Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							COOLING SYSTEM
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Nm lbf ft
Oil cooler pipes 30................................................................ 22
Radiator filler plug (plastic) 6............................................... 4.5 
						

							MANIFOLD AND EXHAUST SYSTEM
1
DESCRIPTION AND OPERATION CATALYTIC CONVERTERS - V8i
Description
Catalytic converters which form part of the engine
emission control system, are designed to clean the
exhaust gases, by chemically converting pollutant
elements in the exhaust to gases less harmfull to the
environment.
1.Catalysts
2.Oxygen sensors
The front section of the exhaust system from each
cylinder bank contain the ceramic elements of the
catalytic converters. The oxygen sensors, which
transmit information to the fuel ECM for control of the
mixture, are located in the exhaust down pipes.
The Hydrocarbons (HC), Nitogen oxides (NO
x) and
Carbon monoxide (CO) emitted by the engine react
with the catalytic element and exhaust temperature to
convert the toxic gas, into Nitrogen (N2), Carbon
dioxide (CO
2) and water vapour (H2O).
The sophisticated closed loop control system ensures
that mixture is always kept at the optium level for peak
catalyst efficiency. Also, the advanced On Board
Diagnostics ensure that any faults likely to cause
damage to the catalyst are indicated to the driver.However, should the engine be supplied with a rich
mixture causing high CO in the exhaust gas, the
ceramic element will become coated and the useful
life of the catalyst reduced. If the mixture is too weak,
excess oxygen in the exhaust gas will cause the
catalysts to burn out. Similarly, should a cylinder
misfire occur, the unburnt fuel and unburnt oxygen
can cause a catalyst burn out.
CAUTION: The catalyst matrices are fragile
ceramic honeycombs which can become
damaged if roughly treated. Do not use a
hammer or mallet when working on the exhaust
system. 
						

							MANIFOLD AND EXHAUST SYSTEM
1
REPAIR INTERMEDIATE PIPE
Service repair no - 30.10.11
Remove
1.Raise vehicle on ramp [hoist].
2.Release intermediate pipe from mounting
rubber.
3.Remove 2 nuts securing intermediate pipe to tail
pipe.
4.Remove 2 nuts securing intermediate pipe to
front pipe.
5.Release intermediate pipe from front and tail
pipes and remove.
Refit
6.Fit intermediate pipe to front and tail pipes.
7.Secure intermediate pipe to mounting rubber.
8.Fit and tighten nuts securing intermediate pipe to
front pipe,
30 Nm, 22 lbf ft.
9.Fit and tighten nuts securing intermediate pipe to
tail pipe,
30 Nm, 22 lbf ft.
10.Lower vehicle.TAIL PIPE
Service repair no - 30.10.22
Remove
1.Raise vehicle on a ramp [hoist].
2.Remove 2 nuts securing tail pipe to intermediate
pipe.
3.Release tail pipe from mounting rubber.
4.Release tail pipe from intermediate pipe and
feed over rear axle.
5.Remove tail pipe.
Refit
6.Feed tail pipe over rear axle and connect to
intermediate pipe.
7.Secure tail pipe to mounting rubber.
8.Fit nuts and tighten tail pipe to intermediate pipe.
30 Nm, 22 lbf ft.
9.Lower vehicle. 
						

							MANIFOLD AND EXHAUST SYSTEM
1
SPECIFICATIONS, TORQUE TORQUE VALUES
MANIFOLDS AND EXHAUSTS - V8i
Nm lbf ft
Inlet manifold to cylinder head 38......................................... 28
Exhaust manifold to cylinder head 20................................... 15
Exhaust front pipe to manifold 45.......................................... 33
Exhaust front pipe to intermediate pipe 30............................ 22
Exhaust intermediate pipe to rear pipe 30............................ 22 
						

							TRANSFER GEARBOX
1
DESCRIPTION AND OPERATION LT230Q TRANSFER GEARBOX
Description
The LT230Q transfer gearbox is a permanent 4 wheel
drive, two speed ratio reducing gearbox, incorporating
high and low range outputs with mechanically lockable
centre differential (diff-lock). High/low range and
diff-lock selection are made via a single lever located
forward of the main gear lever.
The transfer gearbox is mounted at the rear of the
main gearbox, the mainshaft of which extends into the
transfer casing. A transfer gear, supported on taper
roller bearings and splined to the gearbox mainshaft,
passes the drive to an intermediate gear cluster
supported on a single shaft and rotating on taper roller
bearings.The intermediate gears pass the drive to high and low
speed gears on the rear output shaft. The rear output
shaft passes through the speed transducer drive
housing, which also forms the mounting for the park
brake. A worm gear fitted to the rear output shaft
drives a pinion fitted in the speed transducer housing.
Integral with the output shafts is a differential
assembly which compensates for speed differences
between the front and rear prop shafts. To prevent all
the power being transmitted to the axle offering the
least resistance, a diff-lock is provided. Selection of
differential lock engages, through mechanical linkage,
a dog clutch with the front output shaft, this action
locks the centre differential and provides a fixed drive,
giving equal power to the front and rear output shafts. 
						

