31 Withdraw drive pinio...

Page 189: ...ed as a pair 44 Examine differential case to crown wheel joint face for burrs and damage which could lead to crown wheel run out when fitted ASSEMBLE Differential 45 Fit differential lower wheel and t...

Page 190: ...icator reading 61 Add 0 127 mm for bearing pre load to total noted in preceding instruction The sum is then equal to nominal value of shims required for differential bearings Shims are available in ra...

Page 191: ...d face adjacent to serial number are of no significance during servicing 78 The figure marked on end face opposite to serial number indicates in thousandths of an inch deviation from nominal required...

Page 192: ...ind pinion inner bearing track Example 2 Reading obtained LH side 0 1524mm Reading obtained RH side 0 2032mm Add 0 1524mm 0 2032mm 0 0508mm Divide by 2 0 0508 divided by 2 0 0254mm Therefore add 0 025...

Page 193: ...it a new collapsable bearing spacer flared end outward to drive pinion and refit outer bearing 91 Fit pinion oil slinger 92 Fit oil seal gasket 93 Fit pinion oil seal lipped side first using general p...

Page 194: ...le spreader LRT 51 503 with pegs 18G131F 105 Remove axle spreader 106 Fit bearing caps in their correct position referring to relationship markings on caps and on axle casing 107 Tighten bearing caps...

Page 195: ...sc WARNING A maximum of two road wheel retaining studs can be renewed Should more studs be unserviceable fit new hub with studs 5 Remove grease seal and inner bearing from hub 6 Remove inner and outer...

Page 196: ...fit a new seal flush with rear face of hub Using service tool LRT 54 003 LST137 seal replacer and drift Apply grease between seal lips 10 Assemble brake disc to hub line up reassembly marks Applying...

Page 197: ...Remove 6 bolts from stub axle to axle casing 3 Remove mudshield 4 Remove stub axle and joint washer Renew rear stub axle oil seal 5 Remove and discard oil seal Lubricate seal and lip with EP90 oil Usi...

Page 198: ...c if original hub is to be refitted 4 Remove 5 bolts and separate hub from brake disc 5 Drift out grease seal and inner bearing from hub and discard seal HUB COMPONENTS 1 Dust cap 2 Drive shaft circli...

Page 199: ...ith lip side leading fit new seal to hub using special tool LRT 54 003 LST 137 seal replacer and drift 18G 134 Drive in seal flush with rear face of hub Apply grease between seal lips 10 Fit brake dis...

Page 200: ...e to axle casing 3 Remove mudshield 4 Remove stub axle and joint washer 5 Remove rear axle shaft from axle casing Renew rear stub axle oil seal 6 Remove and discard oil seal Lubricate seal and lip EP9...

Page 201: ...uracy to ensure that all fixings are tightened to the correct torque Nm REAR AXLE Pinion housing to axle case 41 Crown wheel to differential case 58 Differential bearing cap to pinion housing 90 Diffe...

Page 202: ...ll axles are supported by two taper bearings and driven by drive flanges which are splined to the one piece stub shaft constant velocity joint Front axle hub and swivel housing 1 Axle casing 2 Ventila...

Page 203: ...bearings are lubricated with grease and the swivel housing and differential with oil On later vehicles identified by having only a filler plug in the swivel housing grease is used to lubricate the ho...

Page 204: ...investigating leaks or checking oil levels it is essential that all the lubrication is drained from any housing with a high level and that the other levels are checked Swivel oil should be checked fo...

Page 205: ...uts and bolts tie propeller shaft to one side 14 Release axle ventilation pipe banjo and lower axle assembly Remove road springs 15 Disconnect anti roll bar link See FRONT SUSPENSION Repair Anti roll...

Page 206: ...m driveshaft 5 Remove 5 bolts and withdraw driving member and joint washer 6 Bend back lock washer tabs 7 Remove locknut and lock washer 8 Remove hub adjusting nut 9 Remove spacing washer 10 Remove hu...

Page 207: ...mount a dial gauge using bracket LRT 99 503 and rest pin in a loaded condition on end of drive shaft 21 Fit a suitable bolt to threaded end of drive shaft Move drive shaft in and out noting dial gauge...

Page 208: ...s to be refitted 4 Remove 5 bolts and separate hub from brake disc 5 Drift out grease seal and inner bearing from hub and discard seal 6 Drift out inner and outer bearing tracks 7 Clean hub and drift...

Page 209: ...vel and drain plugs being deleted 3 Remove 6 bolts retaining stub axle to swivel housing 4 Remove mud shield 5 Remove stub axle and joint washer 6 Wthdraw axle shaft and constant velocity joint from a...

Page 210: ...let drive joint in fully Renew stub axle thrust ring oil seal and bearing 16 Drill and chisel off thrust ring taking care to avoid damaging stub axle 17 Remove bearing and oil seal using special tool...

Page 211: ...ousing to axle case 31 Remove inner oil seal from back of housing 32 Remove top bearing track from swivel bearing housing NOTE Use lower bearing opening to gain access to upper bearing track 33 If wor...

Page 212: ...ate with 7 bolts and spring washers Tighten to 11 Nm 8 lbf ft 51 Fit tie rod and drag link and secure with new cotter pins Tighten fixing to 40 Nm 30 lbf ft 52 Fit brake disc shield 53 Loosely fit loc...

Page 213: ...swivel pin housing 78 Lower swivel pin to swivel pin housing 78 Oil seal retainer to swivel pin housing 11 Swivel bearing housing to axle case 73 Pinion housing to axle case 41 Crown wheel to differen...

Page 214: ...the steering caused by road wheel deflections when operating on rough terrain Power steering system The power steering system comprises a hydraulic pump which is belt driven from the engine and suppl...

Page 215: ...ntralizing worm valve 7 Ball race 8 Teflon seals for valve sleeve 9 Bearing adjuster locknut and seal 10 Worm shaft pressure seal circlip and dirt excluder 11 Teflon and rubber seal for piston 12 End...

Page 216: ...olumn and incorporates valve ports in its outer diameter to align with those in the sleeve The torsion bar which is secured to the worm and input shaft with pins 6 at each end holds the valve ports in...

Page 217: ...o high pump speed will circulate through the regulator valve located in the pump unit causing the temperature of the fluid and the pump to rise rapidly CAUTION To avoid excessive fluid temperatures wh...

Page 218: ...during manufacture and determines the opening pressure of pressure relief valve 3 No flow through box High pressure When the steering is turned the rotary valve effectively stops all fluid flow throug...

Page 219: ...Correct idle speed See ENGINE TUNING DATA Information 300 Tdi Engine 8 Is problem resolved YES end NO go to 9 9 Bypass steering box using adaptor tap LRT 57 001 10 Is correct pressure obtained YES de...

Page 220: ...nections for leaks All leaks must be rectified before attempting to test the system 5 Check steering pump drive belt tension and renew belt if necessary See ELECTRICAL Repair Auxiliary drive Belt 6 As...

Page 221: ...n a vice using soft jaws Compress and extend the unit by hand Resistance should be equal in both directions 3 If it is felt that the unit is outside acceptable limits fit a new steering damper STEERIN...

