Land Rover Defender Workshop Rover Manual
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01INTRODUCTION 8 INFORMATION JUMP STARTING WARNING: Hydrogenandoxygen gases are produced duringnormal battery operation. Thisgasmixture canexplode if flames, sparksorlighted tobacco arebrought near battery. Whencharging orusing abattery in an enclosed space,always provide ventilation and shield youreyes. Keep outofreach ofchildren. Batteries contain sulphuric acid.Avoid contact withskin, eyes, or clothing. Also,shield eyeswhen working near battery toprotect against possible splashing of acid solution. Incase ofacid contact withskin, eyes, orclothing, flushimmediately withwater for a minimum offifteen minutes. Ifacid isswallowed, drink largequantities ofmilk orwater, followed by milk ofmagnesia, abeaten egg,orvegetable oil. SEEK MEDICAL AIDIMMEDIATELY. To Jump Start-Negative GroundBattery WARNING: Toavoid anypossibility of injury useparticular carewhen connecting a booster batterytoadischarged battery. 1. Position vehicles sothat jump leads willreach, ensuring thatvehicles DONOT TOUCH, alternatively afully charged slavebattery maybe positioned onfloor adjacent tovehicle. 2. Ensuring thatignition andallelectrical accessories areswitched off,that parking brake is applied andneutral isselected, connectthe jump leads asfollows; A. Connect oneendoffirst jumper cabletopositive (+) terminal ofbooster battery. B. Connect otherendoffirst jumper cabletopositive (+) terminal ofdischarged battery. C. Connect oneendofsecond jumpercableto negative terminalofbooster battery. D. Connect otherendofsecond jumpercabletoa good earth pointonthe disabled vehicle(eg.engine front lifting eye,asshown inJ6086), NOTTO NEGATIVE TERMINAL OFDISCHARGED BATTERY. Keepjumper leadaway frommoving parts, pulleys, drivebeltsandfanblade assembly. WARNING: Makingfinalcable connection could cause anelectrical arcwhich if made nearbattery couldcause an explosion. 3. Ifbooster batteryisinstalled inanother vehicle, start engine andallow toidle. 4. Start engine ofvehicle withdischarged battery, following startingprocedure inOwners Manual. CAUTION: Ifvehicle failstostart within a maximum timeof12 seconds, switch ignition offand investigate cause.Failing to follow thisinstruction couldresult in irrepairable damagetocatalyst, iffitted. 5. Remove negative (-)jumper cablefromthe engine andthen terminal ofbooster battery. 6. Remove positive(+)jumper cablefrompositive terminals ofbooster batteryanddischarged battery.
INTRODUCTION9 INFORMATION ABBREVIATIONS ANDSYMBOLS USEDINTHIS MANUAL Across flats(bolt size) AF ............................................ After bottom deadcentre ABDC ................................... After topdead centre ATDC ......................................... Alternating current a.c. ................................................. Ampere amp ................................................................ Ampere hour amphr .................................................... Before bottom deadcentre BBDC ................................ Before topdead centre BTDC ...................................... Bottom deadcentre BDC ............................................. Brake horsepower bhp ................................................ British Standards BS .................................................... Carbon monoxide CO .................................................. Centimetre cm ............................................................. Centigrade (Celsius) C ................................................ Cubic centimetre cm3 ................................................... Cubic inch in3 ............................................................... Degree (angle) degor° ............................................... Degree (temperature) degor° ..................................... Diameter dia. ............................................................... Direct current d.c. ......................................................... Electronic ControlUnit ECU ........................................ Fahrenheit F ................................................................. Feet ft ........................................................................... Feet perminute ft/min .................................................. Fifth 5th ........................................................................ First 1st ........................................................................ Fluid ounce floz .......................................................... Foot pounds (torque) lbfft ............................................ Fourth 4th ..................................................................... Gramme (force) gf ........................................................ Gramme (mass) g ........................................................ Gallons gal ................................................................... High tension (electrical) H.T. ........................................ Internal diameter I.D. ................................................... Inches ofmercury in.Hg .............................................. Inches in ...................................................................... Kilogramme (force) kgf ................................................. Kilogramme (mass.) kg ................................................ Kilogramme centimetre(torque) kgf.cm ....................... Kilogramme persquare millimetre kgf/mm2 ................. Kilogramme persquare centimetre kgf/cm2 ................. Kilogramme metres(torque) kgf.m .............................. Kilometres km .............................................................. Kilometres perhour 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 pergallon mpg .................................................... Miles perhour mph ...................................................... Minute (angle) ............................................................ Minus (oftolerance) - ................................................... Negative (electrical) - ................................................... Newton metres(torque) Nm ........................................ Number No. ................................................................. Ohms ohm ................................................................... Ounces (force) ozf ....................................................... Ounces (mass) oz ........................................................ Ounce inch(torque) ozf.in. .......................................... Outside diameter O.D. ................................................. Part number PartNo. ................................................... Percentage % ............................................................... Pints pt ......................................................................... Plus (tolerance) + ......................................................... Positive (electrical) + .................................................... Pound (force) lbf .......................................................... Pounds inch(torque) in.lbf. .......................................... Pound (mass) lb ........................................................... Pounds persquare inch P.S.I. ..................................... Ratio : ........................................................................... Reference ref. .............................................................. Revolution perminute rev/min ..................................... Right-hand RH ............................................................. Second (angle) ........................................................... Second (numerical order) 2nd ...................................... Specific gravity sp.gr. ................................................... Square centimetres cm2 ............................................... Square inches in2 ......................................................... Standard wiregauge 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 British Standard Pipe BSP ........................................... Unified Coarse UNC .................................................... Unified Fine UNF .........................................................
01INTRODUCTION 10 INFORMATION CROSS REFERENCE OFEMISSION SYSTEM TERMINOLOGY NEW TERM (ACRONYM) Accelerator pedal (AP) ................................................. Air cleaner (ACL) .......................................................... Air conditioning (AC) .................................................... Battery positive voltage (B+) ........................................ Closed loop (CL) .......................................................... Closed throttleposition (CTP) ...................................... Canister purgevalve (CANPV) .................................... Data linkconnector (DLC) ........................................... Diagnostic troublecode (DTC) ..................................... Distributor ignition (DI) ................................................. Engine controlmodule (ECM) ...................................... Engine coolant level (ECL) ........................................... Engine coolant temperature (ECT) .............................. Engine coolant temperature sensor (ECTS) ................ Engine speed (RPM) .................................................... Evaporative emissionsystem (EVAP) .......................... Engine fueltemperature sensor (EFTS) ...................... 4th gear, 3rdgear etc. (4GR,3GR) .............................. Fuel pump (FP) ............................................................ Fan control module (FCM) ........................................... Generator (GEN) .......................................................... Ground (GND) .............................................................. Heated oxygen sensor (H02S) .................................... Idle aircontrol (IAC) ...................................................... Idle aircontrol valve (IACV) ......................................... Ignition controlmodule (ICM) ....................................... Intake airtemperature (IAT) ......................................... Manifold vacuumzone (MVZ) ...................................... Mass airflow sensor (MAFS) ....................................... Open loop (OL) ............................................................ Relay module (RM) ...................................................... Solid staterelaymodule (SSRM) ................................. Three waycatalytic converter (TWC) .......................... Throttle body (TB) ........................................................ Throttle position sensor (TPS) ...................................... Transmission range (TR) .............................................. Wide openthrottle (WOT) ............................................ OLD TERM (ACRONYM) Throttle pedal (-) .......................................................... Air cleaner (-) ............................................................... Air conditioning (AC) .................................................... Battery plus,bat+,bat feed (B+) ................................. Closed loop (-) ............................................................. Closed throttle, idleposition (-) .................................... Charcoal canisterpurgevalve (-) ................................. Serial link (-) ................................................................ Fault code (-) ............................................................... Electronic ignition (-) .................................................... Electronic controlunit (ECU) ........................................ Coolant level (-) ........................................................... Coolant temperature (temp) ......................................... Coolant temperature thermistor (-) .............................. Engine speed (rev/min) ................................................ Evaporative losssystem (ELC) ................................... Fuel temperature thermistor (-) .................................... Fourth gear,3rdgear (-) .............................................. Fuel pump (-) ............................................................... Condenser fantimer (-) ................................................ Alternator (-) ................................................................ Ground, earth (B-) ........................................................ Lambda (02)sensor (-) ................................................ Idle speed control (ISC) ................................................ Stepper motor (-) ......................................................... Ignition module (-) ........................................................ Intake temperature/ambient temperature (-) ................ Manifold depression, vacuum (-) ................................. Air flow meter (-) .......................................................... Fault codedisplay unit (-) ............................................ Open loop (-) ............................................................... Relay (-) ....................................................................... Control unit (-) .............................................................. Catalyst, catalyticconverter (CAT) .............................. Throttle housing (-) ...................................................... Transmission gear (-) ................................................... Full throttle, wideopen throttle (WOT) .........................
