1997 Land Rover DEFENDER All Models Service and Repair Manual

AMENDMENT INSTRUCTION SHEET DEFENDER WORKSHOP MANUAL Publication Number LRL0097ENG Amendment Number: LD003.97 Date: 09/97 To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an Amendment Instruction Sheet will be issued with each set of revised pages. The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the Contents pages, all revised and new pages have the issue date at the foot of each page, together with an indication of whether the pages are revised or new. This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment has been incorporated. Do not discard previous Amendment Instruction sheets. Your manual is only complete to this issue providing all prior Amendments are included. The filing instructions give section and page numbers affected. Additional pages or complete new sections may be issued, insert the pages as instructed. FILING INSTRUCTIONS Section Discard Existing Pages Insert New Pages Reason for Amendment 51 - Rear Axle and Final Drive - Repairs Pages 1 to 5 Pages 1 to 5 Clarification of wheel nut torque figures. 54 - Front Axle and Final Drive - Repairs Pages 1, and 3 Pages 1, and 3 Clarification of wheel nut torque figures. 57 - Steering - Repairs Page 5 Page 5 Clarification of wheel nut torque figures. 60 - Front Suspension - Repairs Pages 1, and 3 Pages 1, and 3 Clarification of wheel nut torque figures. 64 - Rear Suspension - Repairs Page 1 Page 1 Clarification of wheel nut torque figures. 70 - Brakes - Repairs Pages 7, 11, and 13 Pages 7, 11, and 13 Clarification of wheel nut torque figures. 74 - Wheels and Tyres - Repairs Page 5 Pages 5, and 7 Clarification of wheel nut torque figures.

01 04 05 07 09 10 12 17 19 26 30 33 37 41 47 51 54 57 60 64 74 70 75 76 80 82 84 86 88 Workshop manual DEFENDER 300Tdi This manual covers vehicles from 1996 model year 01 INTRODUCTION 04 GENERAL SPECIFICATION DATA 05 ENGINE TUNING DATA 07 GENERAL FITTING REMINDERS 09 LUBRICANTS, FLUIDS AND CAPACITIES 10 MAINTENANCE 12 ENGINE Tdi 19 FUEL SYSTEM Tdi 26 COOLING SYSTEM Tdi 30 MANIFOLD AND EXHAUST SYSTEM 33 CLUTCH 37 MANUAL GEARBOX 41 TRANSFER GEARBOX 47 PROPELLER SHAFTS 51 REAR AXLE AND FINAL DRIVE 54 FRONT AXLE AND FINAL DRIVE 57 STEERING 60 FRONT SUSPENSION 64 REAR SUSPENSION 70 BRAKES 74 WHEELS AND TYRES 76 CHASSIS AND BODY 80 HEATING AND VENTILATION 82 AIR CONDITIONING 84 WIPERS AND WASHERS 86 ELECTRICAL 88 INSTRUMENTS Publication Part No. LRL 0097 ENG Published by Rover Technical Communication  1996 Rover Group Limited

INTRODUCTION 1 INFORMATION INTRODUCTION This workshop manual covers vehicles from 1996 model year onwards. Amendments and additional pages will be issued to ensure that the manual covers latest models. Amendments and additions will be identified by the addition of a dated footer at the bottom of the page. This Workshop Manual is designed to assist skilled technicians in the efficient repair and maintenance of Land Rover Defender 300Tdi vehicles. Individuals who undertake their own repairs should have some skill and training, and limit repairs to components which could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such as steering, brakes, suspension or supplementary restraint system should be carried out by a Land Rover Dealer. Repairs to such items should NEVER be attempted by untrained individuals. WARNINGS, CAUTIONS and NOTES are given throughout this Manual in the following form: WARNING: Procedures which must be followed precisely to avoid the possibility of personal injury. CAUTION: This calls attention to procedures which must be followed to avoid damage to components. NOTE: This calls attention to methods which make a job easier or gives helpful information. DIMENSIONS The dimensions quoted are to design engineering specification. Alternative unit equivalents, shown in brackets following the dimensions, have been converted from the original specification. REFERENCES References to the left or right hand side in the manual are made when viewing the vehicle from the rear. With the engine and gearbox assembly removed, the crankshaft end of the engine is referred to as the front. To reduce repetition, some operations covered in this Manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out, particularly where safety related items are concerned. REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that Land Rover parts are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories: Safety features embodied in the vehicle may be impaired if other than Land Rover parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturer’s specification. Torque spanner values given in the Workshop Manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be replaced with a new one. Certain fasteners must not be re-used. These fasteners are specified in the Workshop Manual. POISONOUS SUBSTANCES Many liquids and other substances used are poisonous and therefore must not be consumed. It is also advisable to keep all substances away from open wounds. These substances among others include anti-freeze, brake fluid, fuel, windscreen washer additives, air conditioning refrigerant, lubricants and various adhesives.

01 INTRODUCTION 2 INFORMATION FUEL HANDLING PRECAUTIONS The following information provides basic precautions which must be observed if fuel is to be handled safely. It also outlines the other areas of risk which must not be ignored. This information is issued for basic guidance only, and in any case of doubt, appropriate enquiries should be made of your local Fire Officer or Fire Department. Fuel vapour is highly flammable and in confined spaces is also very explosive and toxic and when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of fuel is very dangerous. Always have a fire extinguisher containing FOAM CO 2 GAS, or POWDER close at hand when handling fuel, or when dismantling fuel systems and in areas where fuel containers are stored. WARNING: lt is imperative that the battery is not disconnected during fuel system repairs as arcing at the battery terminal could ignite fuel vapour in the atmosphere. Always disconnect the vehicle battery BEFORE carrying out work on the fuel system. Whenever fuel is being handled, transferred or stored, or when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any leadlamps used must be flame proof and kept clear of spillage. No one should be permitted to repair components associated with fuel without first having had fuel system training. Hot fuel handling precautions WARNING: Before commencing any operation requiring fuel to be drained from the fuel tank, the following procedure must be adhered to: 1. Allow sufficient time for the fuel to cool, thus avoiding contact with hot fuels. 2. Vent the system by removing the fuel filler cap in a well ventilated area. Refit the filler cap until the commencement of fuel drainage. Fuel transfer WARNING: Fuel must not be extracted or drained from any vehicle while it is standing over a pit. The transfer of fuel from the vehicle fuel tank must be carried out in a well ventilated area. An approved transfer tank must be used according to the transfer tank manufacturer’s instructions and local regulations, including attention to grounding of tanks. Fuel tank removal A FUEL VAPOUR warning label must be attached to the fuel tank upon removal from the vehicle. Fuel tank repair Under no circumstances should a repair to any tank be attempted.

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1997 Land Rover DEFENDER All Models Service and Repair Manual

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