							41TRANSFER GEARBOX
2
DESCRIPTION AND OPERATION The diff-lock should only be engaged during severe
off-road conditions and should be disengaged as soon
as conditions permit.
A shiftlock device, used as a park facility, is fitted and
prevents accidental gear disengagement when the
ignition is switched off. An audible neutral alarm is
also fitted to alert the driver, when parking, to move
the gear lever to the high or low position. 
						

							TRANSFER GEARBOX
1
FAULT DIAGNOSIS LT230Q 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.Bearing plate joint. 
						

							41TRANSFER GEARBOX
2
FAULT DIAGNOSIS OIL LEAKS
Verify that oil leak is from transfer box and not main
gearbox before proceeding with checks.
Prior to road test
1.Check oil level in transfer box is correct.
2.Check tightness of level and drain plugs.
3.Check breather system for blockage. To validate
system pipe must be removed, inspected,
rectified as necessary and refitted.
4.Remove all traces of oil from exterior of transfer
box.
Take vehicle for short road test.
1.Identify source of leaks and rectify as follows.
Front or rear output seal leaking:-
1.Drain oil and remove leaking output flange.
2.Inspect seal track on flange for surface damage.
If damaged renew component.
3.Remove and discard oil seal.
4.Inspect seal locating bore and remove any sharp
edges which may damage new oil seal.
5.Fit new seal.
6.Fit output flange and all other parts.
7.Add oil to correct level into gearbox.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
Cover plate sealant leaking.
1.Drain oil and remove leaking cover plate.
2.Remove all traces of joint sealant from both joint
faces.
3.Degrease all components and apply a thin film of
Hylomar sealant, 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 gearboxes.
1.Site vehicle onto a ramp [hoist].
2.Select neutral in transfer box and select 4th gear
in main gearbox.
3.Run engine at 2000 rpm with clutch/drive
engaged.
4.Observe joint between main and transfer boxes.
5.If oil leak is found establish if it is gear oil.
6.If so, leak is originating from transfer box.
7.Check two inner (main/transfer) bolts are oil
tight, as these holes are tapped into the main
transfer case.
8.Remove transfer box to inspect mainshaft collar
seal track condition, and front face of transfer
case for porosity.
See Repair, LT230Q
Transfer Gearbox
9.If these areas require servicing, transfer gearbox
input seal must also be renewed.
CAUTION: Avoid damaging new seal lip
and ensure seal is fitted flush with
machined face. Also ensure new seal is
not damaged when refitting transfer gearbox.
10.If red A.T.F type oil is seen leaking during
workshop test, investigate main gearbox for
cause of leak.
Detent plug or electrical switch leaks.
1.Detent plugs and electrical switches do not
usually leak. It must be noted that they fit into
open tapped holes in transfer case and therefore
should be considered when looking for source of
leak. 
						

							TRANSFER GEARBOX
1
REPAIR LT230Q TRANSFER GEARBOX
Service repair no - 41.20.25/99
Remove
The transfer gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
adaptor plateLRT-99-010.
WARNING: Where use of a transmission
hoist is necessary, it is absolutely
essential to follow the manufacturers
instructions to ensure safe and effective use of
the equipment.
1.Position vehicle on a ramp [hoist].
2.Select LOW range gear and leave vehicle in
neutral.
3.Disconnect battery negative lead.
4.Remove centre console.
See CHASSIS AND
BODY, Repair, centre console
5.Remove carpet from transmission tunnel.
6.Remove high-low selector housing cover from
transmission tunnel.
7.Remove 3 trim studs securing handbrake lever
gaiter.
8.Release handbrake lever gaiter for access to
handbrake cable linkage. 
						

							41TRANSFER GEARBOX
2
REPAIR
9.Remove split [cotter] pin and clevis pin securing
handbrake cable to lever.
10.Remove 2 screws securing fan cowl to upper
retaining brackets.
11.Release 2 clips securing upper fan cowl.
12.Remove upper fan cowl.
13.Raise ramp [hoist].
14.Drain transfer gearbox oil.
See SECTION 10,
Maintenance, under vehicle maintenance
15.Remove exhaust front pipe.See EMISSION
CONTROL, Repair, front pipe/catalytic
converter
16.Remove 2 nuts securing intermediate pipe to tail
pipe.
17.Release intermediate pipe from tail pipe and
remove from mounting.
18.Remove 8 bolts securing chassis crossmember.
19.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
20.Remove crossmember.
21.Remove body jack.