Land Rover Defender 300 Tdi (97-99) - Service Manual / Repair Manual

LAND ROVER DEFENDER 300TDI (97-99) - WORKSHOP MANUAL

- English Service Manual in PDF format, to vehicles Land Rover Defender 300TDI (97-99).


CONTENTS:

DEFENDER 300TDI 1997-1999

01 - INTRODUCTION
INTRODUCTION
Dimensions
References
Repairs And Replacements
Poisonous Substances
Fuel Handling Precautions
Synthetic Rubber
Recommended Sealants
Used Engine Oil
Accessories And Conversions
Wheels And Tyres
Steam Cleaning
Specification
Special Service Tools
Copyright
Jacking
Hydraulic Vehicle Ramp (Four Post)
Two Post Vehicle Ramps
Dynamometer Testing
Towing
Transporting The Vehicle By Trailer
Jump Starting
Abbreviations And Symbols Used In This Manual
Cross Reference Of Emission System Terminology
Vehicle Identification Number (Vin)
Location Of Identification Numbers
Fault Diagnostic Equipment
Reading This Manual

04 - GENERAL SPECIFICATION DATA
INFORMATION
300tdi Engine
Fuel System
Cooling System
Clutch
Transmission
Steering
Suspension
Road Spring Data
Shock Absorbers
Brakes
Air Conditioning
Wiper Motors
Electrical
Bulbs
Vehicle Weights And Payload
Towing Weights
Off-Road Performance
Tyre Size And Pressures
Wheels
Vehicle Dimensions

05 - ENGINE TUNING DATA
INFORMATION
300tdi Engine
Injection Pump
Heater Plugs
Injectors
Turbocharger

07 - GENERAL FITTING REMINDERS
INFORMATION
General Fitting Reminders
Precautions Against Damage
Safety Precautions
Preparation
Dismantling
Inspection-General
Ball And Roller Bearings
Oil Seals
Joints And Joint Faces
Flexible Hydraulic Pipes, Hoses
Fuel System Hoses
Metric Bolt Identification
Metric Nut Identification
Keys And Keyways
Tab Washers
Cotter Pins
Nuts
Locking Wire
Screw Threads
Unified Thread Identification
09 - LUBRICANTS, FLUIDS AND CAPACITIES
INFORMATION
Recommended Lubricants And Fluids
Lubrication Practice
Capacities
Anti-Freeze
Recommended Fuel
Fuel Tank Capacity

10 - MAINTENANCE
MAINTENANCE
Service Schedule
Vehicle Interior
Vehicle Exterior
Under Bonnet Maintenance
Under Vehicle Maintenance

12 - ENGINE
ADJUSTMENT
Valve Clearances - Check And Adjust
REPAIR
Cylinder Compression Test
Engine Oil Pressure Test
Engine
Crankshaft Pulley
Front Cover Plate And Seal
Camshaft Drive Belt
Crankshaft Gear
Crankshaft Oil Seal
Camshaft Gear
Camshaft Oil Seal
Injection Pump Gear
Front Cover Gasket
Engine Oil Sump
Oil Pick-Up Strainer
Flywheel
Crankshaft Rear Oil Seal
Crankshaft Bearing Bush
Flywheel Housing
Oil Filter
Oil Temperature Control Valve
Oil Filter Head Gasket
Cylinder Head Gasket
Oil Pump
Oil Pressure Relief Valve
SPECIFICATIONS, TORQUE
Torque Values

19 - FUEL SYSTEM
DESCRIPTION AND OPERATION
Description
Operation
ADJUSTMENT
Throttle Cable
Egr Throttle Position Sensor
Low And High Idle Speed Adjustment
Throttle Pedal Adjustment
Injection Pump Timing - Check And Adjust
Turbocharger Boost Pressure - Check
Priming The Fuel System
REPAIR
Fuel Injection Pump
Fuel Injectors
Fuel Lift Pump
Fuel Sedimentor
Fuel Filter Assembly
Fuel Filter Element
Side Mounted Fuel Tank
Side Mounted Fuel Tank - 5 Door Vehicles
Rear Mounted Fuel Tank - 110/130
Twin Tank Change-Over Tap Assembly
Heater Plugs
Heater Plug Control Unit
Air Cleaner
Air Cleaner Element
Throttle Cable
Throttle Pedal
Turbocharger Inlet Hose
Turbocharger Oil Feed Pipe
Turbocharger Oil Drain Pipe
Intercooler
Egr Valve
Egr Valve Modulator
Egr Throttle Position Sensor
Egr Control Unit