Page 222: ...wer Steering Pump YES See Overhaul Power Steering Box Symptom Steering heavy stiff poor castor return action 1 Are tyres correct type and pressure NO See INTRODUCTION Information Wheels and Tyres YES...

Page 223: ...TYRES Repair Wheel Balancing 2 Check the steering hydraulic damper function See Steering Damper 3 Check steering column universal joints for wear and correct alignment See Repair Lower Steering Shaft...

Page 224: ...oblem resolved YES end NO continue 4 Is problem stiff steering YES See Stiff Steering Checklist NO Go to 6 5 Is problem resolved YES end NO go to 8 6 Is problem steering niggle YES Replace radius arm...

Page 225: ...ment Centralise Steering Box 5 Is problem resolved YES end NO contact local technical office 3 VEER UNDER BRAKING From 1 GENERAL STEERING 1 Vehicle veers under braking bleed brake system 2 Is problem...

Page 226: ...ER STEERING FLUID LEAKS 1 Is fluid level correct YES go to 3 NO Refill or drain to correct level Bleed system check for leaks See Repair Power Steering System Bleed 2 Is problem resolved YES end NO co...

Page 227: ...bleed PAS system See Repair Power Steering System Bleed NO go to 13 11 Does moan remain YES do figure 8 manoeuvres NO end 12 Does moan remain YES continue NO end 13 Is noise an intermittent grunt YES...

Page 228: ...oblem 2 Steering load assessment drive at 16 km h 10 mph Put 90 turn input into steering wheel check self centering The self centering should be equal on each lock but not necessarily return to exactl...

Page 229: ...y 3 Near end of operation 2 ensure vehicle is driven in a straight line on level ground and halted 4 Tighten panhard rod mounting arm nut to110 Nm 81 lbf ft 5 Tighten the 2 fixings tie bar to steering...

Page 230: ...pecifications torque Torque Values 7 Oil leaks check front and rear axle hubs for leak and repair as necessary 8 Brake system check brake system for leaks pipe condition pad wear contamination disc we...

Page 231: ...sh If backlash exists loosen locknut and repeat adjustment procedure 9 Turn steering wheel lock to lock and check no tightness exists 10 Ensure front wheels are aligned and in straight ahead position...

Page 232: ...ck stop adjustment may be carried out using following procedure Check 1 Measure stop bolt protrusion A Refer to table for correct setting Adjust 2 Loosen stop bolt locknut 3 Turn stop bolt as required...

Page 233: ...t horizontal centre line of wheels 6 Check tightness of clamp bolt fixings Tighten to 14 Nm 10lbf ft Adjust 7 Slacken clamps at both ends of track rod 8 Rotate track rod to increase or decrease its ef...

Page 234: ...l joint Slacken top bolt of lower universal joint and withdraw shaft 5 Prise centre cap from steering wheel 6 Remove steering wheel retaining nut and withdraw wheel from column spline 7 Disconnect bat...

Page 235: ...shear bolts securing switch to column 17 Remove switch and collect 2 plain washers between switch and clamp 18 Remove brake pedal box See BRAKES Repair Brake pedal 19 Remove bolt securing tie bar to...

Page 236: ...pplicable See ELECTRICAL Repair Vehicle immobilisation and alarm system 38 Fit switch assembly on steering column and tighten clamping screw 39 Connect switch assembly multi plugs and electrical leads...

Page 237: ...icle on a hoist 3 Remove road wheel 4 Remove panhard rod See FRONT SUSPENSION Repair Panhard rod 5 Disconnect steering damper from drag link 6 Disconnect drag link from drop arm see J6305 on opposite...

Page 238: ...leed 28 Recheck fluid level and replace cap 29 With engine running test steering system for leaks by holding steering in both full lock directions CAUTION Do not maintain this pressure for more than 3...

Page 239: ...nds in any one minute to avoid overheating fluid and possibly damaging seals 8 Carry out road test POWER STEERING FLUID RESERVOIR Service repair no 57 15 08 Remove 1 Position drain tin beneath reservo...

Page 240: ...ingress of dirt 10 Remove 4 bolts securing steering pump bracket to engine auxiliary mounting bracket 11 Remove pump and bracket assembly 12 Remove 3 bolts and detach mounting bracket from pump Refit...

Page 241: ...t ahead position line up assembly marks 11 Position shaft assembly onto steering column Move assembly up spline to enable lower universal joint to fit onto steering box splines 12 Align bolt holes wit...

Page 242: ...ing lock starter switch to column 8 Remove steering lock and collect 2 washers between lock and clamp Refit 9 Fit steering lock switch in position and line up with switch plunger 10 Secure lock to col...

Page 243: ...screws 7 Ensure switch gaiters grommets are correctly located and nacelle is aligned with switch assembly brackets 8 Fully tighten screws 9 Fit steering wheel See Steering wheel 10 Reconnect battery D...

Page 244: ...Adjustment Centralise steering box 11 Align reassembly marks and fit drop arm onto steering box splines 12 Fit new tab washer and retaining nut Tighten to 176 Nm 130 lbf ft and bend over tab washer 1...

Page 245: ...olt securing steering damper to drag link bracket 4 Remove retaining nuts washers and rubber bush securing damper to chassis mounting 5 Withdraw damper 6 Check rubber bushes and washers renew if neces...

Page 246: ...k rod ball joints using LRT 57 018 7 Remove track rod 8 Slacken clamp bolts 9 Unscrew ball joints Refit 10 Fit new ball joints to track rod and loosely tighten clamp bolts 11 Screw in ball joints to f...

Page 247: ...ag link bracket 6 Remove split pin and castellated nut securing drag link ball joints to swivel housing arms 7 Disconnect drag link ball joints using LRT 57 018 8 Remove drag link 9 Slacken clamp bolt...

Page 248: ...tained between lock stops See Adjustment Steering lock stops Adjust drag link length to suit 19 Tap ball joints in direction shown so both pins are in same angular plane 20 Tighten clamp bolts to 14 N...

Page 249: ...s and bleed screw Hold steering box over suitable container turn input shaft from lock to lock until oil is drained Refit bleed screw 3 Rotate retainer ring until one end is 12 mm from extractor hole...

Page 250: ...cage cup and shim washers Retain shims for reassembly NOTE Should difficulty be experienced warm casing and bearing assembly Cool bearing cup using a mandrel and tap steering box on a bench Steering b...

Page 251: ...ft Sector shaft assembly 26 Check there is no side play on roller 27 If side play on roller exists fit a new sector shaft 28 Check condition of adjuster screw threads Check adjuster end float Fit new...

Page 252: ...es 37 If required replace all three rings using ring expander LRT 57 019 The expander will not pass over rings already fitted Remove rings to allow access without damaging seal grooves 38 Warm rings a...

Page 253: ...seal and fit to piston 51 Slide piston assembly into cylinder with rack tube outwards Reassemble NOTE When fitting replacement oil seals lubricate with recommended fluid and ensure absolute cleanlines...

Page 254: ...rn in worm adjuster to increase reading by 0 21 0 34 Nm with locknut tight 100 Nm 74 lbf ft Use worm adjusting wrench LRT 57 006and locknut wrench LRT 57 028 Fitting rack and piston 68 Screw slave bol...

