Land Rover Defender Workshop Rover Manual
Have a look at the manual Land Rover Defender Workshop Rover Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 364 Land Rover manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
GENERALFITTINGREMINDERS 1 INFORMATION GENERAL FITTINGREMINDERS WORKSHOP SAFETYISYOUR RESPONSIBILITY! The suggestions, cautionsandwarnings inthe section areintended toserve asreminders for trained andexperienced mechanics.Thismanual is not adefinitive guidetoautomotive mechanics or workshop safety. Shop equipment, shopenvironment, andtheuse and disposal ofsolvents, fluids,andchemicals are subject togovernment regulationswhichare intended toprovide alevel ofsafety. Itis your responsibility toknow andcomply withsuch regulations. PRECAUTIONS AGAINSTDAMAGE 1. Always fitcovers toprotect fenders before commencing workinengine compartment. 2. Cover seatsandcarpets, wearclean overalls and wash hands orwear gloves beforeworking inside vehicle. 3. Avoid spilling hydraulic fluidorbattery acidon paint work. Wash offwith water immediately if this occurs. UsePolythene sheetstoprotect carpets andseats. 4. Always usearecommended ServiceToolwhere specified. 5. Protect temporarily exposedscrewthreads by replacing nutsorfitting plastic caps. SAFETY PRECAUTIONS 1. Whenever possible,usealift when working beneath vehicle,inpreference tojacking. Chock wheels aswell asapplying parkingbrake. WARNING: Donot use apit when removing fuelsystem components. 2. Never relyonajack alone tosupport vehicle. Use axle stands carefully placedatjacking points toprovide rigidsupport. 3. Ensure thatasuitable formoffire extinguisher is conveniently located. 4. Check thatanylifting equipment usedhas adequate capacityandisfully serviceable. 5. Disconnect battery. WARNING: Donot disconnect anypipes in air conditioning system,unlesstrained and instructed todo so. Arefrigerant is used which cancause blindness ifallowed to contact eyes. 6. Ensure thatadequate ventilation isprovided when volatile degreasing agentsarebeing used. 7. Do not apply heatinan attempt tofree stiff fixings; aswell ascausing damage toprotective coatings, thereisarisk ofdamage toelectronic equipment andbrake linings fromstray heat.
07GENERAL FITTINGREMINDERS 2 INFORMATION PREPARATION 1. Clean components andsurrounding areapriorto removal. 2. Blank offany openings exposedbycomponent removal usinggreaseproof paperandmasking tape. 3. Immediately sealfuel, oilorhydraulic lineswhen separated, usingplastic capsorplugs, to prevent lossoffluid andentry ofdirt. 4. Close openendsofoilways, exposed by component removal,withtapered hardwood plugs orreadily visibleplastic plugs. 5. Immediately acomponent isremoved, placeitin a suitable container; useaseparate container for each component anditsassociated parts. 6. Before dismantling acomponent, cleanit thoroughly witharecommended cleaningagent; check thatagent issuitable forallmaterials of component. 7. Clean bench andprovide marking materials, labels, containers andlocking wirebefore dismantling acomponent. DISMANTLING 1. Observe scrupulous cleanliness when dismantling components, particularlywhen brake, fuelorhydraulic systempartsarebeing worked on.Aparticle ofdirt oracloth fragment could cause adangerous malfunction iftrapped in these systems. 2. Blow outalltapped holes,crevices, oilwaysand fluid passages withanairline. Ensure thatany O-rings usedforsealing arecorrectly replaced or renewed, ifdisturbed. 3. Use marking inktoidentify matingparts,to ensure correctreassembly. Ifa centre punchor scriber isused theymayinitiate cracks or distortion ofcomponents. 4. Wire together matingpartswhere necessary to prevent accidental interchange (e.g.roller bearing components). 5. Wire labels ontoall parts which aretobe renewed, andtoparts requiring further inspection beforebeingpassed forreassembly; place these partsinseparate containers from those containing partsforrebuild. 6. Do not discard apart dueforrenewal untilithas been compared withthenew part, toensure that its correct replacement hasbeen obtained. INSPECTION-GENERAL 1. Never inspect acomponent forwear or dimensional checkunless itis absolutely clean; a slight smear ofgrease canconceal anincipient failure. 2. When acomponent isto be checked dimensionally againstfiguresquoted forit,use correct equipment (surfaceplates,micrometers, dial gauges, etc.)inserviceable condition. Makeshift checkingequipment canbe dangerous. 3. Reject acomponent ifits dimensions areoutside limits quoted, orifdamage isapparent. Apart may, however, berefitted ifits critical dimension is exactly limitsize, andisotherwise satisfactory. 4. Use Plastigauge 12Type PG-1 forchecking bearing surfaceclearances. Directionsforits use, andascale giving bearing clearances in 0,0025 mmsteps areprovided withit.
