Land Rover Defender Workshop Rover Manual
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BRAKES15 REPAIR TRANSMISSION BRAKE 1. Pin 2. Washer 3. C clip 4. Brake shoe 5. Cable lever 6. Hold down spring 7. Dished washer 8. Brake drum 9. Screw 10. Brake cable 11. Adjuster slide 12. Aadjuster nut 13. Spring 14. Adjuster slide 15. Adjuster bolt 16. Dished washer 17. Hold down spring 18. Brake shoe 19. Hold down pin 20. Hold down pin 21. Abutment plate 22. Back plate 23. Spring
70BRAKES 16 REPAIR TRANSMISSION BRAKESHOES Service repairno-70.45.18 Remove 1. Park vehicle onlevel ground, chockroadwheels and release handbrake. Alternatively, raise vehicle onaramp. 2. Disconnect rearpropeller shaftfrom transmission outputflangeatbrake drum. 3.Slacken offtransmission brakedrumadjustment bolt. 4. Remove singlescrewsecuring brakedrumto output flange. 5. Withdraw drumtoexpose brakeassembly. 6. Release topand bottom springs frombrake shoes, seeJ6337. 7. Grip dished washer withapair ofpliers, depress washer andturn through 90°. 8. Remove dishedwasher, complete withhold down spring andpinfrom bothshoes. 9. Move brake shoes outfrom adjuster slides, release fromabutment plateandremove from backplate. 10. Check thatsprings aresatisfactory forcontinued use. Ifnew brake shoes aretobe fitted, the srings should alsoberenewed. Refit 11. Locate RHbrake shoeinslide andsecure brake shoe andlever assembly tobackplate withhold down pin,spring anddished washer. 12. Locate LHbrake shoeinslide andfitabutment plate between bothbrake shoes. Secure LH shoe withhold down pin,spring anddished washer. 13. Fitpull-off springs tobrake shoes. 14. Fitbrake drum. Tighten screwto 25Nm (18 lbf/ft). 15. Check thathand brake leverisreleased. 16. Screw inand tighten adjuster boltuntil brake drum willnot rotate byhand. 17. Tighten adjuster boltto 25Nm (18lbf/ft)to ensure brakedrumislocked. 18. Slacken offadjuster boltby1.5 turns togive shoes arunning clearance. Checkthatthedrum is free torotate. 19. Fitpropeller shafttooutput flange. Tighten fixings to 46Nm (34lbf/ft). 20. Remove wheelchocks andcheck operation of handbrake.
BRAKES17 REPAIR HANDBRAKE CABLE Service repairno-70.35.25 Remove 1. Park vehicle onlevel ground, chockroadwheels and release handbrake. Alternatively, raise vehicle onramp. 2. Remove 3trim studs andliftup handbrake gaiter. 3. Remove splitpin,clevis pin,washer and disconnect cablefromhandbrake lever. 4. Slacken offtransmission brakedrumadjusting screw. 5. Disconnect propellershaftfromoutput flange. 6. Remove retaining screwandwithdraw brake drum. 7. Release handbrake cableclevis fromabutment on cable lever, seeJ6337, andpullthrough aperture inback plate. 8. Pull cable fromheelboard andremove from vehicle. Refit 9. Feed newcable through heelboard ensuring rubber grommet iscorrectly located. 10. Position cableoverguide plate,insertthrough backplate andconnect tocable lever. 11. Fitcable tohandbrake leverandsecure with clevis pinand split pin. 12. Fithandbrake gaiter. 13. Fitbrake drum. Tighten screwto 25Nm (18 lbf/ft). 14. Screw inand tighten adjuster boltuntil brake drum willnot rotate byhand. 15. Tighten adjuster boltfurther to 25Nm (18lbf/ft) toensure brakedrumislocked. 16. Slacken offadjuster boltby1.5 turns togive brake shoes running clearance. Checkthatthe drum isfree torotate. 17. Slacken locknutandadjust cabletogive the handbrake pawltwonotches freemovement on the rachet before beingfullyoperational onthird notch (brake shoesarefully expanded against drum). NOTE: Cableadjustment isfor anew cable or tocompensate forcable stretch. Cable adjustment mustnotbeused totake up brake shoewear. 18. Fitpropeller shafttooutput flange. Tighten fixings to 46Nm (34lbf/ft). 19. Remove wheelchocks andcheck operation of handbrake.