Page 255: ...move slave bolt fitted at instruction 68 Press cover into cylinder just to clear retainer ring groove 80 Fit retaining ring to groove with one end of ring positioned 12 mm from extractor hole Adjustin...

Page 256: ...tted between valve and worm assembly inner bearing cup and casing The original shim washer value will give correct torque peak position unless major components have been replaced Procedure 88 With inp...

Page 257: ...grease Fit dirt excluder using LRT 57 027 When fitted correctly outer shoulder of excluder is 4 00 4 50 mm from face of box dimension X 95 Remove drop arm Smear inner lip of dirt excluder with PTFE gr...

Page 258: ...rop arm nut 176 Sector shaft cover to steering box 75 Steering box to chassis 81 Steering box fluid pipes 14mm thread 15 Steering box fluid pipes 16mm thread 20 Tie bar 81 PAS pump High pressure fluid...

Page 259: ...oth axle and chassis locations Two rubber bearing bushes with retaining straps secure the rear of the anti roll bar to the chassis mountings while bushed links support the front of the bar to the fron...

Page 260: ...ble bushes Ensure tubing locates on outer edge of bush and not on rubber inner Refit 5 Fit replacement bushes CAUTION Apply pressure to outer edge of bush and not rubber inner 6 Fit panhard rod to axl...

Page 261: ...it road wheel remove chassis stands and jack Tighten wheel nuts to correct torque Alloy wheels 130 Nm 96 lbf ft Steel wheels 100 Nm 80 lbf ft Heavy duty wheels 170 Nm 125 lbf ft FRONT SHOCK ABSORBER S...

Page 262: ...Nm 125 lbf ft FRONT ROAD SPRING Service repair no 60 20 11 Remove 1 Remove front shock absorber See Front shock absorber CAUTION Avoid over stretching brake hoses If necessary loosen hose connector l...

Page 263: ...Remove 1 Mark for reassembly position of rubber bushes on anti roll bar 2 Remove 4 nuts bolts and washers securing both anti roll bar bush straps to chassis mounting brackets 3 Remove nuts bolts wash...

Page 264: ...few turns 3 Release link joint using special tool 18G 1063A as shown 4 Remove castellated nut and link Refit 5 Fit link and castellated nut Ensure ball joint link arm points up Tighten nut to 40 Nm 3...

Page 265: ...tightened to the correct torque Nm Anti roll bar Strap nyloc nuts 30 Ball link self lock nut 68 Castellated nut 40 Drag link to axle 40 Securing ring for mounting turret 14 Radius arm to chassis 176...

Page 266: ...rt both sides of the A frame of the link assembly secured by single retaining bolts A Boge Hydromat self levelling unit can be fitted as an option on 110 130 models to give additional support when the...

Page 267: ...t 14 Secure shock absorber Tighten fixing to 37 Nm 27 lbf ft 15 Fit road wheels remove chassis stands and jack Tighten wheel nuts to correct torque Alloy wheels 130 Nm 96 lbf ft Steel wheels 100 Nm 80...

Page 268: ...ER Service repair no 64 35 44 Remove 1 Support rear of chassis on stands allow axle to hang freely 2 Remove fixings upper link bracket to frame 3 Remove fixings upper links to pivot bracket 4 Remove u...

Page 269: ...nk rear fixings 4 Remove mounting bracket fixings at side member bracket 5 Remove lower link complete 6 Remove locknut 7 Remove mounting bracket from lower link Renew bush 8 Press out rubber bushes 9...

Page 270: ...ckets 3 Remove nuts bolts washers and rubber bushes securing anti roll bar to links 4 Remove anti roll bar Refit 5 Position rubber bushes on anti roll bar Fit joint towards axle 6 Fit anti roll bar wi...

Page 271: ...o 64 30 09 Remove WARNING The levelling unit contains pressurised gas and MUST NOT be dismantled Repair is by replacement of complete unit only 1 Raise and support the vehicle under chassis and use a...

Page 272: ...e with 4 nuts and tighten to 47 Nm 35 lbf ft 13 Fit levelling unit to lower ball joint and secure gaiter 14 Attach webbing strap to chassis cross member 15 Fit upper links to the pivot bracket and ret...

Page 273: ...accuracy to ensure that all fixings are tightened to the correct torque Nm Anti roll bar Strap nyloc nuts 30 Ball link self lock nut 68 Castellated nut 40 Top link to mounting bracket 176 Bottom link...

Page 274: ...ed A cable controlled parking brake operates a single drum brake mounted on the output shaft of the transfer gearbox and is completely independent of the main braking system The basic hydraulic system...

Page 275: ...the other is compensated for by fluid from the separate reservoirs in the supply tank moving through the feed holes in the cylinder Conversely the final return movement of the plunger assemblies cause...

Page 276: ...0 Models Hydraulic system A Primary circuit B Secondary circuit C Pressure reducing valve PRV 1 LH rear brake caliper 2 T connector 3 RH rear brake caliper 4 Brake servo 5 Master cylinder and reservoi...

Page 277: ...not impaired the following warnings must be adhered to DO NOT use any petroleum based cleaning fluids or any proprietary fluids containing petrol DO NOT use brake fluid previously bled from the system...

Page 278: ...ired Clean glass receptacle Bleed hose Wrench Approx 2 litres 3 pints brake fluid See LUBRICANTS FLUIDS AND CAPACITIES Information Recommended lubricants and fluids Master cylinder bleed 1 Disconnect...

Page 279: ...ntainer for disposal 8 The reservoir is a push fit in the master cylinder and secured by seals Carefully ease the reservoir from the master cylinder by rolling it from the seals Note that the two seal...

Page 280: ...LUBRICANTS FLUIDS AND CAPACITIES Information Recommended lubricants and fluids 12 Bleed the brake system See Brake system bleed 13 Reconnect battery and road test vehicle SERVO NON RETURN VALVE Servi...

Page 281: ...at rear of pedal box 5 Remove blanking grommets from each side of pedal box 6 Remove split pin and clevis pin securing servo push rod to brake pedal 7 Remove 4 nuts and plain washers securing servo to...

Page 282: ...ng pin and withdraw pedal pivot shaft 6 Remove brake pedal complete with pivot bushes 7 Examine components for wear or damage renew as necessary 8 If it is necessary to fit new pivot bushes they must...

Page 283: ...0 500 press each piston back into its bore Ensure that displaced brake fluid does not overflow from reservoir Refit 8 Fit brake pads 9 Fit pad retaining pins and anti rattle springs Secure with new sp...

Page 284: ...ch piston back into its bore Ensure that displaced brake fluid does not overflow from reservoir Refit 7 Insert brake pads 8 Fit anti rattle springs and secure with retaining pins 9 Apply service brake...

Page 285: ...IR FRONT BRAKE CALIPER ASSEMBLY Key to caliper 1 Caliper 2 Bleedscrew 3 Anti rattle springs 4 Pad retaining pins 5 Split pin 6 Friction pads 7 Piston 8 Wiper seal retainer 9 Wiper seal 10 Fluid seal 1...