GENERALFITTINGREMINDERS 3 INFORMATION BALL ANDROLLER BEARINGS CAUTION: Neverrefitaball orroller bearing withoutfirstensuring thatitis in a fully serviceable condition. 1. Remove alltraces oflubricant frombearing under inspection bywashing inasuitable degreaser; maintainabsolute cleanliness throughout operations. 2. Inspect visually formarkings ofany form on rolling elements, raceways, outersurface of outer ringsorinner surface ofinner rings. Reject any bearings foundtobe marked, sinceany marking inthese areas indicates onsetofwear. 3. Holding innerracebetween fingerandthumb of one hand, spinouter raceandcheck thatit revolves absolutely smoothly.Repeat,holding outer raceandspinning innerrace. 4. Rotate outerringgently withareciprocating motion, whileholding innerring;feelforany check orobstruction torotation, andreject bearing ifaction isnot perfectly smooth. 5. Lubricate bearinggenerously withlubricant appropriate toinstallation. 6. Inspect shaftandbearing housing for discolouration orother marking suggesting that movement hastaken placebetween bearingand seatings. (Thisisparticularly tobe expected if related markings werefound inoperation 2). 7. Ensure thatshaft andhousing areclean andfree from burrs before fittingbearing. 8. Ifone bearing assembly ofapair shows an imperfection itis generally advisable toreplace both withnew bearings; anexception couldbe made ifthe faulty bearing hadcovered alow mileage, anditcould beestablished that damage wasconfined toitonly. 9. When fittingbearing toshaft, applyforceonlyto inner ringofbearing, andonly toouter ringwhen fitting intohousing, asshown above. 10. Inthe case ofgrease lubricated bearings(e.g. hub bearings) fillspace between bearingand outer sealwithrecommended gradeofgrease before fittingseal. 11. Always markcomponents ofseparable bearings (e.g. taper rollerbearings) indismantling, to ensure correctreassembly. Neverfitnew rollers in aused outer ring,always fitacomplete new bearing assembly.
07GENERAL FITTINGREMINDERS 4 INFORMATION OIL SEALS NOTE: Ensure thattheseal running track is free from pits,scores, corrosion and general damage priortofitting replacement seal. 1. Always fitnew oilseals when rebuilding an assembly. 2. Carefully examinesealbefore fittingtoensure that itis clean andundamaged. 3. Coat thesealing lipswith clean grease; pack dust excluder sealswithgrease, andheavily grease duplexsealsincavity between sealing lips. 4. Ensure thatseal spring, ifprovided, iscorrectly fitted. 5. Place lipofseal towards fluidtobe sealed and slide intoposition onshaft, usingfittingsleeve when possible toprotect sealing lipfrom damage by sharp corners, threadsorsplines. Iffitting sleeve isnot available, useplastic tubeortape to prevent damage tosealing lip. 6. Grease outsidediameter ofseal, place square to housing recessandpress intoposition, using great careandifpossible abell piece toensure that seal isnot tilted. Insome cases itmay be preferable tofitseal tohousing beforefittingto shaft. Never letweight ofunsupported shaftrest in seal. 7. Ifcorrect service toolisnot available, usea suitable driftapproximately 0,4mm (0.015 in) smaller thanoutside diameter ofseal. Usea hammer VERYGENTLY ondrift ifa press isnot suitable. 8. Press ordrift seal into depth ofhousing if housing isshouldered, orflush withface of housing wherenoshoulder isprovided. Ensure that theseal does notenter thehousing ina tilted position. NOTE: Mostcases offailure orleakage of oil seals aredue tocareless fitting,and resulting damagetoboth seals and sealing surfaces. Careinfitting isessential if good results aretobe obtained. NEVERuseaseal which hasbeen improperly storedorhandled, such ashung onahook ornail.
