Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual
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01INTRODUCTION 6 INFORMATION 3.Position an axle stand under right hand axle tube, carefully lower jack until axle sits securely on both axle stands, remove trolley jack. 4.Before commencing work on underside of vehicle re-check security of vehicle on stands. 5.Reverse procedure when removing vehicle from stands. Raise rear of vehicle 1.Position cup of hydraulic arm under differential casing. 2.Raise vehicle to enable axle stands to be installed under left and right hand axle tubes. 3.Lower jack until axle sits securely on axle stands, remove trolley jack. 4.Before commencing work on underside of vehicle re-check security of vehicle on stands. 5.Reverse procedure when removing vehicle from stands. HYDRAULIC VEHICLE RAMP (FOUR POST) Use only a drive on type ramp which supports vehicle on its road wheels. If a wheel-free condition is required, use a drive on ramp incorporating a wheel-free system providing support beneath axle casings. Alternatively, place vehicle on a firm, flat floor and support on axle stands. TWO POST VEHICLE RAMPS 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 installed on a Two Post ramp responsibility for safety of vehicle and personnel performing service operations is in the hands of the Service Provider.DYNAMOMETER TESTING The front and rear axles cannot be driven independently. WARNING: DO NOT attempt to drive individual wheels with vehicle supported on floor jacks or stands. Four wheel dynamometers Provided that front and rear dynamometer rollers are rotating at identical speeds and that normal workshop safety standards are applied, there is no speed restriction during testing except any that may apply to the tyres. Two wheel dynamometers IMPORTANT: Use a four wheel dynamometer for brake testing if possible. If brake testing on a single axle rig is necessary it must be carried out with propeller shaft to rear axle removed, AND neutral selected in BOTH main gearbox and transfer gearbox. When checking brakes, run engine at idle speed to maintain servo vacuum. If checking engine performance, the transfer box must be in high range and propeller shaft to stationary axle must be removed.
INTRODUCTION 7 INFORMATION TOWING CAUTION: The vehicle has permanent four-wheel drive. The following towing instructions must be adhered to: Towing the vehicle on all four wheels with driver operating steering and brakes. 1.Turn ignition key to position 1 to release steering lock. 2.Select neutral in main gearbox and transfer gearbox. 3.Secure tow rope, chain or cable to front towing eyes (alternative types shown). 4.Release the parking brake. CAUTION: The brake servo and power assisted steering system will not be functional without the engine running. Greater pedal pressure will be required to apply the brakes, the steering system will require 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 the front axle is to be trailed turn ignition key to position 1 to release steering lock. 2.Select neutral in main gearbox and transfer box. CAUTION: The steering wheel and/or linkage must be secured in a straight ahead position. DO NOT use the steering lock mechanism for this purpose. TRANSPORTING THE VEHICLE BY TRAILER Lashing/towing eyes are provided on front and rear of the chassis side members, see J6085, to facilitate the securing of the vehicle to a trailer or other means of transportation. CAUTION: Underbody components must not be used as lashing points. Install vehicle on trailer and apply park brake. Select neutral in main gearbox.
01INTRODUCTION 8 INFORMATION JUMP STARTING WARNING: Hydrogen and oxygen gases are produced during normal battery operation. This gas mixture can explode if flames, sparks or lighted tobacco are brought near battery. When charging or using a battery in an enclosed space, always provide ventilation and shield your eyes. Keep out of reach of children. Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also, shield eyes when working near battery to protect against possible splashing of acid solution. In case of acid contact with skin, eyes, or clothing, flush immediately with water for a minimum of fifteen minutes. If acid is swallowed, drink large quantities of milk or water, followed by milk of magnesia, a beaten egg, or vegetable oil. SEEK MEDICAL AID IMMEDIATELY. To Jump Start - Negative Ground Battery WARNING: To avoid any possibility of injury use particular care when connecting a booster battery to a discharged battery. 1.Position vehicles so that jump leads will reach, ensuring that vehiclesDO NOT TOUCH, alternatively a fully charged slave battery may be positioned on floor adjacent to vehicle. 2.Ensuring that ignition 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 of booster battery. B.Connect other end of first jumper cable to positive (+) terminal of discharged battery. C.Connect one end of second jumper cable to negative terminal of booster battery. D.Connect other end of second jumper cable to a good earth point on the disabled vehicle (eg. engine front lifting eye, as shown in J6086),NOT TO NEGATIVE TERMINAL OF DISCHARGED BATTERY.Keep jumper lead away from moving parts, pulleys, drive belts and fan blade assembly. WARNING: Making final cable connection could cause an electrical arc which if made near battery could cause an explosion. 3.If booster battery is installed in another vehicle, start engine and allow to idle. 4.Start engine of vehicle with discharged battery, following starting procedure in Owners Manual. CAUTION: If vehicle fails to start within a maximum time of 12 seconds, switch ignition off and investigate cause. Failing to follow this instruction could result in irrepairable damage to catalyst, if fitted. 5.Remove negative (-) jumper cable from the engine and then terminal of booster battery. 6.Remove positive (+) jumper cable from positive terminals of booster battery and discharged battery.