26 - COOLING SYSTEM
DESCRIPTION AND OPERATION
Engine Cooling System
Engine (Coolant) Cooling
Coolant Circulation
Viscous Fan
ADJUSTMENT
Drain And Refill Cooling System
REPAIR
Viscous Coupling And Fan
Fan Cowl
Fan Pulley
Water Pump
Auxiliary Mounting Bracket And Gasket
Thermostat
Radiator
Expansion Tank

30 - MANIFOLD AND EXHAUST SYSTEM
DESCRIPTION AND OPERATION
Manifolds And Exhaust System
REPAIR
Induction Manifold
Induction/Exhaust Manifold Gasket
Exhaust Manifold/Turbocharger Assembly
Exhaust Front Pipe
Intermediate Pipe - 90
Intermediate Pipe - 110/130
Tailpipe - 90
Tailpipe - 110/130

33 - CLUTCH
DESCRIPTION AND OPERATION
Description
Operation
FAULT DIAGNOSIS
Clutch Assembly Conditions
Clutch Spin - Drag
Clutch Slip
Clutch Judder - Fierce
Fault/Symptom Chart
Clutch Noise - Mechanical Faults
Hydraulic Faults
ADJUSTMENT


Clutch Pedal And Master Cylinder Setting
REPAIR
Clutch Assembly
Bleed Hydraulic System
Master Cylinder
Clutch Pedal
Release Bearing Assembly
Slave Cylinder
OVERHAUL
Master Cylinder - Overhaul
Slave Cylinder - Overhaul

37 - MANUAL GEARBOX
DESCRIPTION AND OPERATION
R380 Gearbox
FAULT DIAGNOSIS
R380 Gearbox
ADJUSTMENT
Gear Change Lever Bias Spring - Adjust
Fifth Gear Stop Screw - Adjust
REPAIR
R380 Gearbox
SPECIFICATIONS, TORQUE
Torque Values

41 - TRANSFER GEARBOX
DESCRIPTION AND OPERATION
Transfer Gearbox
FAULT DIAGNOSIS
Transfer Gearbox - Oil Seal Locations
Oil Leaks
REPAIR
Transfer Gearbox
SPECIFICATIONS, TORQUE
Torque Values

47 - PROPELLER SHAFTS
DESCRIPTION AND OPERATION
Propeller Shaft
FAULT DIAGNOSIS
Vibration Harshness
REPAIR
Propeller Shaft
OVERHAUL
Propeller Shaft

51 - REAR AXLE AND FINAL DRIVE
DESCRIPTION AND OPERATION
Description
FAULT DIAGNOSIS
Fault Diagnosis
REPAIR
Rear Axle
Rear Hub Assembly - 90
Rear Hub Assembly - 110/130
Differential Assembly - 90
OVERHAUL
Differential Assembly - 110/130
Rear Hub Assembly - 90
Rear Stub Axle - 90
Rear Hub - 110/130
Rear Stub Axle - 110/130
SPECIFICATIONS, TORQUE
Torque Values

54 - FRONT AXLE AND FINAL DRIVE
DESCRIPTION AND OPERATION
Description
FAULT DIAGNOSIS
Fault Diagnosis
REPAIR
Front Axle Assembly
Front Hub Assembly
OVERHAUL
Front Differential
Front Hub
Front Stub Axle, Constant Velocity Joint And Swivel Pin Housing
SPECIFICATIONS, TORQUE
Torque Values

57 - STEERING
DESCRIPTION AND OPERATION
Description
FAULT DIAGNOSIS
Insufficient Power Assistance
Power Steering System - Test
Steering Damper
Steering Faults
Steering Stability And Veer Under Braking
1. General Steering
2. Steering Veer
3. Veer Under Braking
4. Directional Stability
Power Steering Fluid Leaks
Power Steering System - Excessive Noise
Power Steering System - Grunt
Visual And Safety Checks