70BRAKES 18 REPAIR VACUUM PUMP Service repairno-70.50.19 Remove NOTE: Toease pump removal setengine to T.D.C. onNo.1 cylinder. 1. Disconnect battery. 2. Remove aircleaner See FUEL SYSTEM, Repair, Aircleaner . 3.Detach servohosefromvacuum pump. 4. Remove boltsecuring aircleaner support bracket strut. 5. Remove 6bolts securing vacuumpump. 6. Detach pumpcomplete withstrut andharness bracket. Notelocation ofstrut andbracket for Refit. Refit 7. Clean mating facesofpump andblock. 8. Loosely assemble pumptoblock withanew gasket andwith aircleaner strutandharness bracket locatedunderheads ofbolts noted during Remove. 9. Evenly tightenbolts,todepress pumpplunger, finally tightening to 25Nm (18lbf/ft). 10. Secure struttoair cleaner bracket. 11. Connect vacuumhoseandsecure withclip. 12. Refit aircleaner See FUEL SYSTEM, Repair, Air cleaner .
BRAKES1 OVERHAUL Key tomaster cylinder 1. Water ingress seal 2. Transfer housing 3. Vacuum seal 4. Guide ring 5. Retaining ring 6. O ring seal 7. Primary plungerassembly 8. Lseal 9. Secondary plunger 10. Washer 11. Recuperating seal(primary cup) 12. Seal retainer 13. Springs 14. Swirl tube 15. Master cylinder body 16. Reservoir seals 17. Reservoir 18. Low fluidlevel switch andcap
70BRAKES 2 OVERHAUL MASTER CYLINDER Service repairno-70.30.09 Before starting overhaul procedure refertogeneral brake service practice SeeRepair, General brake service practice . Dismantling mastercylinder 1. Disconnect batteryandremove mastercylinder from servo SeeRepair, Mastercylinder. 2. Before commencing overhaulprocedure thoroughly cleanmaster cylinder andinspect outer surfaces fordamage andcondition, renew complete assembly ifnecessary. 3. The reservoir isapush fitin master cylinder and secured byseals. Carefully easereservoir from master cylinder byrolling itfrom seals as illustrated. 4. Using softjaws, oneeither sideofmaster cylinder flangeandclamp flange inasuitable vice. Remove wateringress Oring seal from master cylinder toservo flange anddiscard. 5.Hold outside oftransfer housing withasuitable pair ofgrips, carefully pull,while working pliersin a backwards andforwards rockingmotionto ease housing offmaster cylinder, discard housing andvacuum seal. 6.Withdraw 2reservoir sealsfrommaster cylinder and note theirpositions ininlet ports for reassembly. Discardbothseals. 7. Remove retaining ringand Oring seal from machined outersurface ofmaster cylinder, discard bothsealandretaining ring.
BRAKES3 OVERHAUL 8. Remove guideringfrom mouth ofmaster cylinder whichsupports primaryplunger assembly andplace toone side, thiscomponent is not part ofmaster cylinder servicekitand isto be refitted onassembly ofunit. 9. Pull primary plunger assembly outofmaster cylinder. NOTE: Theprimary plunger assembly cannot bebroken downanyfurther andis serviced asacomplete unit.Discard assembly. 10. The secondary plungerassembly willremain at bottom ofmaster cylinder bore,plunger canbe easily expelled bytapping assembly onapiece of timber untilplunger appears atcylinder mouth, carefully pullplunger frommaster cylinder. 11.Ifswirl tubewasnotexpelled atsame timeas secondary plunger,repeataboveoperation to expel itfrom bottom ofmaster cylinder boreand discard. 12. Clean allparts withGirling cleaning fluidor unused brakefluidandplace cleaned partsonto a clean sheet ofpaper. Inspect cylinder boreand plungers forsigns ofcorrosion, ridgesandscore marks. Provided workingsurfaces areinperfect condition, newseals fromaGirling Service repair kitmay beused. Renewing secondary plungerseals A.Springs B. Seal retainer C. Recuperating seal(primary cup) D. Washer E. L seal 13. Remove components abovefromsecondary plunger anddiscard: NOTE: Asmall screwdriver withend rounded andpolished isrequired to remove Lseal. DONOT damage secondary plunger. 14.Coat newseals inunused brakefluidandfirstly fit L seal toplunger. 15. Fitwasher followed byrecuperating seal.Fitseal retainer andsprings, ensuresprings are correctly seated.