INTRODUCTION 9 INFORMATION ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL Across flats (bolt size) AF............................................ After bottom dead centre ABDC................................... After top dead centre ATDC......................................... Alternating current a.c.................................................. Ampere amp................................................................ Ampere hour amp hr.................................................... Before bottom dead centre BBDC................................ Before top dead centre BTDC...................................... Bottom dead centre BDC............................................. Brake horse power bhp................................................ British Standards BS.................................................... Carbon monoxide CO.................................................. Centimetre cm............................................................. Centigrade (Celsius) C................................................ Cubic centimetre cm 3................................................... Cubic inch in3............................................................... Degree (angle) deg or° ............................................... Degree (temperature) deg or° ..................................... Diameter dia................................................................ Direct current d.c.......................................................... Electronic Control Unit ECU........................................ Fahrenheit F................................................................. Feet ft........................................................................... Feet per minute ft/min.................................................. Fifth 5th........................................................................ First 1st........................................................................ Fluid ounce fl oz.......................................................... Foot pounds (torque) lbf ft............................................ Fourth 4th..................................................................... Gramme (force) gf........................................................ Gramme (mass) g........................................................ Gallons gal................................................................... High tension (electrical) H.T......................................... Internal diameter I.D.................................................... Inches of mercury in. Hg.............................................. Inches in...................................................................... Kilogramme (force) kgf................................................. Kilogramme (mass.) kg................................................ Kilogramme centimetre (torque) kgf.cm....................... Kilogramme per square millimetre kgf/mm 2................. 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 thread LHThd............................................... Litres litre.....................................................................Low tension l.t.............................................................. Maximum max............................................................. Metre m........................................................................ Millilitre ml.................................................................... Millimetre mm............................................................... Miles per gallon mpg.................................................... Miles per hour mph...................................................... Minute (angle) ............................................................ Minus (of tolerance) -................................................... Negative (electrical) -................................................... Newton metres (torque) Nm........................................ Number No.................................................................. Ohms ohm................................................................... Ounces (force) ozf....................................................... Ounces (mass) oz........................................................ Ounce inch (torque) ozf.in........................................... Outside diameter O.D.................................................. Part number Part No.................................................... Percentage %............................................................... Pints pt......................................................................... Plus (tolerance) +......................................................... Positive (electrical) +.................................................... Pound (force) lbf.......................................................... Pounds inch (torque) in.lbf........................................... Pound (mass) lb........................................................... Pounds per square inch P.S.I...................................... Ratio :........................................................................... Reference ref............................................................... Revolution per minute rev/min..................................... Right-hand RH............................................................. Second (angle) ........................................................... Second (numerical order) 2nd...................................... Specific gravity sp.gr.................................................... Square centimetres cm 2............................................... Square inches in2......................................................... Standard wire gauge s.w.g.......................................... Synchroniser/Synchromesh synchro........................... Third 3rd....................................................................... Top dead centre TDC.................................................. United Kingdom UK...................................................... Vehicle Identification Number VIN............................... Volts V......................................................................... Watts W....................................................................... SCREW THREADS British Standard Pipe BSP........................................... Unified Coarse UNC.................................................... Unified Fine UNF.........................................................
