Land Rover Defender V8i Workshop Supplement 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. 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, 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 10M0490),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 negative (-) 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........................................ Electronic Fuel Injection EFI........................................ 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........................................................ Outside diameter O.D.................................................. Part number Part No.................................................... Percentage %............................................................... Pints pt......................................................................... Plus (tolerance) +......................................................... Positive (electrical) +.................................................... Pound (force) lbf.......................................................... Pounds inch (torque) lbf.in........................................... 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 American Standard Taper Pipe NPTF......................... 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)....................................... Inertia fuel shut-off (IFS).............................................. Inertia fuel shut-off switch (IFSS)................................. Intake air temperature (IAT)......................................... Malfunction indicator lamp (MIL).................................. Manifold vacuum zone (MVZ)...................................... Mass air flow sensor (MAFS)....................................... Multiport fuel injection (MFI)........................................ On board diagnostic (OBD).......................................... Open loop (OL)............................................................ Park/neutral position (PNP)......................................... Park/neutral position switch (PNPS)............................ Programmable read only memory (PROM).................. Relay module (RM)...................................................... Service reminder indicator (SRI).................................. Solid state relay module (SSRM)................................. Three way catalytic converter (TWC).......................... Throttle body (TB)........................................................ Throttle position sensor (TPS)...................................... Torque converter clutch (TCC).................................... Transmission range (TR).............................................. Transmission range selector (TRS)............................. Vehicle speed sensor (VSS)........................................ 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 (-)........................................................ Inertia switch (-)........................................................... Inertia switch (-)........................................................... Intake temperature/ambient temperature (-)................ EFI warning lamp (-).................................................... Manifold depression, vacuum (-)................................. Air flow meter (-).......................................................... Electronic fuel injection (EFI)....................................... Fault code display unit (-)............................................ Open loop (-)............................................................... Park or neutral (-)......................................................... Start inhibit switch (-)................................................... Chip, PROM (PROM)................................................... Relay (-)....................................................................... Check engine light (-)................................................... Control unit (-).............................................................. Catalyst, catalytic converter (CAT).............................. Throttle housing (-)...................................................... Throttle potentiometer (-)............................................. Direct drive clutch (DDC).............................................. Transmission gear (-)................................................... Shift lever, shifter (-).................................................... Road speed transducer (-)........................................... 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. SAL LD V B M 3 W A SAL= World manufacturer identifier LD= Land Rover Defender V= 90inch B= 2 door Station Wagon M= 4.0 V8i 3= RH drive auto W= 1998 MY, volume build A= Solihull build
01INTRODUCTION 12 INFORMATION LOCATION OF IDENTIFICATION NUMBERS Engine serial number - V8i Engine Stamped on a cast pad on the cylinder block, between numbers 3 and 5 cylinders. NOTE: The appropriate engine compression ratio is stamped above the serial number. Automatic gearbox serial number The serial number is stamped on a plate attached to the LH side of the casing. Transfer gearbox 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.
INTRODUCTION 13 INFORMATION 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.
01INTRODUCTION 14 INFORMATION FAULT DIAGNOSTIC EQUIPMENT TESTBOOK Land Rover Vehicles are equipped with substantial electronics to provide the best performance from the vehicle systems. Diagnostic equipment named TestBook is available to expand the diagnostic and fault finding abilities of the Dealer workshop. A diagnostic connector, located below the passenger compartment fuse box, is provided to facilitate the procedures. This repair manual is produced with TestBook in mind. Features of TestBook include:- ·Fully upgradable support for the technician. ·Structured diagnostics to accomodate 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.
04 - GENERAL SPECIFICATION DATA CONTENTS Page INFORMATION ENGINE 4.0 V8i 1................................................................................................... ENGINE MANAGEMENT SYSTEM (GEMS) 3....................................................... COOLING SYSTEM 4............................................................................................. AUTOMATIC TRANSMISSION 5............................................................................ SHIFT SPEEDS - AUTOMATIC ZF 6...................................................................... STEERING 7........................................................................................................... SUSPENSION 7...................................................................................................... BRAKES 8............................................................................................................... AIR CONDITIONING 9............................................................................................ WIPER MOTORS 9................................................................................................. ELECTRICAL 10..................................................................................................... BULBS 11............................................................................................................... VEHICLE WEIGHTS AND PAYLOAD 12................................................................ TOWING WEIGHTS 12........................................................................................... OFF-ROAD PERFORMANCE 13............................................................................ WHEELS AND TYRES 14....................................................................................... VEHICLE DIMENSIONS 14....................................................................................