1994-2006 Land Rover Defender OEM Service & 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.

INTRODUCTION 3 INFORMATION SYNTHETIC RUBBER Many ’0’ ring seals, flexible pipes and other similar items which appear to be natural rubber are made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe, and does not present a health hazard. However, if the material is damaged by fire or excessive heat, it can break down and produce highly corrosive Hydrofluoric acid which can cause serious burns on contact with skin. Should the material be in a burnt or overheated condition handle only with seamless industrial gloves. Decontaminate and dispose of the gloves immediately after use. If skin contact does occur, remove any contaminated clothing immediately and obtain medical assistance without delay. In the meantime, wash the affected area with copious amounts of cold water or limewater for fifteen to sixty minutes. RECOMMENDED SEALANTS A number of branded products are recommended in this manual for use during maintenance and repair work. These items include: HYLOMAR GASKET AND JOINTING COMPOUND and HYLOSIL RTV SILICONE COMPOUND. They should be available locally from garage equipment suppliers. If there is any problem obtaining supplies, contact the following company for advice and the address of the nearest supplier. MARSTON LUBRICANTS LTD. Hylo House, Cale Lane, New Springs, Wigan WN2 1JR Tel 01942 824242 USED ENGINE OIL WARNING: Prolonged and repeated contact with engine or motor oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. Used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided. Handling precautions 1. Avoid prolonged and repeated contact with oils, particularly used engine oils. 2. Wear protective clothing, including impervious gloves where applicable. 3. Do not put oily rags in pockets. 4. Avoid contaminating clothes, particularly underwear, with oil. 5. Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear. 6. First aid treatment must be obtained immediately for open cuts and wounds. 7. Use barrier creams, before each work period, to help the removal of oil from the skin. 8. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. 9. Do not use gasoline, kerosene, diesel fuel, petrol, thinners or solvents for washing the skin. 10. If skin disorders develop, obtain medical advice. 11. Where practicable, degrease components prior to handling. 12. Where there is a risk of eye contact, eye protection should be worn, for example, goggles or face shields; in addition an eye wash facility should be provided. Disposing of used oils Environmental protection precaution It is illegal to pour used oil onto the ground, down sewers or drains, or into waterways. Dispose of used oil through authorised waste disposal contractors. If in doubt contact your Local Authority for advice on disposal facilities.

01 INTRODUCTION 4 INFORMATION ACCESSORIES AND CONVERSIONS DO NOT FIT unapproved accessories or conversions, as they could affect the safety of the vehicle. Land Rover will not accept liability for death, personal injury, or damage to property which may occur as a direct result of the fitting of non-approved conversions to the vehicle. WHEELS AND TYRES WARNING: DO NOT replace the road wheels with any type other than genuine Land Rover wheels which are designed for multi-purpose on and off road use and have very important relationships with the proper operation of the suspension system and vehicle handling. Replacement tyres must be of the make and sizes recommended for the vehicle, and all tyres must be the same make, ply rating and tread pattern. STEAM CLEANING To prevent consequential rusting, any steam cleaning within the engine bay MUST be followed by careful re-waxing of the metallic components affected. Particular attention must be given to the steering column, engine coolant pipes and hose clips. SPECIFICATION The specification details and instructions set out in this Manual apply only to a range of vehicles and not to any one. For the specification of a particular vehicle purchasers should consult their Dealer. The Manufacturer reserves the right to vary specifications with or without notice, and at such times and in such manner as it thinks fit. Major as well as minor changes may be involved in accordance with the Manufacturer’s policy of constant product improvement. Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the Manufacturer or Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof. SPECIAL SERVICE TOOLS The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently, and safely. Where special tools are specified, only these tools should be used to avoid the possibility of personal injury or damage to the components. Also, the amount of time which they save can be considerable. Special tools bulletins will be issued periodically giving details of new tools as they are introduced. All orders and enquiries from the United Kingdom should be sent direct to V. L. Churchill. Overseas orders should be placed with the local V. L. Churchill distributor, where one exists. Countries where there is no distributor may order direct from: V. L. Churchill Limited, PO Box 3, Daventry, Northants, England, NN11 4NF. The tools recommended in this Workshop Manual are listed in a multi-language illustrated catalogue, obtainable from: Messers. V. L. Churchill at the above address, or from: Land Rover Publications, Character Mailing, Heysham Road, Bootle, Merseyside, L70 1JL COPYRIGHT  1996 Rover Group Limited All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior written permission of Rover Group.

