Land Rover Defender MY2007-ON - Service Manual - Repair Manual

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LAND ROVER DEFENDER MY2007-ON - WORKSHOP MANUAL

- English Workshop Manual in PDF format, to vehicles Land Rover Defender MY2007-ON.


INDEX:

GENERAL INFORMATION

100: Service Information
100-00: General Information
Description and Operation
How To Use This Manual
Important Safety Instructions
General Service Information
Standard Workshop Practices
Health and Safety Precautions
Special Tool Glossary
100-01: Identification Codes
Description and Operation
Identification Codes
100-02: Jacking and Lifting
Description and Operation
Vehicle Recovery
Jacking
Lifting
100-03: Maintenance Schedules
Description and Operation
Maintenance Schedules - Diesel Engines

CHASSIS

204: Suspension
204-00: Suspension System - General Information
Specification
General Procedures
Front Toe Adjustment
204-01: Front Suspension
Description and Operation
Front Suspension
Removal and Installation
Front Stabilizer Bar
Front Stabilizer Bar Link
Panhard Rod
Spring
Front Wheel Bearing and Wheel Hub


Wheel Studs
Front Shock Absorber
Bump Stop
Radius Arm
204-02: Rear Suspension
Description and Operation
Rear Suspension
Removal and Installation
Wheel Bearing and Wheel Hub
Spring
Wheel Studs
Rear Stabilizer Bar
Rear Shock Absorber
Rear Stabilizer Bar Link
Upper Arm
Lower Arm
Axle Bump Stop
204-04: Wheels and Tires
Specification
Description and Operation
Wheels and Tires
Removal and Installation
Wheel and Tire
204-05: Vehicle Dynamic Suspension
Removal and Installation
Rear Air Shock Absorber
205: Driveline
205-01: Driveshaft
Description and Operation
Driveshaft
Removal and Installation
Front Driveshaft
Rear Driveshaft
Disassembly and Assembly
Driveshaft Universal Joint
205-02: Rear Drive Axle/Differential
Specification
Description and Operation
Rear Drive Axle and Differential
Diagnosis and Testing
Rear Drive Axle and Differential
In-Vehicle Repair
Removal and Installation
Axle Assembly
Disassembly and Assembly
205-03: Front Drive Axle/Differential
Specification
Description and Operation
Front Drive Axle and Differential
Diagnosis and Testing
Front Drive Axle
In-Vehicle Repair
Removal and Installation
Axle Assembly
Differential Carrier
Disassembly and Assembly
Front Stub Axle, Constant Velocity (CV) Joint and Swivel Pin
Housing
206: Brake System
206-00: Brake System - General Information
Specification
Description and Operation
Brake System
General Procedures
Brake System Bleeding
206-03: Front Disc Brake
Removal and Installation

Brake Disc
Brake Pads
Brake Caliper
206-04: Rear Disc Brake
Removal and Installation
Brake Disc
206-05: Parking Brake and Actuation
General Procedures
Parking Brake Shoe and Lining Adjustment
Removal and Installation
Parking Brake Cable
Shoes
Parking Brake Switch
206-06: Hydraulic Brake Actuation
Removal and Installation
Brake Master Cylinder
Brake Pedal and Bracket
Brake Pressure Control Valve
Disassembly and Assembly
Brake Master Cylinder
206-07: Power Brake Actuation
Specification
Removal and Installation
Brake Booster
Brake Booster Non-Return Valve
Brake Vacuum Pump
206-09: Anti-Lock Control - Traction Control
Diagnosis and Testing
Anti-Lock Control - Traction Control
Removal and Installation
Anti-Lock Brake System (ABS) Module
Hydraulic Control Unit (HCU)
Front Wheel Speed Sensor
Rear Wheel Speed Sensor
211: Steering System
211-00: Steering System - General Information
Specification
Description and Operation
Steering System
Diagnosis and Testing
Steering System
General Procedures
Power Steering System Filling and Bleeding
Power Steering System Flushing
Steering Gear Adjustment
Steering Gear Centralization
Steering Lock Stop Adjustment
211-02: Power Steering
Specification
Description and Operation
Power Steering
Removal and Installation
Steering Gear
Power Steering Fluid Reservoir
Power Steering Pump
Disassembly and Assembly
Steering Gear
211-03: Steering Linkage
Removal and Installation
Tie Rod End
Steering Linkage Damper
Sector Shaft Arm Drag Link
Steering Gear Drop Arm
211-04: Steering Column
Removal and Installation
Steering Column
Steering Column Lower Shaft
Steering Wheel
211-05: Steering Column Switches
Description and Operation
Steering Column Switches
Removal and Installation
Ignition Switch
Steering Column Lock and Ignition Switch Housing
Steering Column Multifunction Switch RH
Steering Column Multifunction Switch LH