INTRODUCTION11 INFORMATION VEHICLE IDENTIFICATION NUMBER(VIN) The Vehicle Identification Numberandthe recommended maximumvehicleweights arestamped on aplate riveted tothe brake pedalboxinthe engine compartment. TheVINisalso stamped onaplate visible through theLHside ofthe windscreen, see J6088. A. Type approval B. Identification C. Maximum permittedladenweight forvehicle D. Maximum vehicleandtrailer weight E. Maximum roadweight-front axle F. Maximum roadweight-rear axle The number isalso stamped onthe RH side ofthe chassis tothe rear ofthe front lashing eye,seeJ6089. The Vehicle Identification Numberidentifies the manufacturer, modelrange, wheelbase,bodytype, engine, steering, transmission, modelyearandplace of manufacture. Thefollowing exampleshowsthe coding process. S A L LD HMF7TA SAL =World manufacturer identifier LD =Land Rover Defender H =110 inch, V= 90inch, K= 130 inch M =4door Station Wagon, A= 90 Soft Top, Hard Top, Pick-up, B= 2door Station Wagon, E= 2door 130 Crew cab,F= 4door 130Crew cab,H= 130 High Capacity Pick-up F = 2.5L (300Tdi) 7 = RH drive, 5speed manaul, 8= LH drive, 5speed manual T = 1996 MY,volume build,N= 1996 MY,non-volume buildA = Solihull build,F= CKD, assembled locallyfromkit
01INTRODUCTION 12 INFORMATION LOCATION OFIDENTIFICATION NUMBERS Engineserialnumber -300Tdi Engine The 300Tdi enginenumber isstamped onthe cylinder block onthe RH side ofthe engine abovethe camshaft frontcover plate. Maingearbox R380serial number Stamped onacast padonthe bottom RHside ofthe gearbox. Transfer gearboxLT230serialnumber The serial number isstamped onthe LHside ofthe gearbox casingbelowthemainshaft rearbearing housing adjacent tothe bottom cover,seeJ6092. Front axleserial number Stamped onthe front ofLH axle tube, inboard of radius armmounting bracket. Rearaxleserial number Stamped onthe rear ofLH axle tube, inboard of spring mounting.