GENERALFITTINGREMINDERS 5 INFORMATION JOINTS ANDJOINT FACES 1. Always usecorrect gaskets wheretheyare specified. 2. Use jointing compound onlywhen recommended. Otherwisefitjoints dry. 3. When jointing compound isused, applyinathin uniform filmtometal surfaces; takegreat careto prevent itfrom entering oilways,pipesorblind tapped holes. 4. Remove alltraces ofold jointing materials prior to reassembly. Donot use atool which could damage jointfaces. 5. Inspect jointfaces forscratches orburrs and remove withafine fileoroil stone; donot allow removed materialordirt toenter tapped holesor enclosed parts. 6. Blow outany pipes, channels orcrevices with compressed air,fitnew Orings orseals displaced byair blast. FLEXIBLE HYDRAULIC PIPES,HOSES 1. Before removing anybrake orpower steering hose, cleanendfittings andarea surrounding them asthoroughly aspossible. 2. Obtain appropriate plugsorcaps before detaching hoseendfittings, sothat ports canbe immediately coveredtoexclude dirt. 3. Clean hoseexternally andblow through with airline. Examine carefullyforcracks, separation of plies, security ofend fittings andexternal damage. Rejectanyhose found faulty. 4. When refitting hose,ensure thatnounnecessary bends areintroduced, andthathose isnot twisted beforeorduring tightening ofunion nuts. 5. Containers forhydraulic fluidmust bekept absolutely clean. 6. Do not store brake fluidinan unsealed container. Itwill absorb water,andfluid inthis condition wouldbedangerous touse due toa lowering ofits boiling point. 7. Do not allow brake fluidtobe contaminated with mineral oil,oruse acontainer whichhas previously containedmineraloil. 8. Do not re-use brakefluidbled from system. 9. Always useclean brake fluidtoclean hydraulic components. 10. Fitacap toseal ahydraulic unionandaplug to its socket afterremoval toprevent ingressofdirt. 11. Absolute cleanliness mustbeobserved with hydraulic components atall times. 12. After anywork onhydraulic systems,inspect carefully forleaks underneath thevehicle whilea second operator appliesmaximum pressureto the brakes (engine running) andoperates the steering.