POWERTRAIN

303: Engine
303-00: Engine System - General Information
General Procedures
Bearing Inspection
Camshaft Bearing Journal Clearance
Camshaft Bearing Journal Diameter
Camshaft End Play
Camshaft Lobe Lift
Camshaft Surface Inspection
Connecting Rod Cleaning
Connecting Rod Large End Bore
Crankshaft End Play
Cylinder Bore Out-of-Round
Cylinder Head Distortion
Cylinder Block Distortion
Exhaust Manifold Cleaning and Inspection
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Spring Free Length
Valve Stem Diameter
303-01: Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma
Specification
Description and Operation
Engine
Diagnosis and Testing
Engine
General Procedures
Engine Oil Draining and Filling
In-Vehicle Repair
Camshafts
Crankshaft Pulley
Crankshaft Front Seal
Crankshaft Rear Seal
Cylinder Head
Engine Mount LH
Engine Mount RH
Exhaust Manifold
Flywheel
Intake Manifold
Oil Cooler
Oil Filter Housing
Oil Pan
Oil Pump
Rocker Arm
Timing Cover
Timing Chain
Valve Cover
Removal
Engine
Disassembly
Engine
Assembly
Engine
Installation
Engine
303-03: Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Specification
Description and Operation
Engine Cooling
Diagnosis and Testing
Engine Cooling
General Procedures
Cooling System Draining, Filling and Bleeding
Cooling System Draining and Vacuum Filling
Removal and Installation
Coolant Expansion Tank
Cooling Fan
Cooling Fan Shroud
Coolant Pump
Radiator
Thermostat
303-04A: Fuel Charging and Controls - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma
Specification
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls
General Procedures
Fuel Injection Component Cleaning
Removal and Installation
Fuel Injector
Fuel Injection Pump
Fuel Metering Valve
Fuel Pressure Relief Valve
Fuel Rail
303-04B: Fuel Charging and Controls - Turbocharger - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma
Specification
Description and Operation
Turbocharger
Diagnosis and Testing
Turbocharger
Removal and Installation
Turbocharger
303-05: Accessory Drive - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Specification
Description and Operation
Accessory Drive
Diagnosis and Testing
Accessory Drive
Removal and Installation
Accessory Drive Belt
Accessory Drive Belt Idler Pulley
Accessory Drive Belt Tensioner
Accessory Drive Component Bracket
303-06: Starting System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Specification
Description and Operation
Starting System
Diagnosis and Testing
Starting System
Removal and Installation
Starter Motor
303-07: Glow Plug System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Specification
Description and Operation
Glow Plug System
Diagnosis and Testing
Glow Plug System
Removal and Installation
Glow Plug
303-08: Engine Emission Control - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma
Specification
Description and Operation
Engine Emission Control
Diagnosis and Testing
Engine Emission Control
Removal and Installation
Exhaust Gas Recirculation (EGR) Cooler
Exhaust Gas Recirculation (EGR) Valve
303-12: Intake Air Distribution and Filtering - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma
Specification
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering
Removal and Installation
Air Cleaner
Air Cleaner Element
Air Cleaner Outlet Pipe
Charge Air Cooler
303-14: Electronic Engine Controls - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma
Specification
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls
Removal and Installation
Accelerator Pedal Position (APP) Sensor
Camshaft Position (CMP) Sensor
Crankshaft Position (CKP) Sensor
Cylinder Head Temperature (CHT) Sensor
Engine Control Module (ECM)
Engine Oil Pressure (EOP) Sensor
Manifold Absolute Pressure and Temperature (MAPT)
Sensor
Mass Air Flow (MAF) Sensor
308: Manual Transmission/Transaxle, Clutch and Transfer Case
308-00: Manual Transmission/Transaxle and Clutch - General Information
General Procedures
Clutch System Bleeding
Clutch Pedal Freeplay Adjustment
308-01: Clutch - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma
Specification

