1999-2002 Land Rover Defender TD5 TDI 8 Service & Repair Manual

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TABLE OF' CONTENTS SECTION Introduction mI ...................................................................................................... ................................................................................... El General Specification Data .......................... Engine Tuning Data.. .I!. ............................................................. ..................................................................................... Torque Wrench Settings.. mb .................................................................................. m I General Fitting Instructions ..................................................... ..................................................................................................... El " 1 Recommended Lubricants, Fluids and Capacities.. Maintenance El El El Engine ............................................................................................................. ,~ Cooling System .................................................................................................. ..................................................................... Fuel System (including Fuel Injection) ... ." ..I Clutch.. ............................................................................................................ O J ......................................................................... w El w Manual Gearbox and Transfer Box Propeller Shafts.. Rear Axle and Final Drive ................................................................................................ .................................................................................... .......................................................................................................... \ Steering.. Suspension ........................................................................................................ Brakes ............................................................................................................. Electrical .......................................................................................................... BOOK 2 5

BOOK ONE CONTENTS 05 Page ENGINE TUNING DATA Section Number ri - Repairsand replacement parts - Poisonous substances -Fuel handling precautions -Fuel tank draining and repair J . . - - Service tools 5 - Location of vehicle identification numbers 6 06 TORQUE WRENCH SETINGS El GENERAL SPECIFICATION DATA - V8 engine data -2.25 litre petrol engine data -2.25 litre petrol engine data - 2.25 litre dicscl cnginc data - 2.50 litre dicsel engine data - General data - all models - Tyrepressures - Replacemcnt bulbs and units - Vchiclc wcights 1 3 5 7 9 11 19 19 20 - V8 engine tuning data - 2.25 litre petrol engine tuning data - 2.5 litre petrol engine tuning data - 2.25 and 2.50 litre dicscl engine tuning data 7 :I'.. i , .. . ... ,.. .E. , 1

Book One Contents (cont’d) 07 Section GENERAL FITTING INSTRUCTIONS - Precautionsagainst damage - Safetyprecautions - Preparation and dismantling - Inspection of components - Ball and roller bearings - Oil seals - Jointsand joint faces - Flexible hydraulic pipes and hoses - Metric bolt identification - Metric nut identification - Hydraulic fittings - Keys and keyways - Tab washers, split pins, nuts and locking wire - Screw threads - Unified thread identification 1091 RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES 1 1 1 2 2 2 3 3 3 4 4 5 5: 5 6 - - Recommendcd lubricants - Anti -freeze proportions - Corrosion inhibitor - Capacities - Maintenance Schedules - Maintenance - lubrication - Maintenance - general maintenance and adjustments 2

01 fi;y :i: INTRODUCTION ... ,:.; :.?" , ... ..:I. .!I, I . ._ ...,., , . ..'. This Workshop Manual covers the Land Rover Ninety and One Ten range of vehicles. It is primarily designed to assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles. Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be completed within the time stated in the 'Repair Operation Times'. The Manual has been produced in separate books; this allows the information to be distributed throughout the specialist areas of the modern service facility. A table of contents in Book 1 lists the major components and systems together with the section and book numbers. The cover of each book details the sections contained within that book. The title page of each book carries the part numbers required to order replacement books, binders or complete Service Manuals. This can be done through the normal channels. 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 water pump end of the engine is referred to as the front. To reduce repetition, 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. 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. During the period of running-in from new, certain adjustments may vary from the specification figures given in this Manual. These adjustments will be re-set by the Distributor or Dealer at the After Sales Service, and thereafter should be maintained at the figures specified in the Manual. REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only 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 wrench setting figures given in the Repair Operation Manual must bc strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the vehicle conform to mandatory requirements existing in their country of origin. The terms of the Owners Service Statement may be invalidated by the fitting of other than Land Rover parts. A11 Land Rover parts have the full backing of the Owners Service Statement. Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts. POISONOUS SUBSTANCES Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should as far as possible be kept away from open wounds. These substances among others include antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives. FUEL HANDLING PRECAUTIONS The following information provides basic precautions which must be observed if petrol (gasoline) 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. GENERAL Petrol/gasoline vapour is highly flammable and in confined spaces is also very explosive and toxic. When petroI/gasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is potentially very dangerous. .. . .... . becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can 3

1999-2002 Land Rover Defender TD5 TDI 8 Service & Repair Manual

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