Land Rover Defender V8i Workshop Supplement Rover Manual
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57STEERING 4 REPAIR Refit 15.Clean mating faces of PAS pump and engine. 16.Fit PAS pump and engine lifting bracket to engine. 17.Fit and tighten bolts securing PAS pump to engine to 35 Nm (26 lbf.ft). 18.Remove plugs. 19.Connect PAS pipe to pump and tighten union to 20 Nm (15 lbf.ft). 20.Connect PAS hose to pump and secure with clip. 21.Position pulley to PAS pump. 22.Coat threads of PAS pump pulley bolts with Loctite 242. 23.Restrain pulley using Allen key and tighten bolts to 10 Nm (7 lbf.ft). 24.Fit drive belt.See ELECTRICAL, Repair, Auxiliary drive belt; Refit 25.Reconnect battery negative lead. 26.Bleed power steering system. See Adjustment, power steering system - bleed 27.Remove container.
STEERING 5 REPAIR STEERING LOWER SHAFT Service repair no - 57.40.25 Remove 1.Set road wheels and steering wheel in straight ahead position. 2.Loosen clip securing air inlet hose to MAF sensor. 3.Loosen clip securing air inlet hose to plenum chamber. 4.Remove air inlet hose. 5.Mark relationship of steering column inner shaft to top universal joint. 6.Remove 2 bolts from top universal joint. 7.Remove lower bolt from bottom universal joint. 8.Loosen upper bolt from bottom universal joint. 9.Remove steering shaft and collect universal joints. 10.Inspect universal joints for wear and excessive play. Renew if necessary. 11.Inspect universal joints for stiffness. Lubricate if necessary.Refit 12.Fit universal joints to steering shaft so pinch bolts line up with flats on shaft. 13.Fit steering shaft assembly to steering column and steering box. 14.Align bolt holes with grooves in splines. Fit pinch bolts and tighten to 25 Nm (18 lbf.ft). 15.Fit air inlet hose between plenum chamber and MAF sensor. 16.Tighten clips securing hose to plenum chamber and MAF sensor.
STEERING 1 SPECIFICATIONS, TORQUE TORQUE VALUES Nm lbf.ft Drag link to drop arm 40........................................................ 30 Ball joint nuts 40.................................................................... 30 Clamp bolt nuts 14................................................................ 10 Steering column bracket nuts 22........................................... 16 Steering wheel nut 50........................................................... 37 Tie bar to mounting nut - initial torque 80.............................. 60 Tie bar to mounting nut - final torque 110............................... 80 Universal joint pinch bolt 25.................................................. 18 PAS box Adjuster locknut 60....................................................... 45 Drop arm nut 175........................................................... 130 Sector shaft cover to steering box 75........................... 55 Steering box to chassis 80........................................... 60 Steering box fluid pipes 14mm thread 15..................... 11 Steering box fluid pipes 16mm thread 20..................... 15 Tie bar 81..................................................................... 60 Adjuster grub screw 5................................................ 4 PAS pump High pressure fluid pipe 20.......................................... 15 Power steering pump mounting 35.............................. 25 Pulley bolts, power steering pump 10.......................... 7 Hose clamp 3............................................................. 2 Front clamping bracket bolts 9................................... 7 PAS reservoir Hose clamp 3............................................................. 2 The following Torque values are for screws and bolts that are not specified. METRIC Nm lbf.ft M5 6........................................................................... 4.5 M6 9........................................................................... 7 M8 25........................................................................... 18 M10 45......................................................................... 33 M12 90......................................................................... 65 M14 105......................................................................... 77 M16 180......................................................................... 133 UNC / UNF 1/4 9........................................................................... 7 5/16 24......................................................................... 18 3/8 39........................................................................... 29 7/16 78......................................................................... 58 1/2 90........................................................................... 65 5/8 135........................................................................... 100
70 - BRAKES CONTENTS Page REPAIR GENERAL BRAKE SERVICE PRACTICE 1........................................................... FLUID LEVEL CHECK / TOP-UP 1......................................................................... BRAKE SYSTEM BLEED 2.....................................................................................