Description and Operation
Clutch - Vehicles With: 6-Speed Manual Transmission -
MT82
Removal and Installation
Clutch Disc and Pressure Plate
Pilot Bearing
308-02: Clutch Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Specification

Description and Operation
Clutch Controls - Vehicles With: 6-Speed Manual
Transmission - MT82
Removal and Installation
Clutch Slave Cylinder
308-03: Manual Transmission/Transaxle
Specification
Description and Operation
Manual Transmission - Vehicles With: 6-Speed Manual
Transmission - MT82
General Procedures
Transmission Draining and Filling
In-Vehicle Repair
Gearshift Control Shaft Seal
Input Shaft Seal
Output Shaft Seal
Removal and Installation
Selector Shaft Detents
Removal
Transmission
Disassembly
Transmission
Disassembly and Assembly of Subassemblies
Synchronizers
Assembly
Transmission
Installation
Transmission
308-06: Manual Transmission/Transaxle External Controls - 2.4L Duratorq-
TDCi HPCR (103kW/140PS) - Puma
Specification
Description and Operation
External Controls - Vehicles With: 6-Speed Manual
Transmission - MT82
Removal and Installation
Gearshift Lever
308-07A: Transfer Case - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Specification
Description and Operation
Transfer Case - Vehicles With: 6-Speed Manual
Transmission - MT82
General Procedures
Transfer Case Draining and Filling
Transfer Case High/Low Range Selector Rod Adjustment
In-Vehicle Repair
Transfer Case Extension Housing
Transfer Case Front Output Shaft Seal
Transfer Case High/Low Range Linkage
Transfer Case Input Shaft Seal
Transfer Case Lower Cover
Transfer Case Rear Cover
Transfer Case Rear Output Shaft Seal
Removal
Transfer Case
Installation
Transfer Case
308-07B: Four-Wheel Drive Systems
General Procedures
Differential Lock Indicator Switch Adjustment
Removal and Installation
Transfer Case Low Range Indicator Switch
Differential Lock Indicator Switch
309: Exhaust System
309-00: Exhaust System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Specification
Description and Operation
Exhaust System - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma
Removal and Installation
Catalytic Converter
Front Muffler
310: Fuel System
310-00: Fuel System - General Information
General Procedures
Diesel Filter Water Drain-Off
Fuel Tank Draining
Low-Pressure Fuel System Bleeding
Quick Release Coupling
310-01: Fuel Tank and Lines - 2.4L Duratorq-TDCi HPCR (103kW/140PS)
-    Puma
Specification
Description and Operation
Fuel Tank and Lines - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma
Removal and Installation
Fuel Cooler
Fuel Filter
Fuel Level Sender
Fuel Tank
Fuel Tank Filler Pipe