01INTRODUCTION 10 INFORMATION CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY NEW TERM (ACRONYM) Accelerator pedal (AP)................................................. Air cleaner (ACL).......................................................... Air conditioning (AC).................................................... Battery positive voltage (B+)........................................ Closed loop (CL).......................................................... Closed throttle position (CTP)...................................... Canister purge valve (CANPV).................................... Data link connector (DLC)........................................... Diagnostic trouble code (DTC)..................................... Distributor ignition (DI)................................................. Engine control module (ECM)...................................... Engine coolant level (ECL)........................................... Engine coolant temperature (ECT).............................. Engine coolant temperature sensor (ECTS)................ Engine speed (RPM).................................................... Evaporative emission system (EVAP).......................... Engine fuel temperature sensor (EFTS)...................... 4th gear, 3rd gear etc. (4GR, 3GR).............................. Fuel pump (FP)............................................................ Fan control module (FCM)........................................... Generator (GEN).......................................................... Ground (GND).............................................................. Heated oxygen sensor (H02S).................................... Idle air control (IAC)...................................................... Idle air control valve (IACV)......................................... Ignition control module (ICM)....................................... Intake air temperature (IAT)......................................... Manifold vacuum zone (MVZ)...................................... 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 throttle (WOT)............................................OLD TERM (ACRONYM) Throttle pedal (-).......................................................... Air cleaner (-)............................................................... Air conditioning (AC).................................................... Battery plus, bat +, bat feed (B+)................................. Closed loop (-)............................................................. Closed throttle, idle position (-).................................... Charcoal canister purge valve (-)................................. Serial link (-)................................................................ Fault code (-)............................................................... Electronic ignition (-).................................................... Electronic control unit (ECU)........................................ Coolant level (-)........................................................... Coolant temperature (temp)......................................... Coolant temperature thermistor (-).............................. Engine speed (rev/min)................................................ Evaporative loss system (ELC)................................... Fuel temperature thermistor (-).................................... Fourth gear, 3rd gear (-).............................................. Fuel pump (-)............................................................... Condenser fan timer (-)................................................ Alternator (-)................................................................ Ground, earth (B-)........................................................ Lambda (02) sensor (-)................................................ Idle speed control (ISC)................................................ Stepper motor (-)......................................................... Ignition module (-)........................................................ Intake temperature/ambient temperature (-)................ Manifold depression, vacuum (-)................................. Air flow meter (-).......................................................... Fault code display unit (-)............................................ Open loop (-)............................................................... Relay (-)....................................................................... Control unit (-).............................................................. Catalyst, catalytic converter (CAT).............................. Throttle housing (-)...................................................... Transmission gear (-)................................................... Full throttle, wide open throttle (WOT).........................
INTRODUCTION 11 INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) The Vehicle Identification Number and the recommended maximum vehicle weights are stamped on a plate riveted to the brake pedal box in the engine compartment. The VIN is also stamped on a plate visible through the LH side of the windscreen, see J6088. A.Type approval B.Identification C.Maximum permitted laden weight for vehicle D.Maximum vehicle and trailer weight E.Maximum road weight-front axle F.Maximum road weight-rear axle The number is also stamped 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, transmission, model year and place of manufacture. The following example shows the coding process. SALLDHMF7TA SAL= World manufacturer identifier LD= Land Rover Defender H= 110 inch,V= 90inch,K= 130 inch M= 4 door Station Wagon,A= 90 Soft Top, Hard Top, Pick-up,B= 2 door Station Wagon,E= 2 door 130 Crew cab,F= 4 door 130 Crew cab,H= 130 High Capacity Pick-up F= 2.5L (300Tdi) 7= RH drive, 5 speed manaul,8= LH drive, 5 speed manual T= 1996 MY, volume build,N= 1996 MY, non-volume build A= Solihull build,F= CKD, assembled locally from kit
01INTRODUCTION 12 INFORMATION LOCATION OF IDENTIFICATION NUMBERS Engine serial number - 300Tdi Engine The 300Tdi engine number is stamped on the cylinder block on the RH side of the engine above the camshaft front cover plate. Main gearbox R380 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 bearing housing adjacent to the bottom cover, see J6092. Front axle serial number Stamped on the front of LH axle tube, inboard of radius arm mounting bracket. Rear axle serial number Stamped on the rear of LH axle tube, inboard of spring mounting.
