1999 LAND ROVER DEFENDER Workshop Manual

Workshop Manual
Werkplaatshandboek
Manual d'Atelier
Werkstatthandbuc h
Manuale d'Officina
Manual de Taller
Manual de Oficina
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DEFENDER 1999 & 2002 MY
WORKSHOP MANUAL SUPPLEMENT& BODY REPAIR MANUAL
This Supplement supersedes Workshop Manual VDR 100250
and should be used in conjunction with the following Manuals:
Workshop Manual - Defender 300 Tdi LRL 0097
Overhaul Manual - R380 gearbox LRL 0003 3rd edition
Overhaul Manual - LT230T Transfer gearbox LRL 0081 3rd edition
Publication Part No. LRL 0410ENG (3rd Edition)
 Land Rover 2001
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic,
mechanical, recording or other means without prior permission from Land Rover.
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CONTENTS
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE
17 EMISSION CONTROL
18 ENGINE MANAGEMENT SYSTEM
19 FUEL SYSTEM
26 COOLING SYSTEM
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
47 PROPELLER SHAFTS
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
76 CHASSIS AND BODY
77 PANEL REPAIRS
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
88 INSTRUMENTS
01
04
05
07
09
10
12
17
18
19
26
30
33
37
41
47
57
60
64
70
76
77
82
84
86
88
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01 - INTRODUCTION
CONTENTS
Page
INFORMATION
INTRODUCTION 1..................................................................................................
DIMENSIONS 1.......................................................................................................
REFERENCES 1.....................................................................................................
REPAIRS AND REPLACEMENTS 1.......................................................................
POISONOUS SUBSTANCES 1..............................................................................
FUEL HANDLING PRECAUTIONS 2......................................................................
SYNTHETIC RUBBER 3.........................................................................................
RECOMMENDED SEALANTS 3.............................................................................
USED ENGINE OIL 3..............................................................................................
ACCESSORIES AND CONVERSIONS 4...............................................................
WHEELS AND TYRES 4.........................................................................................
STEAM CLEANING 4..............................................................................................
SPECIFICATION 4..................................................................................................
SPECIAL SERVICE TOOLS 4................................................................................
JACKING 5..............................................................................................................
HYDRAULIC VEHICLE RAMP (FOUR POST) 6.....................................................
TWO POST VEHICLE RAMPS 6............................................................................
DYNAMOMETER TESTING 6................................................................................
TOWING 7..............................................................................................................
TRANSPORTING THE VEHICLE BY TRAILER 7..................................................
JUMP STARTING 8................................................................................................
ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL 9.............................
CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY 10....................
VEHICLE IDENTIFICATION NUMBER (VIN) 11.....................................................
LOCATION OF IDENTIFICATION NUMBERS 12...................................................
FAULT DIAGNOSTIC EQUIPMENT 13..................................................................
READING THIS SUPPLEMENT 14........................................................................
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INTRODUCTION
1
INFORMATION INTRODUCTION
This Workshop Manual Supplement covers vehicles
from 1999 and 2002 model year onwards. The Body
Repair Manual has also been incorporated into this
supplement. Amendments and additional pages will
be issued, when necessary, to ensure that the
supplement covers latest models.
This Supplement is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover Defender 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, CAUTIONSandNOTESare 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
Supplement 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 Supplement 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 Supplement.
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.
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