Road Test Procedure
Stiff Steering Checklist
Visual Check And Basic Adjustments
Steering Linkage Inspect
ADJUSTMENT
Power Steering Box - Adjust
Centralise Steering Box
Steering Lock Stops
Front Wheel Alignment
Power Steering Pump Drive Belt
REPAIR
Steering Column
Power Steering Box
Power Steering System - Bleed
Power Steering Fluid Reservoir
Power Steering Pump
Power Steering Pump Drive Belt
Lower Steering Shaft And Universal Joints
Steering Wheel
Steering Column Lock
Steering Column Nacelle
Drop Arm
Steering Damper
Track Rod And Linkage
Drag Link And Drag Link Ends
OVERHAUL
Power Steering Box - Adwest
SPECIFICATIONS, TORQUE
Torque Values

60 - FRONT SUSPENSION
DESCRIPTION AND OPERATION
Description
REPAIR
Self Locking Nuts
Panhard Rod
Radius Arm
Front Shock Absorber
Front Road Spring
Bump Stop
Anti-Roll Bar
Anti-Roll Bar Links
SPECIFICATIONS, TORQUE
Torque Values

64 - REAR SUSPENSION
DESCRIPTION AND OPERATION
Description
REPAIR
Rear Road Spring
Rear Shock Absorber
Bump Stop
Suspension Link - Upper
Suspension Link - Lower
Anti-Roll Bar
Anti-Roll Bar Links
Self Levelling Unit
SPECIFICATIONS, TORQUE
Torque Values

70 - BRAKES
DESCRIPTION AND OPERATION
Description
Operation
REPAIR
General Brake Service Practice
Fluid Level Check / Top Up
Brake System Bleed
Master Cylinder
Pressure Reducing Valve (Prv)
Servo Non Return Valve
Servo Assembly
Brake Pedal
Front Brake Pads - All Models
Rear Brake Pads
Front Brake Caliper Assembly
Front Brake Calipers
Front Brake Discs
Rear Brake Caliper Assembly
Rear Brake Calipers
Rear Brake Disc
Transmission Brake Shoes
Handbrake Cable
Vacuum Pump
OVERHAUL

Master Cylinder

74 - WHEELS AND TYRES
DESCRIPTION AND OPERATION
Types Of Wheel Rims And Tyres
FAULT DIAGNOSIS
Tyre Wear Chart
Fault - Symptoms
REPAIR
General Information
Tyre Inspection
Wheels Inspection
Valves Inspection
Tyre Pressures
Wheel Balancing
Tyre Fitting
Wheels
Wheel Stud

76 - CHASSIS AND BODY
DESCRIPTION AND OPERATION
Chassis And Body
Chassis Frame Alignment
REPAIR
Door Trim Casing
Window Regulator - Rear Side Door
Exterior Handle - Rear Side Door
Sill Locking Button - Rear Side Door
Remote Control Lever - Rear Side Door
Door Latch - Rear Side Door
Door Glass - Rear Side Door
Mounting Panel - Front Door
Sill Locking Button - Front Door
Window Regulator - Front Door
Remote Control Lever - Front Door
Exterior Handle - Front Door
Latch Assembly - Front Door
Door Glass - Front Door
Locking Barrel - Front Door
Door Striker - Adjust
Rear Seat Cushion - 90
Rear Seat Squab - 90
Rear Bench Seat
Front Seat Belts
Rear Seat Belts - 90/110 Station Wagon, Inward Facing Seats
Rear Seat Belts - 110
Side Trim Panel - 90 Station Wagon
Side Trim Panel - 110 Station Wagon
Rear End Trim Panel - 90/110 Station Wagon
Cubby Box - 90/110 Station Wagon
Rear Grab Handle - 90/110 Station Wagon
Rear End Lining - 90/110 Station Wagon
Front Headlining - 90 Station Wagon
Rear Headlining - 90 Station Wagon
Tail Door Trim Casing
Tail Door Lock
Tail Door Striker - Adjust
Sun Roof
Interior Mirror
Sun Visors
Bonnet Lock
Bonnet Release Cable
Lower Fascia Panel (Heater Duct) Assembly
Front Undertray
Rear Undertray
Access Panel - Front Undertray
Access Panel - Rear Undertray