07GENERAL FITTINGREMINDERS 6 INFORMATION FUEL SYSTEM HOSES CAUTION: Allfuel hoses aremade upof two laminations, anarmoured rubberouter sleeve andaninner vitoncore.Ifany of the fuel system hoseshavebeen disconnected, it is imperative thattheinternal boreisinspected to ensure thattheviton lining hasnotbecome separated fromtheamoured outersleeve. Anew hose must befitted ifseparation isevident. METRIC BOLTIDENTIFICATION 1.An ISO metric boltorscrew, madeofsteel and larger than6m m in diameter canbeidentified by either ofthe symbols ISOMor M embossed or indented ontop ofthe head. 2. Inaddition tomarks toidentify themanufacture, the head isalso marked withsymbols toindicate the strength grade,e.g.8.8,12.9 or14.9, where the first figure givestheminimum tensile strength ofthe bolt material intens ofkgf/mm 2 . 3. Zinc plated ISOmetric boltsandnuts are chromate passivated, agold-bronze colour. METRIC NUTIDENTIFICATION 1.Anut with anISO metric thread ismarked on one face oron one ofthe flats ofthe hexagon with thestrength gradesymbol 8,12 or14. Some nutswithastrength 4,5or 6 are also marked andsome havethemetric symbol Mon the flatopposite thestrength grademarking. 2. Aclock facesystem isused asan alternative method ofindicating thestrength grade.The external chamfers oraface ofthe nutismarked in aposition relativetothe appropriate hour mark onaclock facetoindicate thestrength grade. 3. Adot isused tolocate the12Oclock position and adash toindicate thestrength grade.Ifthe grade isabove 12,two dots identify the12 Oclock position. KEYS ANDKEYWAYS 1. Remove burrsfromedges ofkeyways withafine file and clean thoroughly beforeattempting to refit key. 2. Clean andinspect keyclosely; keysaresuitable for refitting onlyifindistinguishable fromnew, as any indentation mayindicate theonset ofwear. TAB WASHERS 1. Fitnew washers inall places wheretheyare used. Always fitanew tabwasher. 2. Ensure thatthenew tabwasher isof the same design asthat replaced.
GENERALFITTINGREMINDERS 7 INFORMATION COTTER PINS 1.Fitnew cotter pinsthroughout whenreplacing any unit. 2. Always fitcotter pinswhere cotterpinswere originally used.Donot substitute spring washers: thereisalways agood reason forthe use ofacotter pin. 3. Allcotter pinsshould befitted asshown unless otherwise stated. NUTS 1. When tightening aslotted orcastellated nut never loosen itto insert cotter pinorlocking wire except inthose recommended caseswhere this forms partofan adjustment. Ifdifficulty is experienced, alternativewashersornuts should be selected, orwasher thickness reduced. 2. Where self-locking nutshave been removed itis advisable toreplace themwithnew ones ofthe same type. NOTE: Wherebearing pre-load isinvolved nuts should betightened inaccordance with special instructions. LOCKING WIRE 1. Fitnew locking wireofthe correct typeforall assemblies incorporating it. 2. Arrange wiresothat itstension tendstotighten the bolt heads, ornuts, towhich itis fitted. SCREW THREADS 1. Both UNFandMetric threads toISO standards are used. Seebelow forthread identification. 2. Damaged threadsmustalways bediscarded. Cleaning upthreads withadie ortap impairs the strength andcloseness offitof the threads and is not recommended. 3. Always ensurethatreplacement boltsareat least equal instrength tothose replaced. 4. Do not allow oil,grease orjointing compound to enter blindthreaded holes.Thehydraulic action on screwing inthe bolt orstud could splitthe housing. 5. Always tightenanut orbolt tothe recommended torque value.Damaged orcorroded threadscan affect thetorque reading. 6. To check orre-tighten abolt orscrew toa specified torquevaluefirstloosen aquarter ofa turn, thenre-tighten tothe correct value. 7. Oil thread lightlybefore tightening toensure a free running thread,exceptinthe case of threads treatedwithsealant/lubricant, and self-locking nuts. UNIFIED THREAD IDENTIFICATION 1.Bolts Acircular recessisstamped inthe upper surface of the bolt head. 2. NutsAcontinuous lineofcircles isindented onone of the flats ofthe hexagon, paralleltothe axis of the nut. 3. Studs, BrakeRods,etc. The component isreduced tothe core diameter for ashort length atits extremity.
LUBRICANTS,FLUIDSANDCAPACITIES 1 INFORMATION RECOMMENDED LUBRICANTSANDFLUIDS All climates andconditions AMBIENTTEMPERATURE °C COMPONENT SPECIFICATIONVISCOSITY -30-20-10 010 20 30 40 50 Diesel RES.22.OL.PD-215W/40 Engine sump orCCMC PD-2 or API CD Main Gearbox manual ATF Dexron IID Final driveunits APIorGL5 90EP Swivel pinhousings MIL-L -2105 or MIL -L -2105B 80EP * Co rD Power steering ATFDexron IID Transfer box APIGL4 orGL5 90EP LT230T MIL-L -2105 or MIL -L -2105B 80EP Co rD NOTE: *Molytex EP00grease onlater vehicles withfiller plug onlyinswivel pinhousing.