70BRAKES 4 OVERHAUL Assembling mastercylinder CAUTION: Itis important thatthefollowing instructions arecarried outprecisely, otherwise damagecouldbecaused tonew seals when inserting plungers intocylinder bore. Generous amountsofnew brake fluidshould be used tolubricate partsduring assembly. NOTE:Thoroughly checkthatnodebris is lodged influid passageways anddrillings. If debris isfound, carefully remove, re-clean cylinderandre-check. 16. Fitnew swirl tubetobottom ofcylinder bore. 17.Lubricate secondary plungerandcylinder bore. Offer plunger assembly tocylinder until recuperation sealisresting centrally inmouth of bore. Gently introduce plungerwithacircular rocking motion, asillustrated. Ensuringthatseal does notbecome trapped, easesealintobore and slowly pushplunger downboreinone continuous movement. 18. Fitprimary plunger assembly usingsame method asfor secondary plunger,pushplunger down bore. 19. Fitoriginal guideringtosupport primaryplunger. 20. Coat anew Oring with brake fluidandfitto its respective grooveonouter location surfaceof master cylinder. CAUTION: Oring should notberolled down outerlocation surfaceofmaster cylinder butshould beslightly stretched and eased downcylinder andinto itsgroove. Do not over stretch seal. 21. Fitanew retaining ringonouter surface of master cylinder ensuring thatserrations ofring are facing mounting flange. 22. Fittwo new reservoir sealsintheir respective ports. 23. Fitanew vacuum sealtoeither primary plunger or tobottom oftransfer housing bore,openface of seal towards primaryplunger guidering. 24. Lubricate vacuumsealwithbrake fluid,fit transfer housing tomaster cylinder, push housing fullyuptocylinder mounting flange.Do not adjust transfer housing afterfitting. 25. Lubricate anew water ingress sealwithbrake fluid, slightly stretchsealandease itdown housing untilseal isin correct position between housing andflange. 26. Roll reservoir intotopofmaster cylinder, reversing procedure describedininstruction 3. 27. Fitmaster cylinder toservo See Repair, Master cylinder . 28. Reconnect battery,androad testvehicle.
WHEELSANDTYRES 1 DESCRIPTION ANDOPERATION TYPES OFWHEEL RIMSANDTYRES Description Dependent onspecification andmodel type,the vehicle isequipped withpressed steeloralloy wheel rims, bothusing tubeless radialplytyres. Tyre codes The text, codes andnumbers mouldedintothetyre wall vary between tyremanufacturers, howevermost tyres aremarked withtheinformation showninthe illustrated example. NOTE:Theillustration isan example ofthe type ofmarkings mouldedintotyres andis for guidance only.Forspecific tyre specifications See GENERAL SPECIFICATION DATA, Information, Tyresizeandpressures . 1. Type oftyre construction -Radial Ply 2. Load index -104 3. Speed symbol -So rT 4. USA Tyrequality grading -Tread wear160 Traction Atemperature B 5. Tread wearindicators mouldedintotread pattern are located atintervals aroundthetyre and marked byacode -E66 103S6 6. Tyres withMud Snow typetread pattern are marked -M&S 7. Tyre reinforcing mark-Reinforced 8. USA Load andpressure secification - (900Kg(1984LBS) at340KA (50PSI) MACS PRESS 9. Tyre size-205 16ot235/70 R16 10. Type oftyre -TUBELESS 11. Country ofmanufacture -MADE INGREAT BRITAIN 12. USA Compliance symbolandidentification - DOT AB7C DOFF267 13. European typeapproval identification -E11 01234 14. Tyre construction -SIDE WALL 2PLIES RAYON. TREAD2RAYON 2STEEL 15. Manufacturers brandname/type -TRACTION PLUS mzxM
WHEELSANDTYRES 1 FAULT DIAGNOSIS TYRE WEAR CHART FAULT CAUSE REMEDY Rapid wearat Tyresunder-inflated Inflatetocorrect pressure shoulders Wornsuspension components Replaceworncomponents i.e. ball joints, panhard rod bushes, steering damper Excessive corneringspeeds Rapid wearat centre Tyres over-inflated Inflatetocorrect pressure of tread Wear atone shoulder Track outofadjustment Adjusttracktocorrect figure Bent panhard rod Checkandreplace wornordamaged components Bald spots ortyre Wheeloutofbalance Balancewheelandtyre cupping assembly Excessive radialrunout Checkrunoutandreplace tyre if necessary Shock absorber worn Replaceshockabsorber Excessive braking Tyre scalloped Trackoutofadjustment Adjusttoetocorrect figure Worn suspension components Replacetyreasnecessary Excessive corneringspeeds CAUTION: Thisdiagnosis chartisfor general guidance onlyanddoes notnecessarily include every cause ofabnormal tyrewear.