Page 286: ...RNING Do not separate caliper halves 7 Clean outer surfaces of caliper using aerosol brake cleaner 8 Using special tool LRT 70 500 clamp pistons in inboard half of caliper Gently keeping fingers clear...

Page 287: ...Bleed brake system See Brake System Bleed 22 Press brake pedal firmly several times to locate friction pads 23 Fit road wheels remove axle stands Finally tighten road wheel nuts to correct torque Allo...

Page 288: ...0 BRAKES 12 REPAIR REAR BRAKE CALIPER ASSEMBLY Key to rear caliper 1 Caliper 2 Bleed screw 3 Pad retaining springs 4 Brake pads 5 Piston 6 Wiper seal retainer 7 Wiper seal 8 Fluid seal 9 Retaining pin...

Page 289: ...tons from their bores by applying air pressure to fluid inlet port It is unlikely both pistons will expel at same time regulate rate with a suitable piece of wood inserted between two pistons 9 Finall...

Page 290: ...ess brake pedal firmly several times to locate pads 24 Fit road wheels remove axle stands Finally tighten road wheel nuts to correct torque Alloy wheels 130 Nm 96 lbf ft Steel wheels 100 Nm 80 lbf ft...

Page 291: ...ever 6 Hold down spring 7 Dished washer 8 Brake drum 9 Screw 10 Brake cable 11 Adjuster slide 12 Aadjuster nut 13 Spring 14 Adjuster slide 15 Adjuster bolt 16 Dished washer 17 Hold down spring 18 Brak...

Page 292: ...10 Check that springs are satisfactory for continued use If new brake shoes are to be fitted the srings should also be renewed Refit 11 Locate RH brake shoe in slide and secure brake shoe and lever as...

Page 293: ...insert through backplate and connect to cable lever 11 Fit cable to handbrake lever and secure with clevis pin and split pin 12 Fit handbrake gaiter 13 Fit brake drum Tighten screw to 25 Nm 18 lbf ft...

Page 294: ...vacuum pump 6 Detach pump complete with strut and harness bracket Note location of strut and bracket for Refit Refit 7 Clean mating faces of pump and block 8 Loosely assemble pump to block with a new...

Page 295: ...cuum seal 4 Guide ring 5 Retaining ring 6 O ring seal 7 Primary plunger assembly 8 L seal 9 Secondary plunger 10 Washer 11 Recuperating seal primary cup 12 Seal retainer 13 Springs 14 Swirl tube 15 Ma...

Page 296: ...Carefully ease reservoir from master cylinder by rolling it from seals as illustrated 4 Using soft jaws one either side of master cylinder flange and clamp flange in a suitable vice Remove water ingr...

Page 297: ...e as secondary plunger repeat above operation to expel it from bottom of master cylinder bore and discard 12 Clean all parts with Girling cleaning fluid or unused brake fluid and place cleaned parts o...

Page 298: ...rt primary plunger 20 Coat a new O ring with brake fluid and fit to its respective groove on outer location surface of master cylinder CAUTION O ring should not be rolled down outer location surface o...

Page 299: ...size and pressures 1 Type of tyre construction Radial Ply 2 Load index 104 3 Speed symbol S or T 4 USA Tyre quality grading Tread wear 160 Traction A temperature B 5 Tread wear indicators moulded int...

Page 300: ...adjustment Adjust track to correct figure Bent panhard rod Check and replace worn or damaged components Bald spots or tyre Wheel out of balance Balance wheel and tyre cupping assembly Excessive radial...

Page 301: ...OPELLER SHAFTS Fault diagnosis Vibration Harshness NOTE In the event that any apparent vibration is not eliminated at this stage go to steering Fault Diagnosis Fault Symptom Steering vibration road wh...

Page 302: ...n when handling the wheel to avoid scratching or chipping the finish The alloy wheel rim is of the asymmetric hump type incorporating a safety hump to improve location of the tyre bead in its seat If...

Page 303: ...ed at the correct pressures Tyre pressures must be checked at least once a week and preferably daily if the vehicle is used off road The tyre inflation pressure is calculated to give the vehicle satis...

Page 304: ...tyre tread in order to avoid operator injury during dynamic balancing and to obtain the correct balance Inspect tyres for damage and correct tyre pressures and balance according to the equipment manu...

Page 305: ...eel will cause a bouncing action called wheel tramp This condition will eventually cause uneven tyre wear Dynamic balance Wheel shimmy A Heavy spot B Add balance weights here C Centre line of spindle...

Page 306: ...g patch Always follow manufacturer s instructions when using a puncture repair kit Only punctures in tread area are reparable DO NOT attempt to repair punctures in tyre shoulders or sidewalls Do not a...

Page 307: ...ee INTRODUCTION Information Jacking 3 Remove wheel nuts and carefully withdraw wheel over studs Refit 4 Ensure that retaining studs and nuts are clean 5 Alloy wheels Lightly coat wheel mounting spigot...

Page 308: ...emove wheel See Wheels 2 Drive stud out of driveshaft flange Refit 3 Position stud in flange 4 Install a suitable spacer over stud 5 Using a M16 x 1 5 nut a slave wheel nut is suitable pull stud into...

Page 309: ...tudinals is fitted to facilitate main gearbox and tranfer box assembly removal Should chassis damage occur a comprehensive range of components are available including body support outriggers cross mem...

Page 310: ...76 CHASSIS AND BODY 2 DESCRIPTION AND OPERATION LAND ROVER 90...

Page 311: ...37 0 mm 9 252 250 mm 10 110 mm 11 2360mm Wheelbase 12 636 634 mm 13 488 483 mm 14 488 483 mm 15 3431 1 3426 1 mm 16 588 3 586 3 mm 17 2313 8 2311 8 mm 18 590 5 mm 19 295 25 mm 20 519 60 517 00 mm 21...

Page 312: ...76 CHASSIS AND BODY 4 DESCRIPTION AND OPERATION LAND ROVER 110...

Page 313: ...2794 mm Wheelbase 12 488 483 mm 13 488 483 mm 14 82 79 5 mm 15 750 9 mm 16 750 9 mm 17 439 5 436 5 mm 18 439 5 436 5 mm 19 299 5 295 5 mm 20 500 495 mm 21 500 495 mm 22 594 2 593 4 mm 23 594 2 593 4 m...

Page 314: ...76 CHASSIS AND BODY 6 DESCRIPTION AND OPERATION LAND ROVER 130...

Page 315: ...633 0 mm reference only 2 3569 3 3567 3 mm 3 2421 8 2419 8 mm 4 2317 5 2314 5 mm 5 2188 3 2185 3 mm 6 2119 5 2117 3 mm 7 1990 1988 mm 8 1970 1968 mm 9 2401 8 2399 8 mm 10 110 0 mm reference 11 149 7...

Page 316: ...ctly opposite on each side of the chassis frame 3 Hold a plumb line against each of the measuring points in turn and mark the floor directly beneath the plumb bob 4 Move the vehicle and measure diagon...

Page 317: ...CHASSIS AND BODY 1 REPAIR DOORS RH rear door lock mechanism RH front door lock mechanism...

