AMENDMENT INSTRUCTION SHEET - Land Rover

1 AMENDMENT INSTRUCTION SHEET . DEFENDER workshop manual . Publication Number LRL0097 ENG. AMENDMENT Number: 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.

2 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 Insert New Pages Reason for AMENDMENT Pages 51 - Rear Axle and Pages 1 to 5 Pages 1 to 5 Clarification of wheel nut torque figures.

3 Final Drive - Repairs 54 - Front Axle and Pages 1, and 3 Pages 1, and 3 Clarification of wheel nut torque figures. Final Drive - Repairs 57 - Steering - Repairs Page 5 Page 5 Clarification of wheel nut torque figures. 60 - Front Suspension - Pages 1, and 3 Pages 1, and 3 Clarification of wheel nut torque figures. Repairs 64 - Rear Suspension - Page 1 Page 1 Clarification of wheel nut torque figures. Repairs 70 - Brakes - Repairs Pages 7, 11, and Pages 7, 11, and Clarification of wheel nut torque figures.

4 13 13. 74 - Wheels and Tyres Page 5 Pages 5, and 7 Clarification of wheel nut torque figures. - Repairs 01. workshop manual 04. 05. DEFENDER 300 Tdi 07. 09. 10. This manual covers vehicles from 12. 1996 model year 01 INTRODUCTION 17. 19. 04 GENERAL SPECIFICATION DATA. 05 ENGINE TUNING DATA. 07 GENERAL FITTING REMINDERS. 09 LUBRICANTS, FLUIDS AND CAPACITIES 26. 10 MAINTENANCE. 12 ENGINE Tdi 19 FUEL SYSTEM Tdi 26 COOLING SYSTEM Tdi 30. 30 MANIFOLD AND EXHAUST SYSTEM. 33 CLUTCH. 37 manual GEARBOX. 41 TRANSFER GEARBOX.

5 33. 47 PROPELLER SHAFTS. 51 REAR AXLE AND FINAL DRIVE. 54 FRONT AXLE AND FINAL DRIVE. 57 STEERING 37. 60 FRONT SUSPENSION 41. 64 REAR SUSPENSION. 70 BRAKES. 74 WHEELS AND TYRES 47. 76 CHASSIS AND BODY 51. 80 HEATING AND VENTILATION 54. 82 AIR CONDITIONING. 84 WIPERS AND WASHERS. 86 ELECTRICAL 57. 88 INSTRUMENTS. 60. 64. 74. 70. Publication Part No. LRL 0097 ENG. Published by Rover Technical Communication 1996 Rover Group Limited 75. 76. 80. 82. 84. 86. 88. INTRODUCTION. INTRODUCTION REFERENCES. This workshop manual covers vehicles from 1996 References to the left or right hand side in the manual model year onwards.

6 Amendments and additional are made when viewing the vehicle from the rear. pages will be issued to ensure that the manual covers With the engine and gearbox assembly removed, the latest models. Amendments and additions will be crankshaft end of the engine is referred to as the front. identified by the addition of a dated footer at the bottom of the page. To reduce repetition, some operations covered in this manual do not include reference to testing the vehicle This workshop manual is designed to assist skilled after repair.

7 Technicians in the efficient repair and maintenance of Land Rover Defender 300 Tdi vehicles. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle Individuals who undertake their own repairs should is carried out, particularly where safety related items have some skill and training, and limit repairs to are concerned. 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 REPAIRS AND REPLACEMENTS.

8 Be carried out by a Land Rover Dealer. Repairs to such items should NEVER be attempted by untrained When replacement parts are required it is essential individuals. that Land Rover parts are used. Attention is particularly drawn to the following points WARNINGS, CAUTIONS and NOTES are given concerning repairs and the fitting of replacement parts throughout this manual in the following form: and accessories: Safety features embodied in the vehicle may be impaired if other than Land Rover WARNING: Procedures which must be parts are fitted.

9 In certain territories, legislation followed precisely to avoid the possibility prohibits the fitting of parts not to the vehicle of personal injury. manufacturer's specification. Torque spanner values given in the workshop manual must be strictly CAUTION: This calls attention to adhered to. Locking devices, where specified, must be procedures which must be followed to fitted. If the efficiency of a locking device is impaired avoid damage to components. during removal it must be replaced with a new one. Certain fasteners must not be re-used.

10 These NOTE: This calls attention to methods fasteners are specified in the workshop manual . which make a job easier or gives helpful information. POISONOUS SUBSTANCES. DIMENSIONS. Many liquids and other substances used are poisonous and therefore must not be consumed. It is The dimensions quoted are to design engineering also advisable to keep all substances away from open specification. Alternative unit equivalents, shown in wounds. These substances among others include brackets following the dimensions, have been anti-freeze, brake fluid, fuel, windscreen washer converted from the original specification.