Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual
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70BRAKES 2 OVERHAUL MASTER CYLINDER Service repair no - 70.30.09 Before starting overhaul procedure refer to general brake service practice See Repair, General brake service practice . Dismantling master cylinder 1.Disconnect battery and remove master cylinder from servo See Repair, Master cylinder. 2.Before commencing overhaul procedure thoroughly clean master cylinder and inspect outer surfaces for damage and condition, renew complete assembly if necessary. 3.The reservoir is a push fit in master cylinder and secured by seals. 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 ingress O ring seal from master cylinder to servo flange and discard. 5.Hold outside of transfer housing with a suitable pair of grips, carefully pull, while working pliers in a backwards and forwards rocking motion to ease housing off master cylinder, discard housing and vacuum seal. 6.Withdraw 2 reservoir seals from master cylinder and note their positions in inlet ports for reassembly. Discard both seals. 7.Remove retaining ring and O ring seal from machined outer surface of master cylinder, discard both seal and retaining ring.
BRAKES 3 OVERHAUL 8.Remove guide ring from mouth of master cylinder which supports primary plunger assembly and place to one side, this component is not part of master cylinder service kit and is to be refitted on assembly of unit. 9.Pull primary plunger assembly out of master cylinder. NOTE: The primary plunger assembly cannot be broken down any further and is serviced as a complete unit. Discard assembly. 10.The secondary plunger assembly will remain at bottom of master cylinder bore, plunger can be easily expelled by tapping assembly on a piece of timber until plunger appears at cylinder mouth, carefully pull plunger from master cylinder. 11.If swirl tube was not expelled at same time 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 on to a clean sheet of paper. Inspect cylinder bore and plungers for signs of corrosion, ridges and score marks. Provided working surfaces are in perfect condition, new seals from a Girling Service repair kit may be used. Renewing secondary plunger seals A.Springs B.Seal retainer C.Recuperating seal (primary cup) D.Washer E.L seal 13.Remove components above from secondary plunger and discard: NOTE: A small screwdriver with end rounded and polished is required to remove L seal. DO NOT damage secondary plunger. 14.Coat new seals in unused brake fluid and firstly fit L seal to plunger. 15.Fit washer followed by recuperating seal. Fit seal retainer and springs, ensure springs are correctly seated.
70BRAKES 4 OVERHAUL Assembling master cylinder CAUTION: It is important that the following instructions are carried out precisely, otherwise damage could be caused to new seals when inserting plungers into cylinder bore. Generous amounts of new brake fluid should be used to lubricate parts during assembly. NOTE: Thoroughly check that no debris is lodged in fluid passageways and drillings. If debris is found, carefully remove, re-clean cylinder and re-check. 16.Fit new swirl tube to bottom of cylinder bore. 17.Lubricate secondary plunger and cylinder bore. Offer plunger assembly to cylinder until recuperation seal is resting centrally in mouth of bore. Gently introduce plunger with a circular rocking motion, as illustrated. Ensuring that seal does not become trapped, ease seal into bore and slowly push plunger down bore in one continuous movement. 18.Fit primary plunger assembly using same method as for secondary plunger, push plunger down bore. 19.Fit original guide ring to support 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 of master cylinder but should be slightly stretched and eased down cylinder and into its groove. Do not over stretch seal.21.Fit a new retaining ring on outer surface of master cylinder ensuring that serrations of ring are facing mounting flange. 22.Fit two new reservoir seals in their respective ports. 23.Fit a new vacuum seal to either primary plunger or to bottom of transfer housing bore, open face of seal towards primary plunger guide ring. 24.Lubricate vacuum seal with brake fluid, fit transfer housing to master cylinder, push housing fully up to cylinder mounting flange. Do not adjust transfer housing after fitting. 25.Lubricate a new water ingress seal with brake fluid, slightly stretch seal and ease it down housing until seal is in correct position between housing and flange. 26.Roll reservoir into top of master cylinder, reversing procedure described in instruction 3. 27.Fit master cylinder to servo See Repair, Master cylinder . 28.Reconnect battery, and road test vehicle.