INTRODUCTION13 INFORMATION FAULT DIAGNOSTIC EQUIPMENT TESTBOOK For Defender modelsfittedwiththevehicle Anti-theft Immobilisation andAlarm System, diagnostic equipment, namedTestBook, isavailable toassist in the diagnostic andfault finding abilities ofthe Dealer workshop. Adiagnostic connector, locatedunderthe front centre seat,orcubby box,asshown below,is provided tofacilitate theprocedures. Ifan exhaust gasrecirculation (EGR)system isfitted, this toocan bechecked usingTestBook. Adiagnostic connector, alsolocated underthefront centre seator cubby box,isprovided. Features ofTestbook include:- Fully upgradable supportforthe technician. Structured diagnostics toaccommodate allskill levels. Touch screen operation. Direct printoutofscreen information andtestresults. READING THISMANUAL This manual isdivided intosections shownonthe contents page,alongside arange oficons, familiar to service technicians. Relevant information iscontained withineachofthese sections. Thesearefurther divided intothefollowing sub-sections whichappear atthe foot ofeach page :- Description andoperation. Fault diagnosis. Adjustment. Repair.Overhaul.Specifications, Torque. To avoid repeating information throughthesections, where partofthe repair operation impactsonanother section, across reference isgiven todirect thereader to where theinformation issited. For example: The maintenance sectionstatestheneed torenew drive belt.Across reference sitesthisinformation in: Section 12Engine - Sub-section: Repairs - Heading: Drivebeltrenew.
GENERALSPECIFICATION DATA 1 INFORMATION 300Tdi ENGINE Type Directinjection, turbocharged, intercooled ................................................................................. Number ofcylinders 4 ......................................................... Bore 90,47mm ................................................................................. Stroke 97,00mm ............................................................................... Capacity 2495cc ........................................................................... Compression ratio 19.5:1±0.5:1 ............................................................ Valve operation O.H.V.pushrod operated ................................................................ Crankshaft Main bearing journaldiameter 63,475-63,487 mm .......................................... Regrind dimensions 63,233-63,246 mm ......................................................... Crankpin journaldiameter 58,725-58,744 mm ................................................ Regrind dimensions 58,471-58,490 mm ......................................................... Crankshaft endthrust Takenonthrust washers atcentre mainbearing ....................................................... Crankshaft endfloat 0,05-0,15 mm ......................................................... Main bearings Number andtype 5halved shellswithoilgrooves .............................................................. Diametrical clearance 0,0792-0,0307 mm ....................................................... Connecting rods Length between centres 175,38-175,43 mm ................................................... Diametrical clearance(big-endbearings) 0,025-0,075 mm ........................ End float oncrankpin 0,15-0,356 mm ....................................................... PistonsType Aluminiumalloy,combustion chamberincrown. ................................................................................. Graphitecoatingonsidewalls. Skirt diametrical clearance(atr/angle togudgeon pin)0,025-0,05 mm .... Maximum heightabove combustion face 0,8mm ......................... Gudgeon pins Type Fulyfloating ................................................................................. Fit inpiston Handpushfit ....................................................................... Diameter 30,156-30,163 mm .......................................................................... Clearance inconnecting rod 0,003-0,016 mm ............................................ Piston rings Type: -Top Barreledge,chrome plated ........................................................................ - Second Taperfaced .................................................................. - Oil control Expanderandrails .............................................................. Gap inbore: - Top 0,40-0,60 mm ........................................................................ - Second 0,30-0,50 mm .................................................................. - Oil control 0,30-0,60 mm .............................................................. Clearance inpiston grooves: - Second 0,050-0,085 mm .................................................................. - Oil control 0,050-0,085 mm ..............................................................
04GENERAL SPECIFICATION DATA 2 INFORMATION Camshaft Drive 30mm wide drytoothed belt ................................................................................. Location Righthandside(thrust side) ........................................................................... End float 0,1-0,2 mm ........................................................................... Number ofbearings 4 .......................................................... Material Steelshell, whitemetal lined ............................................................................ ValvesTappet clearance: - Inlet andexhaust 0,20mm ................................................... Seat angle: - Inlet 30° ....................................................................... - Exhaust 45° ................................................................. Head diameter: - Inlet 38,75-39,05 mm ....................................................................... - Exhaust 36,35-36,65 mm ................................................................. Stem diameter: - Inlet 7,960-7,975 mm ....................................................................... - Exhaust 7,940-7,960 mm ................................................................. Valve lift: - Inlet 9,67mm ....................................................................... - Exhaust 9,97mm ................................................................. Cam lift: - Inlet 6,81mm ....................................................................... - Exhaust 7,06mm ................................................................. Valve headstand down: - Inlet 0,81-1,09 mm ....................................................................... - Exhaust 0,86-1,14 mm ................................................................. Valve springs Type Singlecoil ................................................................................. Length, free 46,28mm ...................................................................... Length, under21kgload 40,30mm ................................................. LubricationSystem Wetsump, pressure fed ............................................................................. Pressure, enginewarmatnormal operating speeds 1,76-3,87Kgf/cm 2 (25 -55 Ibf/in 2 ) ........ Oil pump: -Type G-rotorintegral withfront cover. ...................................................................... - Drive offcrankshaft nose ..................................................................... Oil pressure reliefvalve Non-adjustable .................................................... Relief valvespring: - Full length 51,6mm ...................................................................... - Compressed lengthat7.71Kg load 31mm ................................ Oil filter Screw-ondisposable canister ............................................................................. Engine oilcooler Combinedwithcoolant radiator andintercooler ...............................................................