INTRODUCTION 5 INFORMATION JACKING The following instructions must be carried out before raising the vehicle off the ground. 1. Use a solid level ground surface. 2. Apply parking brake. 3. Select 1st gear in main gearbox. 4. Select Low range in transfer gearbox. CAUTION: To avoid damage occurring to the under body components of the vehicle the following jacking procedures must be adhered to. DO NOT POSITION JACKS OR AXLE STANDS UNDER THE FOLLOWING COMPONENTS. Body structure Bumpers Fuel lines Brake lines Front radius arms Panhard rod Steering linkage Rear Trailing links Fuel tank Engine sump Gearbox bell housing Jack or support vehicle by axles only. Vehicle jack The jack provided with the vehicle is only intended to be used in an emergency, for changing a tyre. Do NOT use the jack for any other purpose. Refer to Owner’s Manual for vehicle jack location points and procedure. Never work under a vehicle supported by the vehicle jack. Hydraulic jack A hydraulic jack with a minimum 1500 kg, 3,300 lbs load capacity must be used, see J6083. CAUTION: Do not commence work on the underside of the vehicle until suitable axle stands have been positioned under the axle, see J6084. Raise the front of the vehicle 1. Position cup of hydraulic arm under differential casing. NOTE: The differential casing is not central to the axle. Care should be taken when raising the front road wheels off the ground as the rear axle has less sway stiffness. 2. Raise front road wheels to enable an axle stand to be installed under left hand axle tube.

01 INTRODUCTION 6 INFORMATION 3. Position an axle stand under right hand axle tube, carefully lower jack until axle sits securely on both axle stands, remove trolley jack. 4. Before commencing work on underside of vehicle re-check security of vehicle on stands. 5. Reverse procedure when removing vehicle from stands. Raise rear of vehicle 1. Position cup of hydraulic arm under differential casing. 2. Raise vehicle to enable axle stands to be installed under left and right hand axle tubes. 3. Lower jack until axle sits securely on axle stands, remove trolley jack. 4. Before commencing work on underside of vehicle re-check security of vehicle on stands. 5. Reverse procedure when removing vehicle from stands. HYDRAULIC VEHICLE RAMP (FOUR POST) Use only a ’drive on’ type ramp which supports vehicle on its road wheels. If a ’wheel-free’ condition is required, use a ’drive on’ ramp incorporating a ’wheel-free’ system providing support beneath axle casings. Alternatively, place vehicle on a firm, flat floor and support on axle stands. TWO POST VEHICLE RAMPS The manufacturer of LAND ROVER VEHICLES DOES NOT recommend using ’Two Post’ ramps that employ four adjustable support arms. These are NOT considered safe for Land Rover vehicles. If vehicle is installed on a Two Post ramp responsibility for safety of vehicle and personnel performing service operations is in the hands of the Service Provider. DYNAMOMETER TESTING The front and rear axles cannot be driven independently. WARNING: DO NOT attempt to drive individual wheels with vehicle supported on floor jacks or stands. Four wheel dynamometers Provided that front and rear dynamometer rollers are rotating at identical speeds and that normal workshop safety standards are applied, there is no speed restriction during testing except any that may apply to the tyres. Two wheel dynamometers IMPORTANT: Use a four wheel dynamometer for brake testing if possible. If brake testing on a single axle rig is necessary it must be carried out with propeller shaft to rear axle removed, AND neutral selected in BOTH main gearbox and transfer gearbox. When checking brakes, run engine at idle speed to maintain servo vacuum. If checking engine performance, the transfer box must be in high range and propeller shaft to stationary axle must be removed.

INTRODUCTION 7 INFORMATION TOWING CAUTION: The vehicle has permanent four-wheel drive. The following towing instructions must be adhered to: Towing the vehicle on all four wheels with driver operating steering and brakes. 1. Turn ignition key to position ’1’ to release steering lock. 2. Select neutral in main gearbox and transfer gearbox. 3. Secure tow rope, chain or cable to front towing eyes (alternative types shown). 4. Release the parking brake. CAUTION: The brake servo and power assisted steering system will not be functional without the engine running. Greater pedal pressure will be required to apply the brakes, the steering system will require greater effort to turn the front road wheels. The vehicle tow connection should be used only in normal road conditions, ’snatch’ recovery should be avoided. Rear suspended tow by breakdown vehicle 1. If the front axle is to be trailed turn ignition key to position ’1’ to release steering lock. 2. Select neutral in main gearbox and transfer box. CAUTION: The steering wheel and/or linkage must be secured in a straight ahead position. DO NOT use the steering lock mechanism for this purpose. TRANSPORTING THE VEHICLE BY TRAILER Lashing/towing eyes are provided on front and rear of the chassis side members, see J6085, to facilitate the securing of the vehicle to a trailer or other means of transportation. CAUTION: Underbody components must not be used as lashing points. Install vehicle on trailer and apply park brake. Select neutral in main gearbox.

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1994-2006 Land Rover Defender OEM Service & Repair Manual

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