WHEELS AND TYRES 1 DESCRIPTION AND OPERATION TYPES OF WHEEL RIMS AND TYRES Description Dependent on specification and model type, the vehicle is equipped with pressed steel or alloy wheel rims, both using tubeless radial ply tyres. Tyre codes The text, codes and numbers moulded into the tyre wall vary between tyre manufacturers, however most tyres are marked with the information shown in the illustrated example. NOTE: The illustration is an example of the type of markings moulded into tyres and is for guidance only. For specific tyre specifications See GENERAL SPECIFICATION DATA, Information, Tyre size and pressures .1.Type of tyre construction -Radial Ply 2.Load index -104 3.Speed symbol -SorT 4.USA Tyre quality grading -Tread wear 160 Traction A temperature B 5.Tread wear indicators moulded into tread pattern are located at intervals around the tyre and marked by a code -E66 103S6 6.Tyres with Mud Snow type tread pattern are marked -M&S 7.Tyre reinforcing mark -Reinforced 8.USA Load and pressure secification - (900Kg(1984LBS) at 340KA (50PSI) MACS PRESS 9.Tyre size -205 16 ot 235/70 R16 10.Type of tyre -TUBELESS 11.Country of manufacture -MADE IN GREAT BRITAIN 12.USA Compliance symbol and identification - DOT AB7C DOFF 267 13.European type approval identification -E11 01234 14.Tyre construction -SIDE WALL 2 PLIES RAYON. TREAD 2 RAYON 2 STEEL 15.Manufacturers brand name/type -TRACTION PLUS mzx M
WHEELS AND TYRES 1 FAULT DIAGNOSIS TYRE WEAR CHART FAULT CAUSE REMEDY Rapid wear at Tyres under-inflated Inflate to correct pressure shoulders Worn suspension components Replace worn components i.e. ball joints, panhard rod bushes, steering damper Excessive cornering speeds Rapid wear at centreTyres over-inflated Inflate to correct pressure of tread Wear at one shoulderTrack out of 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 runout Check runout and replace tyre if necessary Shock absorber worn Replace shock absorber Excessive braking Tyre scalloped Track out of adjustment Adjust toe to correct figure Worn suspension components Replace tyre as necessary Excessive cornering speeds CAUTION: This diagnosis chart is for general guidance only and does not necessarily include every cause of abnormal tyre wear.
74WHEELS AND TYRES 2 FAULT DIAGNOSIS FAULT - SYMPTOMS Vibration through steering wheel 1.Check tyre pressures See Repair, Tyre Pressures . 2.Check condition of tyres See Tyre Wear Chart. 3.Check front wheel alignment See STEERING, Adjustment, Front Wheel Alignment . 4.Check wheel balance See Repair, Wheel Balancing . NOTE: In the event that any apparent vibration is not eliminated at this stage See PROPELLER 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 wheel shimmy/wobble) See STEERING, Fault diagnosis, Steering Faults . NOTE: Radial ply tyres have a flexible sidewall, which produces a sidewall bulge making the tyre appear under-inflated. This is a normal condition for radial ply tyres. Do not attempt to reduce this bulge by over-inflating the tyre. Key to illustration 1.Correct inflation. 2.Under-inflation. 3.Over-inflation. 4.Tread contact with road.