GENERALSPECIFICATION DATA 3 INFORMATION FUEL SYSTEM Fuel liftpump type Mechanicalwithhand primer ............................................................ Fuel liftpump pressure 42-55 Kgf/cm 2 (3 -4 lbf/in 2 ) at1800 rpm ..................................................... Fuel filter Paperelement indisposable canister .......................................................................... Air cleaner Paperelement type ........................................................................ COOLING SYSTEM System type Pressurised,spillreturn, thermostatically controlled ..................................................................... waterandantifreeze mixture. Pumpassisted thermo syphon. Coolantradiatorcombined withoilcooler and turbo intercooler. Cooling fan 11blade axialflow433mmdiameter, 1.29:1drive ....................................................................... ratio,withviscous coupling. Pump type Centrifugal,impellor,beltdriven ........................................................................ Thermostat opening 88°C ......................................................... Expansion tankcappressure 1,06Kgf/cm 2 (15 Ibf/in 2 ) (system pressure) ........................................... CLUTCH Type Valeodiaphragm spring ................................................................................. Centre platediameter 235mm ....................................................... Facing material VertoF202grooved ................................................................. Release bearing Balljournal ............................................................... TRANSMISSIONMain gearbox Type R380 Singlehelical constant mesh ....................................................................... Speeds 5forward, 1reverse, allsynchromesh ............................................................................. Transfer box Type LT230 Twospeed reduction onmain gearbox output.Front ...................................................................... andrear drive permanently engagedviaalockable differential Rear axle Type Spiralbevel, fullyfloating shafts ................................................................................. Ratio 3.54:1 .................................................................................
04GENERAL SPECIFICATION DATA 4 INFORMATION Front axle Type Spiralbevel, enclosed constantvelocityjoints,fully ................................................................................. floatingshafts,32°angularity ofuniversal jointonfull lock Ratio 3.54:1 ................................................................................. Propeller shafts Type, frontandrear Tubular51mm dia. .......................................................... Universal joints OpentypeHookes O3EHD ................................................................. STEERING Power steering box Make/type AdwestVaramatic -worm androller box ........................................................................ Ratio Variable:straightahead19.3:1onlock 14.3:1 ................................................................................. Steering wheelturns,lock-to-lock 3.375 .................................... Steering pump Make/type Hobourn-Eatonseries500 ........................................................................ Steering geometry Steering wheeldiameter 412mm(16.22 in) .................................................. Toe-out measurement 0to 2 mm toeout ...................................................... Toe-out included angle 0° to 0° 20 ..................................................... Camber angle 0° * .................................................................. Castor angle 3° * ..................................................................... Swivel pininclination static 7° * ............................................... *Check withvehicle onlevel ground, inunladen condition andfivegallons offuel. Rock thefront ofthe vehicle upand down toallow itto take upanormal static position. Turning circlebetween kerbs 90 models: 265/75 x16 tyres 12,65m(41.5 ft) .............................................................. All other tyres 11,70m(38.4 ft) ................................................................... 110 models: 750 x16 tyres 13,41m(44 ft) .................................................................. 130 models: 750 x16 tyres 15,24m(50 ft) ..................................................................