Land Rover Defender Workshop Rover Manual

AMENDMENTINSTRUCTION SHEET
DEFENDER WORKSHOP MANUAL
Publication NumberLRL0097ENG
Amendment Number:LD003.97 Date:09/97
To ensure thatthismanual iskept uptodate andthatarecord ofamendments tothis manual isavailable, an
Amendment InstructionSheetwillbeissued witheach setofrevised pages.
TheTitle page ofthe Manual isre-issued, andthePart No.has been raised tothe next edition. Exceptforthe
Contents pages,allrevised andnew pages havetheissue dateatthe foot ofeach page, together withan
indication ofwhether...

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Workshop
manual
DEFENDER 300Tdi
This manual coversvehicles from
1996 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNINGDATA
07 GENERAL FITTINGREMINDERS
09 LUBRICANTS, FLUIDSANDCAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
19 FUEL SYSTEM Tdi
26 COOLING SYSTEMTdi
30 MANIFOLD ANDEXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLEANDFINAL DRIVE
54 FRONT AXLEANDFINAL...

INTRODUCTION1
INFORMATION
INTRODUCTION This
workshop manualcoversvehicles from1996
model yearonwards. Amendments andadditional
pages willbeissued toensure thatthemanual covers
latest models. Amendments andadditions willbe
identified bythe addition ofadated footer atthe
bottom ofthe page.
This Workshop Manualisdesigned toassist skilled
technicians inthe efficient repairandmaintenance of
Land Rover Defender 300Tdivehicles.
Individuals whoundertake theirownrepairs should
have some skilland training,...

01INTRODUCTION
2 INFORMATION
FUEL
HANDLING PRECAUTIONS
The following information providesbasicprecautions
which mustbeobserved iffuel isto be handled safely.
It also outlines theother areas ofrisk which mustnot
be ignored.
This information isissued forbasic guidance only,and
in any case ofdoubt, appropriate enquiriesshouldbe
made ofyour local FireOfficer orFire Department.
Fuel vapour ishighly flammable andinconfined
spaces isalso very explosive andtoxic andwhen
diluted withairbecomes areadily ignitable...

INTRODUCTION3
INFORMATION
SYNTHETIC
RUBBER
Many 0ring seals, flexible pipesandother similar
items which appear tobe natural rubberaremade of
synthetic materials calledFluoroelastomers. Under
normal operating conditions thismaterial issafe, and
does notpresent ahealth hazard. However, ifthe
material isdamaged byfire orexcessive heat,itcan
break downandproduce highlycorrosive Hydrofluoric
acid which cancause serious burnsoncontact with
skin. Should thematerial beinaburnt oroverheated
condition...

01INTRODUCTION
4 INFORMATION
ACCESSORIES
ANDCONVERSIONS
DO NOT FITunapproved accessoriesorconversions,
as they could affect thesafety ofthe vehicle.
Land Rover willnot accept liability fordeath, personal
injury, ordamage toproperty whichmayoccur asa
direct resultofthe fitting ofnon-approved conversions
to the vehicle.
WHEELS ANDTYRES
WARNING: DONOT replace theroad
wheels withanytype other thangenuine
Land Rover wheels whicharedesigned for
multi-purpose onand offroad useand have very
important...

INTRODUCTION5
INFORMATION
JACKING The
following instructions mustbecarried outbefore
raising thevehicle offthe ground.
1. Use asolid levelground surface.
2. Apply parking brake.
3. Select 1stgear inmain gearbox.
4. Select Lowrange intransfer gearbox.
CAUTION: Toavoid damage occurring to
the under bodycomponents ofthe vehicle
the following jackingprocedures mustbe
adhered to.
DO NOT POSITION JACKSORAXLE STANDS
UNDER THEFOLLOWING COMPONENTS.
Body structure
Bumpers Fuel lines
Brake lines
Front radius arms...

01INTRODUCTION
6 INFORMATION
3.
Position anaxle stand under righthand axle
tube, carefully lowerjackuntil axle sitssecurely
on both axlestands, remove trolleyjack.
4. Before commencing workonunderside of
vehicle re-check securityofvehicle onstands.
5. Reverse procedure whenremoving vehiclefrom
stands.
Raise rearofvehicle
1. Position cupofhydraulic armunder differential
casing.
2. Raise vehicle toenable axlestands tobe
installed underleftand right hand axletubes.
3. Lower jackuntil axle sitssecurely...

INTRODUCTION7
INFORMATION
TOWING
CAUTION:
Thevehicle haspermanent
four-wheel drive.Thefollowing towing
instructions mustbeadhered to:
Towing thevehicle onallfour wheels withdriver
operating steeringandbrakes.
1. Turn ignition keytoposition 1torelease
steering lock.
2. Select neutral inmain gearbox andtransfer
gearbox.
3. Secure towrope, chain orcable tofront towing
eyes (alternative typesshown).
4. Release theparking brake.
CAUTION: Thebrake servoandpower
assisted steeringsystemwillnotbe
functional...