80 - HEATING AND VENTILATION
DESCRIPTION AND OPERATION
Heating And Ventilation System
Heater Operation
REPAIR
Heater Unit
Blower Motor
Heater Matrix
Resistor Unit
Heater Control Cable - Temperature Control
Heater Control Cable - Air Distribution
Control Cable And Blower Motor Switch

82 - AIR CONDITIONING
DESCRIPTION AND OPERATION
Air Conditioning System
ADJUSTMENT
General Precautions
Remedial Actions
Servicing Precautions
Refrigerant Recovery, Recycling, Recharging
Leak Test System
Air Conditioning System - Performance Test
System Test
Precautions In Handling Refrigerant Lines
Periodic Maintenance
REPAIR
Compressor
Compressor Drive Belt
Condenser Fan And Motors
Condenser
Receiver/Drier
Heater/Cooler Unit - Lh Drive
Evaporator - Lh Drive
Expansion Valve - Lh Drive
Heater Matrix - Lh Drive
Blower Motor Assembly- Lh Drive
Blower Motor Assembly - Rh Drive
Heater/Cooler Unit - Rh Drive
Evaporator - Rh Drive
Expansion Valve - Rh Drive
Heater Matrix - Rh Drive
Resistor, Blower Motor - Lh Drive
Resistor, Blower Motor - Rh Drive

84 - WIPERS AND WASHERS
REPAIR
Wiper Motor And Drive Rack
Wiper Motor And Drive Rack - Vehicle With Air Conditioning Lh Drive
Windscreen Wiper Arms
Windscreen Wiper/Washer Switch
Rear Screen Wiper/Washer Switch
Windscreen Wiper Wheel Boxes - Non Air Conditioned Vehicles
Windscreen Wiper Wheelboxes - Air Conditioned Vehicles
Rear Wiper Motor
OVERHAUL
Wiper Motor

86 - ELECTRICAL
DESCRIPTION AND OPERATION
Electrical Equipment
Generator
Vehicle Immobilisation And Alarm System
Alarm System Components
Alarm System Component Location
Alarm System Operation
Engine Immobilisation
Alarm System Fuses
Immobilisation And Alarm System Circuit Diagram - With Dds
Vehicle Alarm System Built-In Test
FAULT DIAGNOSIS
General Information
Generator Testing
REPAIR
Electrical Precautions
General Precautions
Battery
Electronic Control Unit (Ecu)
Handset Battery
Passive Coil
Immobilisation Spider
Bonnet Switch
Ultrasonic Sensor
Alarm Sounder
Alarm Sounder Relay
Anti-Theft Alarm Indicator Light
Alarm System Fuse
Generator
Auxiliary Drive Belt
Starter Motor
Headlamp
Side, Tail And Direction Indicator Lamps
Side Repeater Lamp
Rear Number Plate Lamp - Bulb Renewal
Rear Number Plate Lamp
Reverse And Fog Guard Lamp - Bulb Renewal
Reverse And Fog Guard Lamp
Interior Lamp - Bulb Removal
Interior Lamp
Reverse Lamp Switch
Warning Lamp Assembly
Instrument Illumination - Bulb Renewal
Starter Switch
Windscreen Wiper/Washer Switch
Direction Indicator/Headlamp/Horn Switch
Main Light Switch
Heated Rear Screen, Rear Fog Lamp And Hazard Warning Switches
Cigar Lighter
Rear Screen Wiper/Washer Switch
Headlamp Levelling Switch
Headlamp Levelling Unit
Headlamp Beam Alignment
Digital Diesel Shut-Off Valve (Dds)

88 - INSTRUMENTS
REPAIR
Instrument Panel
Speedometer
Fuel And Temperature Gauge
Clock - Fascia Panel
Clock - Centre Dash Panel
Warning Light Panel
Printed Circuit - Warning Light Panel
Fuel Gauge Tank Unit - Rear Fuel Tank, 110/130
Fuel Gauge Tank Unit - Side Fuel Tank