Page 318: ...s remove 2 screws and detach door pull 2 Remove single screw behind remote control lever 3 Prise off remote control lever bezel 4 Prise off door locking button bezel 5 Prise out window regulator handl...

Page 319: ...and secure with 2 screws and finisher caps 12 Fit window regulator handle and retain with single screw and finisher WINDOW REGULATOR REAR SIDE DOOR Service repair no 76 31 45 Remove 1 Remove door tri...

Page 320: ...sing EXTERIOR HANDLE REAR SIDE DOOR Service repair no 76 58 02 Remove 1 Remove door trim casing See Door trim casing 2 Peel back sufficient of plastic sheet to gain access to handle mechanism 3 Discon...

Page 321: ...n assembly to door panel with 2 screws 6 Fit operating rod to button assembly and secure with spring clip 7 Re seal plastic sheet and fit door trim casing See Door trim casing REMOTE CONTROL LEVER REA...

Page 322: ...and fit door trim casing See Door trim casing DOOR LATCH REAR SIDE DOOR Service repair no 76 37 13 Remove 1 Remove door trim casing See Door trim casing 2 Peel back sufficient of plastic sheet to rev...

Page 323: ...rear side door 5 Disconnect and remove door sill locking button See Sill locking button 6 Disconnect control rods from latch and door outer handle mechanism 7 Remove 4 screws retaining mounting panel...

Page 324: ...screw heads are screwed down firmly below bottom of channels to prevent damage to glass 18 Fit door check rod and bend end stop back to closed position 19 Fit check stop torsion bar and secure with 2...

Page 325: ...ch mechanism and from plastic clip in mounting panel 5 Slide window regulator arm from mounting panel channel and remove panel with remote control lever and rod Refit 6 Engage window regulator arm in...

Page 326: ...1 Remove door trim casing See Door trim casing 2 Remove plastic sheet 3 Temporarily fit handle position window half open and support with a length of timber 4 Remove 2 lower screws securing mounting...

Page 327: ...lease control rod from plastic clip in mounting panel 5 Remove 2 screws securing remote control lever to mounting panel and withdraw lever and control rod Refit 6 Feed control rod into position and lo...

Page 328: ...ect operating rod from handle mechanism 4 Disconnect rod from locking barrel lever 5 Remove 2 screws and withdraw handle assembly Refit 6 Fit handle to door ensuring that two bezels are in position fl...

Page 329: ...ng care not to damage runner ease runner away from latch and manoeuvre latch assembly from door Refit 9 Carefully ease window runner away sufficiently to enable latch to be located into position 10 Se...

Page 330: ...avel and support with a suitable length of timber 4 Remove 2 self tapping screws securing window glass runner on latch side of door and single screw from hinge side 5 Taking care not to damage paint p...

Page 331: ...elow bottom of runners to prevent damage to glass 12 Locate regulator in window lift channels 13 Fit mounting panel See Mounting panel front door LOCKING BARREL FRONT DOOR Service repair no 76 37 39 R...

Page 332: ...ct operating rod to lock lever and secure with spring clip reversing instruction 4 12 Fit mounting panel See Mounting panel front door DOOR STRIKER ADJUST Service repair no 76 37 23 front door Service...

Page 333: ...in pivot brackets and secure with 4 bolts and spring washers 6 Fit stowage strap REAR SEAT SQUAB 90 Service repair no 78 10 58 99 Remove 1 Release seat cushion stowage strap and lower seat cushion 2 S...

Page 334: ...of squab to body 4 Remove rear bench seat Refit 5 Position rear bench seat to body 6 Position bracket and spacers and loosely fit bolts securing front end of cushion frame to body 7 Loosely fit bolts...

Page 335: ...and remove bolt securing inertia reel to base of B post 6 Remove seat buckle stalk anchorage bolt at inside rear of front seat Refit NOTE Tighten all seat belt anchorage bolts to 32 Nm 24 lbf ft 7 Fi...

Page 336: ...ap strap and buckle straps to body Tighten bolts to 32 Nm 24 lbf ft 7 If required secure seat cushions and belts in stowed position REAR SEAT BELTS 110 Service repair no 76 73 18 Remove 1 Remove rear...

Page 337: ...bench seat SIDE TRIM PANEL 90 STATION WAGON Service repair no 76 13 70 Remove 1 Remove rear seat squabs See Rear seat squab 2 Remove rear end trim panel See Rear end trim panel 3 Prise cap from front...

Page 338: ...elt guide to B post tighten bolt to 32 Nm 24 lbf ft and fit cap 15 Fit rear end trim panel See Rear end trim panel 16 Fit rear seat squab See Rear seat squab SIDE TRIM PANEL 110 STATION WAGON Service...

Page 339: ...h bolts or screws If individual type seats are fitted do not fully tighten fixings at this stage 18 Fit seat belt clip to C post 19 Fit trim panel cap fastener to C post 20 Fit seat belt to wheel arch...

Page 340: ...ed on base of cubby box 8 Remove cubby box Refit 9 Position cubby box to mounting and if applicable insert radio cassette player leads 10 Secure front of cubby box to floor and fit cup holder 11 Open...

Page 341: ...d trim panel 2 Remove rear grab handles See Rear grab handle 3 Carefully prise out 6 trim studs securing rear end lining to mounting brackets 4 Remove rear end lining Refit 5 Position rear end lining...

Page 342: ...th sides pull side trim panel inwards enough to release rear corners of front headlining 11 Lower headlining and remove from vehicle NOTE Take care not to bend the headlining on removal and refitting...

Page 343: ...rear corners of headlining from cant rail on both sides 8 Lower rear headlining from roof and remove from vehicle NOTE Take care not to bend headlining on removal and refitting Refit 9 With assistanc...

Page 344: ...secure with 2 screws 11 Position grab handle and secure with 2 bolts TAIL DOOR LOCK Service repair no 76 37 16 Remove 1 Remove door casing See Tail door trim casing 2 Remove screws washers and nut ret...

Page 345: ...and retighten screws 3 Close door and check for correct latching with door lock 4 Carry out further adjustment as necessary If full adjustment cannot be achieved carry out following 5 Remove striker...

Page 346: ...lean roof area around outer frame seating 9 Position outer frame on roof 10 Fit inner frame to headlining and secure to outer frame with 18 screws but do not fully tighten 11 Check alignment of inner...

Page 347: ...ting plate from headlining Refit 3 Fit mounting plate to headlining 4 Locate lower lug of mirror arm in mounting plate aperture 5 Press mirror arm firmly to engage spring clip in mounting plate apertu...

Page 348: ...ary 15 Fit grille and tighten securing screws 16 Close bonnet BONNET RELEASE CABLE Service repair no 76 16 29 Remove 1 Open bonnet 2 Remove 8 screws securing grille 3 Remove grille 4 Slacken clamping...

Page 349: ...CHASSIS AND BODY 33 REPAIR 17 Fit cable to lock and tighten clamping bolt 18 Check operation of release cable and bonnet lock and adjust if necessary 19 Fit grille and tighten screws 20 Close bonnet...

Page 350: ...control cable air distribution 6 Remove 2 screws withdraw switch panel from lower fascia and disconnect switch multi plugs 7 Prise out Land Rover decal and remove screw securing grab handle to crash p...