INTRODUCTION 13 INFORMATION FAULT DIAGNOSTIC EQUIPMENT TESTBOOK For Defender models fitted with the vehicle Anti-theft Immobilisation and Alarm System, diagnostic equipment, named TestBook, is available to assist in the diagnostic and fault finding abilities of the Dealer workshop. A diagnostic connector, located under the front centre seat, or cubby box, as shown below, is provided to facilitate the procedures. If an exhaust gas recirculation (EGR) system is fitted, this too can be checked using TestBook. A diagnostic connector, also located under the front centre seat or cubby box, is provided. Features of Testbook include :- Fully upgradable support for the technician. Structured diagnostics 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, alongside a range of icons, familiar to service technicians. Relevant information is contained within each of these sections. These are further divided into the following sub-sections which appear at the foot of each page :- Description and operation. Fault diagnosis. Adjustment. Repair. Overhaul. Specifications, Torque. To avoid repeating information through the sections, where part of the repair operation impacts on another section, a cross reference is given to direct the reader to where the information is sited. For example: The maintenance section states the need to renew drive belt. A cross reference sites this information in: Section 12 Engine - Sub-section: Repairs - Heading: Drive belt renew.
GENERAL SPECIFICATION DATA 1 INFORMATION REV: 05/99 300Tdi ENGINE Type Direct injection, turbocharged, intercooled................................................................................. Number of cylinders 4......................................................... Bore 90,47 mm................................................................................. Stroke 97,00 mm............................................................................... Capacity 2495 cc........................................................................... Compression ratio 19.5:1±0.5:1 ............................................................ Valve operation O.H.V. pushrod operated................................................................ Crankshaft Main bearing journal diameter 63,475 - 63,487 mm.......................................... Regrind dimensions 63,233 - 63,246 mm......................................................... Crankpin journal diameter 58,725 - 58,744 mm................................................ Regrind dimensions 58,471 - 58,490 mm......................................................... Crankshaft end thrust Taken on thrust washers at centre main bearing....................................................... Crankshaft end float 0,05 - 0,15 mm......................................................... Main bearings Number and type 5 halved shells with oil 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....................................................... Pistons Type Aluminium alloy, combustion chamber in crown.................................................................................. Graphite coating on sidewalls. Skirt diametrical clearance (at r/angle to gudgeon pin) 0,025 - 0,05 mm.... Maximum height above combustion face 0,8 mm......................... Gudgeon pins Type Fully floating................................................................................. Fit in piston Hand push fit....................................................................... Diameter 30,156 - 30,163 mm.......................................................................... Clearance in connecting rod 0,003 - 0,016 mm............................................ Piston rings Type: - Top Barrel edge, chrome plated........................................................................ - Second Taper faced.................................................................. - Oil control Expander and rails.............................................................. Gap in bore: - Top 0,40 - 0,60 mm........................................................................ - Second 0,30 - 0,50 mm.................................................................. - Oil control 0,30 - 0,60 mm.............................................................. Clearance in piston grooves: - Second 0,050 - 0,085 mm.................................................................. - Oil control 0,050 - 0,085 mm..............................................................
04GENERAL SPECIFICATION DATA 2 INFORMATION Camshaft Drive 30 mm wide dry toothed belt................................................................................. Location Right hand side (thrust side)........................................................................... End float 0,1 - 0,2 mm........................................................................... Number of bearings 4.......................................................... Material Steel shell, white metal lined............................................................................ Valves Tappet clearance: - Inlet and exhaust 0,20 mm................................................... Seat angle: - Inlet 30° ....................................................................... - Exhaust 45° ................................................................. Head diameter: - Inlet 38,75 - 39,05 mm....................................................................... - Exhaust 36,35 - 36,65 mm................................................................. Stem diameter: - Inlet 7,960 - 7,975 mm....................................................................... - Exhaust 7,940 - 7,960 mm................................................................. Valve lift: - Inlet 9,67 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 40,30 mm................................................. Lubrication System Wet sump, pressure fed............................................................................. Pressure, engine warm at normal operating speeds 1,76 - 3,87Kgf/cm 2(25 - 55 Ibf/in2) ........ Oil pump: - Type G-rotor integral with front cover....................................................................... - Drive off crankshaft nose..................................................................... Oil pressure relief valve Non-adjustable.................................................... Relief valve spring: - Full length 51,6mm...................................................................... - Compressed length at 7.71Kg load 31mm................................ Oil filter Screw-on disposable canister............................................................................. Engine oil cooler Combined with coolant radiator and intercooler...............................................................