WHEELS AND TYRES 1 REPAIR REV: 05/99 GENERAL INFORMATION WARNING: This is a multi-purpose vehicle with wheels and tyres designed for both on and off road usage. Only use wheels and tyres specified for use on the vehicle. The vehicle is equipped with tubeless S,T or H rated radial ply tyres as standard equipment. The tyres are of European metric size and must not be confused with the P size metric tyres available in North America. Vehicle wheel sets, including spare wheel, must be fitted with the same make and type of tyre to the correct specification and tread pattern. Under no circumstances must cross-ply or bias-belted tyres be used. For tyre specification and pressures See GENERAL SPECIFICATION DATA, Information, Wheels and Tyres . Steel wheels Tubeless tyres are mounted on 7.0 inch wide by 16 inch diameter steel wheels. Alloy Wheels Tubeless tyres are mounted on 7.0 inch wide by 16 inch diameter cast aluminium alloy wheels. The surface has a paint finish covered with a clear polyurethane lacquer. Care must be taken 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 difficulty is experienced in fitting tyres to this type of rim See Tyre Fitting . WARNING: DO NOT fit an inner tube to an alloy wheel.TYRE INSPECTION Inspect tyres at weekly intervals to obtain maximum tyre life and performance and to ensure compliance with legal requirements. Check for signs of incorrect inflation and uneven wear, which may indicate a need for balancing or front wheel alignment, See Fault diagnosis, Tyre Wear Chart , if the tyres have abnormal or uneven wear patterns. Check tyres at least weekly for cuts, abrasions, bulges and for objects embedded in the tread. More frequent inspections are recommended when the vehicle is regularly used in off road conditions. To assist tyre inspection, tread wear indicators are moulded into the bottom of the tread grooves, as shown in the illustration above. When the tread has worn to a depth of 1.6 mm the indicators appear at the surface as bars which connect the tread pattern across the width of the tread as shown in the illustration above.
74WHEELS AND TYRES 2 REPAIRREV: 05/99 When the indicators appear in two or more adjacent grooves, at three locations around the tyre, a new tyre must be fitted. NOTE: DO NOT attempt to interchange tyres, e.g. from front to rear, as tyre wear produces characteristic patterns depending on their position. If tyre position is changed after wear has occured, the performance of the tyre will be adversely affected. NOTE: Territorial vehicle regulations governing tyre wear MUST be adhered to. WHEELS INSPECTION Regularly check the condition of the wheels. Replace any wheel that is bent, cracked, dented or has excessive runout. VALVES INSPECTION Check condition of inflation valve. Replace any valve that is worn, cracked, loose, or leaking air.TYRE PRESSURES Maximum tyre life and performance will be obtained only if tyres are maintained 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 satisfactory ride and steering characteristics without compromising tyre tread life. For recommended tyre pressures in all conditions See GENERAL SPECIFICATION DATA, Information, Wheels and Tyres . Always check tyre inflation pressures using an accurate gauge and inflate tyres to the recommended pressures only. Check and adjust tyre pressuresONLYwhen the tyres are cold, vehicle parked for three hours or more, or driven for less than 3.2 km (2 miles) at speeds below 64 km/h (40 mph). Do not reduce inflation pressures if the tyres are hot or the vehicle has been driven for more than 3.2 km (2 miles) at speeds over 64 km/h (40 mph), as pressures can increase by 0.41 bars (6 lb/in 2) over cold inflation pressures. CheckALLtyre pressures including the spare. Refit the valve caps as they form a positive seal and keep dust out of the valve.
WHEELS AND TYRES 3 REPAIR WHEEL BALANCING CAUTION: It is essential that all wheel balancing is carried out off the vehicle. The use of on the vehicle balancing could cause component damage or personal injury and MUST NOT be attempted. NOTE: Before attempting to balance a wheel and tyre assembly clean all mud and dirt deposits from both inside and outside rims and remove existing balance weights. Remove stones from the 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 manufacturers instructions. Steel wheels Clean area of wheel rim and attach balance weights in position shown. Alloy wheels Clean area of wheel rim and attach adhesive balance weights in position shown. Cut through rear face of weight strip to detach required weights. CAUTION: Use only correct adhesive balance weights to avoid damage to aluminium wheel rim. DO NOT attempt to use a steel wheel weight on an aluminium wheel.
74WHEELS AND TYRES 4 REPAIR Static balance Wheel tramp A- Heavy spot. B- Add balance weights here. C- Centre line of spindle. Static balance is the equal distribution of weight around the wheel. A statically unbalanced wheel will cause a bouncing action called wheel tramp. This condition will eventually cause uneven tyre wear.Dynamic balance Wheel shimmyA- Heavy spot. B- Add balance weights here. C- Centre line of spindle. Dynamic balance is the equal distribution of weight on each side of the centre line so that when the wheel spins there is no tendency for side to side movement. A dynamically unbalanced wheel will cause wheel shimmy.