Page 351: ...r from lower fascia panel 20 Remove 2 screws and remove both footwell vents from lower fascia panel 21 Remove single screw and detach door check strap cover from LH and RH doors 22 Remove 3 screws sec...

Page 352: ...ttom edge of fascia panel and secure with 3 screws 35 Repeat operation for LH footwell cover retaining plate 36 Fit remaining lower fascia panel fixing screws 37 Locate parcel shelf Ensure all radio a...

Page 353: ...See INSTRUMENTS Repair instrument panel 58 Fit steering column nacelle See STEERING Repair Steering column nacelle 59 Fit steering wheel See STEERING Repair Steering wheel 60 Reconnect battery FRONT U...

Page 354: ...no 76 11 82 Acoustic pad Remove 1 Raise vehicle on ramp 2 Remove 2 bolts securing sides of undertray to front undertray 3 Remove 2 bolts securing rear undertray to chassis crossmember brackets 4 Remov...

Page 355: ...panel Refit 5 If applicable fit acoustic pad to access panel 6 Fit access panel to front undertray Tighten fixings to 14 Nm 10 lbf ft 7 Lower ramp ACCESS PANEL REAR UNDERTRAY Service repair no 76 11 8...

Page 356: ...ent and attached directly to the fascia bulkhead The heating controls are positioned on the outside of the instrument binnacle and cable linked to mechanical flaps in the distribution unit Heater asse...

Page 357: ...nit The air flap 13 controls the supply of heated or ambient air from the heater unit into a plenum chamber integeral with the vehicle fascia Two flaps in the plenum chamber heater duct distribute the...

Page 358: ...Fresh air vents Two fresh air vents are fitted in the windscreen frame and are controlled independently of the vehicle heating system Each vent is operated separately To open the vents push the lever...

Page 359: ...r motor clear of air inlet duct and remove from engine compartment 12 If existing heater unit is to be refitted remove sealing rubber For heater matrix removal See Heater matrix For blower motor remov...

Page 360: ...es of mounting plate and blower motor 10 Fit blower motor to mounting plate and secure with 3 nuts Ensure rubber mountings are correctly fitted 11 Fit impeller to motor shaft and secure with circlip 1...

Page 361: ...tom retaining plates 11 Fit heater unit See Heater unit RESISTOR UNIT Service repair no 80 20 17 Remove 1 Remove heater unit See Heater unit 2 Drill out 4 rivets securing resistor mounting plate to to...

Page 362: ...rs fitted between cover and control lever assembly and retain 7 Remove small bolt and release outer cable retaining clip 8 Slacken grub screw and release inner cable from clevis 9 From inside engine c...

Page 363: ...to lever clevis and fully tighten clevis grub screw 18 Fit outer cable retaining clip and fully tighten securing bolt 19 Fit side cover to control lever assembly Ensure fixing screw spacers are posit...

Page 364: ...r complete with control lever assembly 7 Remove 2 screws securing control lever assembly to side cover and remove cover Note plastic screw spacers fitted between cover and control lever assembly and r...

Page 365: ...t instrument panel See INSTRUMENTS Repair Instrument panel 24 Fit steering column nacelle See STEERING Repair Steering column nacelle CONTROL CABLE AND BLOWER MOTOR SWITCH Service repair no 80 10 17 C...

Page 366: ...12 Fit new control cable to lever assembly peg 13 Fit retaining clip to secure outer cable 14 Reconnect blower motor leads 15 Route cable to rear of instrument panel cowl along bulkhead and out throug...

Page 367: ...he condenser Ancillary components in the system comprise a blower motor 2 also housed in the heater cooler unit and condenser cooling fan motors 6 mounted on a support frame The four major units are i...

Page 368: ...cross the condenser is induced by vehicle movement and assisted by two electric fans attached to the frame of the condenser The refrigerant high pressure vapour enters the condenser inlet on the RH si...

Page 369: ...ease air temperature or to the left BLUE to reduce air temperature 2 Air conditioning indicator lamp Illuminates when the air conditioning system is operating 3 Air conditioning switch Press the RH po...

Page 370: ...ell Push middle button air to fascia vents also provides some air to the footwell Push RH button air to footwell vents also provides some air to the windscreen 6 Air recirculation switch Press the LH...

Page 371: ...dations given with a Refrigerant Recovery Recycling Recharging Station NOTE Suitable protective clothing comprises Wrap around safety glasses or helmet heatproof gloves rubber apron or waterproof over...

Page 372: ...following quantities of refrigerant oil Condenser 40ml Evaporator 80ml Pipe or hose 20ml Receiver drier 20ml Total quantity of refrigerant oil in system 140ml A new compressor is sealed and pressurise...

Page 373: ...n equal amount of new refrigerant oil to compressor before evacuation sequence WARNING Refrigerant must always be recycled before reuse to ensure that the purity of the refrigerant is high enough for...

Page 374: ...om draughts as leakage from the system could be dissipated without detection 2 Follow the instructions issued by the manufacturer of the particular leak detector being used 3 Commence searching for le...

Page 375: ...hermometer psychrometer 5 Start engine and run it at 1500 rev min for 10 minutes with air conditioning switched on 6 Read both pressure gauges and thermometers Check readings against table below with...

Page 376: ...in this section PRECAUTIONS IN HANDLING REFRIGERANT LINES WARNING Wear eye and hand protection when disconnecting components containing refrigerant Plug all exposed connections immediately 1 When disc...

Page 377: ...han 90mm radius 16 Flexible hoses should not be within 100mm of the exhaust manifold 17 Completed assemblies must be checked for refrigeration lines touching metal panels Any direct contact of lines a...

Page 378: ...ssor is to be fitted first drain oil from new compressor Drain and measure oil from old compressor Measure new oil equal to amount from old compressor add 30 ml extra to this amount and refill new com...

Page 379: ...e compressor drive belt Mark direction on belt if refitting Refit 6 Fit compressor drive belt 7 Fit drive belt guard 8 Fit torque meter to centre of tensioner apply and hold a torque of 35 Nm 26 lbf f...

Page 380: ...r lead through fan shroud 7 Fit motor to fan shroud support brackets 8 Reconnect fan lead multi plug and secure with retaining clips 9 Fit fan blade to motor drive shaft 10 Fit grille panel 11 Reconne...

Page 381: ...s to be fitted 16 Discard all pipe connection O rings Cap or plug all connections to prevent ingress of dirt and moisture Refit 17 Coat unions threads and new O rings with refrigerant oil prior to rea...

Page 382: ...Fit receiver drier bottom union connector at condenser 13 Fit high pressure pipe to receiver drier 14 Fit pressure switch multi plug 15 Evacuate and recharge air conditioning system See Adjustment Ref...

Page 383: ...g support bracket to front of heater cooler casing 19 Lift heater cooler unit clear of air duct seal and remove from vehicle 20 Discard all pipe connection O rings Refit 21 Coat unions threads and new...

Page 384: ...d around cover seam Break sealing compound from unit body and top cover 7 Remove 4 screws and 4 nuts from top of cover 8 From front of unit remove 2 screws adjacent to low pressure pipe moulding 9 At...