09LUBRICANTS, FLUIDSANDCAPACITIES 2 INFORMATION Propeller shaftFront and Rear NLGI -2 Multi-purpose LithiumbasedGREASE Lubrication nipples (hubs, balljoints etc.) Seat slides Door lockstriker Brake andclutch reservoirs Brake fluidshaving aminimum boilingpointof260 °C (500 °F) and complying with FMVSS 116DOT4 Engine coolant Useanethylene glycolbased anti-freeze (containing nomethanol) with non-phosphate corrosioninhibitorssuitableforuse inaluminium enginestoensure the protection ofthe cooling systemagainst frostandcorrosion inall seasons. Useone part anti-freeze toone part water forprotection downto-36 °C (-33 °F). IMPORTANT: Coolantsolution mustnotfallbelow proportions onepart anti-freeze tothree partswater, i.e.minimum 25%anti-freeze incoolant otherwise damage toengine isliable tooccur. Oramaximum of60%. Battery lugs, Petroleumjelly. Earthing surfaces NOTE:Donot use Silicone Grease where painthas been removed Air Conditioning System Refrigerant Useonly refrigerant R134a Compressor OilSandenoil LUBRICATION PRACTICE Use ahigh quality oilofthe correct viscosity rangeandservice classification inthe engine duringmaintenance and when topping up.The useofoil not tothe correct specification canlead tohigh oiland fuelconsumption and ultimately todamaged components. Oil tothe correct specification containsadditives whichdisperse thecorrosive acidsformed bycombustion and prevent theformation ofsludge whichcanblock theoilways. Additional oiladditives shouldnotbeused. Always adhere tothe recommended servicingintervals. WARNING: Manyliquids andother substances usedinmotor vehicles arepoisonous. Theymust not beconsumed andmust bekept away fromopen wounds. Thesesubstances, amongothers, include anti-freeze, windscreen washeradditives, lubricants andvarious adhesives.
LUBRICANTS,FLUIDSANDCAPACITIES 3 INFORMATION CAPACITIES The following capacityfiguresareapproximate andareprovided asaguide only. Capacities (approx.)* LitresPints Engine sumpoil 5,8 ................................................................ 10.20 Extra when refilling afterfitting newfilter 0,85 .......................... 1.50 Manual gearbox 2,67 ............................................................... 4.70 Transfer gearboxoil 2,30 ......................................................... 4.00 Front differential 1,70 ............................................................... 3.00 Rear differential 1,70 ................................................................ 3.00 Power steering boxand reservoir LHD 2,90 ............................ 5.00 Power steering boxand reservoir RHD 3,40 ............................ 6.00 Swivel pinhousing oil/grease (each) 0,35 ................................ 0.60 Fuel tankusable fuel 89,0 ........................................................ 19.5gall Cooling system 11,50 ................................................................ 20.20 Washer bottle 3,0 ................................................................... 5.28 NOTE:*All levels mustbechecked bydipstick orlevel plugs asapplicable. ANTI-FREEZE PERCENTAGE CONCENTRATION -50% PROTECTION -LOWER TEMPERATURE LIMIT Complete protection Vehicle maybedriven awayimmediately fromcold, -33 °C (-36 °F). Safe limitprotection Coolant insemi-frozen state.Engine maybestarted and driven awayafterwarm-up period,-41°C (-42 ° F). Lower protection Prevents frostdamage tocylinder head,blockand radiator. Thawoutbefore starting engine, -47°C (-53 ° F). CAUTION: Anti-freeze contentmustnever be allowed tofall below 25%otherwise damage tothe engine isliable tooccur. Also, anti-freeze contentshouldnotexceed 60% as this willgreatly reduce thecooling effectofthe coolant.