BRAKES 1 REPAIR GENERAL BRAKE SERVICE PRACTICE Brake fluid precautions WARNING: Do not allow brake fluid to come into contact with eyes or skin. CAUTION: Brake fluid can damage paintwork, if spilled wash off immediately with plenty of clean water. CAUTION: Use only correct grade of brake fluid. If an assembly fluid is required use ONLY brake fluid. Do NOT use mineral oil, i.e. engine oil etc. CAUTION: Thoroughly clean all brake calipers, pipes and fittings before commencing work on any part of the brake system. Failure to do so could cause foreign matter to enter the system and cause damage to seals and pistons which will seriously impair the efficiency of the brake system. To ensure the brake system efficiency is 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. ·DO NOT flush the brake system with any fluid other than the recommended brake fluid. The brake system should be drained and flushed at the recommended service intervals. Cover all electrical terminals carefully to make absolutely certain that no fluid enters the terminals and plugs.FLUID LEVEL CHECK / TOP-UP WARNING: Clean reservoir body and filler cap before removing cap. Use only fluid from a sealed container. 1.Park vehicle on level ground. 2.Check level is between MIN and MAX marks. 3.If level is below MIN mark top up fluid level to MAX mark on reservoir, using correct fluid. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Brake fluid reservoir CAUTION: Do not fill reservoir above maximum line.
70BRAKES 2 REPAIR BRAKE SYSTEM BLEED Service repair no - 70.25.02 Preparation WARNING: Before bleeding the brake system refer to general brake service practice. See General Brake Service Practice ·During bleed procedure, brake fluid level must not be allowed to fall below the MIN level. Keep reservoir topped up to the MAX level. ·To bleed the hydraulic circuits, four bleed nipples are provided, one at each caliper. ·There are two methods by which air can be removed from the braking system:- 1. MANUAL BLEED PROCEDURE. 2. PRESSURE BLEED PROCEDURE. Pressure bleed procedure Purpose designed equipment for pressure filling and bleeding of hydraulic systems may be used on Land Rover vehicles. The equipment manufacturers instructions must be followed and the pressure must not exceed 4.5 bar (65 lbf/in 2). Manual bleed procedure Equipment required ·Clean glass receptacle ·Bleed hose ·Wrench ·Approx 2 litres (3.5 pints) brake fluid See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids Master cylinder bleed 1.Disconnect battery. 2.Depress brake pedal fully and slowly 5 times. 3.Release the pedal and wait for ten seconds. 4.Air bubbles will rise into the reservoir during these instructions. 5.Repeat instructions until a firm resistance is felt at the pedal. Complete circuit bleed 1.Fit bleed hose to any caliper bleed screw. 2.Dip free end of bleed hose into brake fluid in bleed bottle. 3.Open bleed screw of caliper. 4.Depress brake pedal fully several times until fluid is clear of air bubbles. 5.Keeping pedal fully depressed, tighten bleed screw, then release pedal. 6.Repeat the above procedure on remaining 3 calipers. 7.Fit all bleed screw protection caps. 8.Check/top-up fluid level when bleeding is complete. See Fluid Level Check / Top-Up
76 - CHASSIS AND BODY CONTENTS Page ADJUSTMENT DOOR LOCK STRIKER - ADJUST 1...................................................................... TAIL DOOR STRIKER - ADJUST 1........................................................................ REPAIR REAR SEAT BELTS 1............................................................................................. FRONT SEAT BELTS 2.......................................................................................... SIDE TRIM PANEL 3.............................................................................................. LOWER FASCIA PANEL (HEATER DUCT) ASSEMBLY 4.................................... EXTERIOR ROLL-OVER BAR 7............................................................................. INTERIOR ROLL-OVER BAR 8.............................................................................. REAR SPEAKER PANEL 9..................................................................................... REAR TOW BAR 10................................................................................................ CENTRE CONSOLE 11.......................................................................................... RADIATOR GRILLE 12........................................................................................... GRILLE PANEL 12.................................................................................................. BONNET 13............................................................................................................