Page 385: ...bly in casing Ensure studs for lower mounting bracket are located through bottom of casing 20 Apply mastic sealant around heater matrix pipes to seal pipe apertures in casing Fit seal pad over pipes 2...

Page 386: ...union securing expansion valve to evaporator high pressure pipe 11 Remove expansion valve complete with high pressure pipe 12 Disconnect high pressure pipe from expansion valve 13 Discard all pipe co...

Page 387: ...ove heater cooler unit See Heater cooler unit 2 Remove 7 screws securing outlet duct to heater cooler unit 3 Carefully break sealing compound around edge of duct and pull ducting from unit 4 Remove 15...

Page 388: ...w blower motor Do not fully tighten clip at this stage 17 Insert motor into plastic mounting and fit impeller 18 Locate spacing washers side mounting bracket and fit motor and mounting into motor hous...

Page 389: ...ver sufficiently to release motor Lucar connector and earth eylet Remove cover 4 Remove 6 screws and withdraw blower motor and impeller 5 Remove retaining nut and washer and withdraw impeller from blo...

Page 390: ...ch 10 Remove retaining clip and disconnect control cable from evaporator flap operating rod 11 Remove screw and release outer cable retaining bracket 12 Disconnect blower motor wiring plugs and releas...

Page 391: ...wer motor resistor block to vehicle wing 23 Connect blower motor wiring plugs 24 Fit footwell insulation and carpet 25 Fit control cable to evaporator flap operating rod using new clip Secure outer ca...

Page 392: ...remove 2 nuts and washers securing evaporator matrix to base of casing 12 Lift evaporator matrix from casing complete with side plates 13 Remove side plates 14 Clean sealing compound from all joint se...

Page 393: ...pe 4 Unscrew union and remove expansion valve from evaporator high pressure pipe 5 Remove high pressure pipe from expansion valve 6 Discard all pipe connection O rings Refit 7 Coat unions threads and...

Page 394: ...securing top cover to main casing and heater cooler support frame 8 Carefully break sealing compound around edge of joint seam and remove top cover from main casing 9 Lift out heater matrix 10 Clean s...

Page 395: ...ve screw and detach air conditioning 30 amp fuse bracket from resistor 5 Lift resistor unit from top cover Refit 6 Locate resistor unit in top cover 7 Fit fuse bracket 8 Fit blower motor relay connect...

Page 396: ...If applicable disconnect switch multi plugs and or radio speaker leads 7 Disconnect multi plug from wiper motor 8 Disconnect wiper motor earth lead Not applicable on later models 9 Lift rubber sleeve...

Page 397: ...lead and multi plug 18 Before fitting cover and grab handle fit wiper blades Reconnect battery and test operation of wiper motor and drive assembly If necessary adjust position of wiper blades 19 Fit...

Page 398: ...remove fascia side panel 4 Remove 5 screws and withdraw instrument panel as far as possible without straining wires and cables 5 Remove steering wheel See STEERING Repair Steering wheel 6 Remove 2 sc...

Page 399: ...d drive rack clear of drive tubes Refit 15 Feed drive rack into drive tube until fully located in wheel boxes 16 Finger tighten drive tube nut 17 Position motor mounting pad fit retaining strap includ...

Page 400: ...sition with grub screw retaining adaptor uppermost 5 Push arm on to adaptor so that wiper blade is just clear of windscreen surround rubber 6 Operate wipers and if necessary adjust position of arms WI...

Page 401: ...k vehicle with air conditioning LH drive 4 Remove instrument housing fascia crash pad and ventilator grille panel 5 Slacken steering column support rod lower fixing 6 Remove steering column upper supp...

Page 402: ...ng pad secure with retaining strap and tighten drive tube nut 16 Fully tighten wheelbox back plate nuts 17 Fully tighten both wheelbox spindle nuts 18 Fit wiper arm adaptors and secure with grub screw...

Page 403: ...r vent hose from duct 6 Remove RH vent demister vent fixing and pivot vent and hose aside 7 Remove demister vent top duct 8 Release steering column upper and lower support rods 9 Slacken LH and RH whe...

Page 404: ...ghten fixings to correct torque 26 Fit demister vent top duct 27 Secure RH demister vent and hose 28 Fit LH and RH demister vents to ducts 29 Fit centre and LH fascia top crash rail support brackets 3...

Page 405: ...ture in rear door 9 Position wiper motor mounting bracket and secure to rear door Tighten bolt to 23 Nm 17 lbf ft 10 Reconnect harness multi plug 11 Secure drive spindle to door 12 Fit wiper motor cov...

Page 406: ...and test 14 Check brushes for excessive wear if they are worn to 4 8 mm in length fit a new brush gear assembly 15 Using a push type gauge check that brush spring pressure is 140 to 200 g when bottom...

Page 407: ...olts tightening to 23 Nm 17 lbf ft If a replacement armature is being fitted slacken thrust screw to provide end float for fitting yoke 21 Fit dished washer beneath gear wheel with concave side toward...

Page 408: ...d at all times Of particular importance are those in the charging circuit including those at battery which should be occasionally inspected to see that they are clean and tight In this way any signifi...

Page 409: ...vating relevant warning devices unit is located under fascia behind instrument binnacle Handset and key The handset is the primary source of control for the alarm system i e it arms and disarms the al...

Page 410: ...ioned in a different location according to vehicle type as follows 90 110 Station Wagon RH cantrail trim 90 110 Pick up On headlining between interior lamp and rear view mirror 130 Crewcab On headlini...

Page 411: ...isation spider Inside vehicle battery box 5 Passive coil Over starter switch barrel 6 Bonnet switch Engine compartment LH and RH drive 7 Door switches 8 Ultrasonic sensor Varies according to vehicle t...

Page 412: ...isarmed by entering the emergency key access code see Engine immobilisation override Anti theft alarm indicator light A RED indicator light on the instrument panel indicates the status of the alarm sy...

Page 413: ...as the door is opened the alarm will sound continuously for up to three 30 second periods and continue while the code is being entered 1 With the driver s door closed insert the key into the starter...

Page 414: ...l in the fuse box cover shows the circuits protected the fuse rating and their locations They are also listed below MAIN FUSE BOX Fuse No Value amps Electrical circuit 1 15 Hazard warning lights 2 20...

Page 415: ...86 ELECTRICAL 8 DESCRIPTION AND OPERATION...

Page 416: ...h 15 Vehicle horn 16 Passive coil 17 Starter switch relay 18 Front passenger door switch 19 Hazard warning light fuse 15 amp position 1 20 Ultrasonic sensor 21 Interior lamp and horn fuse 20 amp posit...

Page 417: ...86 ELECTRICAL 10 DESCRIPTION AND OPERATION...

Page 418: ...h 15 Vehicle horn 16 Passive coil 17 Starter switch relay 18 Front passenger door switch 19 Hazard warning light fuse 15 amp position 1 20 Ultrasonic sensor 21 Interior lamp and horn fuse 20 amp posit...

Page 419: ...operate briefly and the anti theft alarm indicator and direction indicator lamps will flash Perimetric tests The anti theft alarm indicator light and direction indicator lamps will flash when 1 Door...

Page 420: ...s instructions 7 Start engine and run at 3000 rev min without accessory load 8 Rotate carbon pile load control to achieve greatest output amps without allowing voltage to fall below 12 0 V A reading...

Page 421: ...locking tabs are disengaged before removal and note orientation to enable correct reconnection Ensure that any protective covers and substances are replaced if disturbed Having confirmed a component...

Page 422: ...y repairs or maintenance to electrical components always disconnect negative lead first If positive lead is disconnected with negative lead in place accidental contact of a wrench to any grounded meta...

Page 423: ...x oil temperature lead and immobiliser warning light leads 10 Remove instrument panel 11 Remove 2 screws securing ECU to fascia cowl LH drive shown On RH drive vehicles ECU is positioned lower down on...

Page 424: ...inutes after key is removed from starter switch Refit 7 Fit new battery into handset retaining clip with positive side uppermost Finger marks will adversely affect battery life if possible avoid touch...

Page 425: ...nacelle upper and lower halves from steering column collect blanking grommet from RH side 14 Disconnect multi plug and remove passive coil from starter switch Refit 15 Feed passive coil plug lead into...

Page 426: ...housing and disconnect spider harness plug 13 Unscrew two nuts and remove immobilisation spider from lid studs NOTE If spider box lid and or sealing gasket is damaged during operation 11 a new lid wi...

Page 427: ...ness multi plug and bonnet switch into mounting bracket Push switch firmly down to secure in position 5 Connect harness multi plug 6 Fit harness retaining clip in mounting bracket ULTRASONIC SENSOR Se...

Page 428: ...reservoir mounting bracket to front LH inside wing 8 Move steering pump reservoir aside to gain access to alarm sounder 9 Disconnect harness multi plug from rear of alarm sounder 10 Unscrew 2 bolts an...

Page 429: ...emove LH front seat cushion 2 Release retaing clip and remove battery access cover 3 Slacken battery negative lead clamp bolt 4 Turn starter switch on 5 Turn starter switch off and remove key 6 Discon...

Page 430: ...and remove key 6 Disconnect battery negative lead NOTE Operation 6 needs to be carried out within 15 seconds to avoid activating battery backed up alarm sounder if fitted NOTE If an alarm sounder wit...

Page 431: ...ect battery negative lead 17 Fit battery access cover 18 Fit LH front seat cushion GENERATOR Service repair no 86 10 02 Remove 1 Disconnect battery 2 Remove drive belt See Auxiliary drive belt 3 Unscr...

Page 432: ...se tensioner 7 Complete removal of belt Mark direction on belt if refitting Refit 8 Using ring spanner release pulley tensioner and fit new drive belt 9 Remove ring spanner drive belt will automatical...

Page 433: ...it also release unit harness plug See Headlamp levelling unit 7 Remove rubber cover 8 Release spring clip and withdraw headlamp bulb NOTE Do not touch bulb glass with fingers If necessary clean bulb w...

Page 434: ...2 Hold bulb holder and twist lens to release 3 Push and twist bulb to remove from holder Refit 4 Fit new bulb if necessary 5 Fit bulb holder to lamp lens 6 Secure lamp to vehicle SIDE REPEATER LAMP S...

Page 435: ...le screw and remove lamp cover and lens 2 Uncsrew 2 fixings and remove metal cover to gain access to lamp fixings and harness leads inside vehicle 3 Disconnect lamp leads from harness 4 Remove 2 bolts...

Page 436: ...it new bulb 5 Fit lens to lamp body REVERSE AND FOG GUARD LAMP Service repair no 86 40 91 Reverse lamp Service repair no 86 40 99 Fog guard lamp Remove 1 From underneath the vehicle lift protective fl...

Page 437: ...Service repair no 86 45 02 Remove 1 Prise lens cover from lamp unit 2 Remove 2 nuts securing lamp unit to headlining and roof mounting bracket 3 Remove lamp unit from mounting bracket studs and discon...

Page 438: ...sing Tighten to 25 Nm 18 lbf ft 5 Fit lamp switch lead multi plug to harness connector 6 Check operation of lamp switch WARNING LAMP ASSEMBLY Service repair no 86 45 60 Warning lamp assembly Service r...

Page 439: ...battery STARTER SWITCH Service repair no 86 65 03 Remove 1 Remove instrument panel See INSTRUMENTS Repair Instrument panel 2 Remove steering column nacelle See STEERING Repair Steering column nacelle...

Page 440: ...SWITCH Service repair no 86 65 55 Remove 1 Remove steering column nacelle See STEERING Repair Steering column nacelle 2 Disconnect 3 steering column switch multi plugs from main harness 3 Slacken cla...

Page 441: ...TEERING Repair Steering column nacelle HEATED REAR SCREEN REAR FOG LAMP AND HAZARD WARNING SWITCHES Service repair no 86 65 36 Heated rear screen Service repair no 86 65 65 Rear fog lamp Service repai...

Page 442: ...Connect electrical leads and illumination bulb 9 Insert cigar lighter into switch housing 10 Fit switch panel to lower fascia REAR SCREEN WIPER WASHER SWITCH Service repair no 84 35 34 Remove 1 Remove...

Page 443: ...switch panel HEADLAMP LEVELLING UNIT Service repair no 86 41 16 Remove 1 Remove headlamp See Headlamp 2 Disconnect headlamp levelling unit harness plug 3 Rotate levelling unit anti clockwise to relea...

Page 444: ...imension B vertically from the ground 3 Switch on main beam and adjust setting as necessary with trimmer screws On vehicles fitted with headlamp levelling units check and adjust headlamp beam alignmen...

Page 445: ...p from shut off solenoid 6 Unscrew terminal nut release terminal lead eyelet and remove DDS valve 7 Remove protective cap retainer and release DDS valve clamp from behind fuel shut off solenoid Refit...

Page 446: ...s and connections to vehicle alarm system if fitted See ELECTRICAL Repair Vehicle immobilisation and alarm system 7 Connect speedometer cable 8 Secure instrument panel 9 Reconnect battery SPEEDOMETER...

Page 447: ...t panel locate earth lead and secure with clamp 7 Fit bulb holder and electrical leads 8 Fit instrument panel See Instrument panel CLOCK FASCIA PANEL Service repair no 88 15 07 Remove 1 Remove 4 screw...

Page 448: ...ve clock from panel Refit 4 Fit clock into dash panel 5 Fit electrical leads and bulb holder 6 Secure switch panel to centre dash WARNING LIGHT PANEL Service repair no 88 20 18 Remove 1 Remove 2 screw...

Page 449: ...e that fuel handling precautions given in Section 01 Introduction are strictly adhered to when carrying out the following instructions Remove 1 Disconnect battery 2 Remove fuel filler cap 3 Remove tan...

Page 450: ...ront seat cushion 3 Release retaining catch and remove seat base cover to gain access to fuel tank 4 Disconnect electrical plug from fuel gauge unit 5 Release locking ring and withdraw fuel gauge unit...

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Rover DEFENDER 300Tdi, Workshop Manual

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Summary of Contents for DEFENDER 300Tdi

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