ELECTRICAL

412: Climate Control System
412-00: Climate Control System - General Information
Specification
Description and Operation
Climate Control System
Diagnosis and Testing
Climate Control System
General Procedures
Air Conditioning (A/C) System Recovery, Evacuation and
Charging
Refrigerant System Tests
Electronic Leak Detection
412-01: Air Distribution and Filtering
Description and Operation
Air Distribution and Filtering
Removal and Installation
Air Inlet Duct
Instrument Panel Registers
412-02: Heating and Ventilation
Specification
Removal and Installation
Blower
Blower Motor
Heater Control Valve
Heater Core
Heater Core and Evaporator Core Housing
Heater Core Housing
412-03: Air Conditioning - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Specification
Removal and Installation
Air Conditioning (A/C) Compressor
Air Conditioning (A/C) Switch
Condenser Core
Condenser Fan
De-Icing Switch
Evaporator Core
Thermostatic Expansion Valve
Receiver Drier
412-04: Control Components
Removal and Installation
Climate Control Assembly
Blower Motor Resistor
%!
413: Instrumentation and Warning Systems
413-01: Instrument Cluster
Specification
Description and Operation
Instrument Cluster
Diagnosis and Testing
Instrument Cluster
Removal and Installation
Instrument Cluster
413-06: Horn
Removal and Installation
Horn
413-07: Clock
Specification
Removal and Installation
Clock
414: Battery and Charging System
414-00: Charging System - General Information
Diagnosis and Testing
Charging System
414-01: Battery, Mounting and Cables
Specification
Description and Operation
Battery and Cables
General Procedures
Battery Connect
Battery Disconnect and Connect
Removal and Installation
Battery
414-02: Generator and Regulator - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma
Specification
Description and Operation
Generator - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma
Removal and Installation
Generator
415: Information and Entertainment Systems
415-01A: Audio Unit
Description and Operation
Audio System
Removal and Installation
Audio Unit
415-01B: Information and Entertainment System
Description and Operation
Navigation System

415-02: Antenna
Removal and Installation
Antenna
415-03: Speakers
Description and Operation
Speakers
Removal and Installation
Instrument Panel Speaker
D-Pillar Speaker
Rear Door Speaker
417: Lighting
417-01: Exterior Lighting
Specification
Description and Operation
Exterior Lighting
General Procedures
Headlamp Adjustment
Removal and Installation
Headlamp Assembly
Headlamp Leveling Motor
Headlamp Leveling Switch
Headlamp Switch
High Mounted Stoplamp
License Plate Lamp
License Plate Lamp Bulb
Rear Fog Lamp Bulb
Rear Lamp Assembly
Reversing Lamp
Reversing Lamp Switch
Side Marker Lamp
Side Turn Signal Lamp
Stoplamp Switch
417-02: Interior Lighting
Description and Operation
Interior Lighting
Removal and Installation
Interior Lamp
Interior Lamp Bulb
418: Electrical Distribution
418-00: Module Communications Network
Description and Operation
Communications Network
419: Electronic Feature Group
419-01A: Anti-Theft – Active
Description and Operation
Anti-Theft – Active
419-01B: Anti-Theft - Passive
Description and Operation
Anti-Theft - Passive
Removal and Installation
Passive Anti-Theft System (PATS) Transceiver

BODY AND PAINT

501: Body and Paint
501-02: Front End Body Panels
Removal and Installation
Fender
Fender Splash Shield
Hood
501-03: Body Closures
Description and Operation
General Procedures
Taildoor Striker Adjustment
Door Striker Adjustment
Removal and Installation
Door
Front Door Reinforcement Panel
Rear Door Reinforcement Panel
Taildoor
501-05: Interior Trim and Ornamentation
Description and Operation
Interior Trim
Removal and Installation
Cowl Side Trim Panel
Engine Cover
Front Door Trim Panel
Interior Rollover Bar
Rear Door Trim Panel
Rear Quarter Trim Panel
Steering Column Shrouds
Sun Visor
Taildoor Trim Panel
501-08: Exterior Trim and Ornamentation
Removal and Installation
Exterior Rollover Bar
Radiator Grille
Rear Folding Step
Towbar
501-09: Rear View Mirrors
Removal and Installation
Interior Mirror
501-10: Seating
Specification
Description and Operation
Seats
Removal and Installation
Front Seat
Front Seat Backrest
Front Seat Backrest Cover
Front Seat Backrest Heater Mat
Front Seat Cushion
Front Seat Cushion Cover
Front Seat Cushion Heater Mat
Heated Seat Switch
Rear Seat
Rear Seat Backrest
Rear Seat Backrest Cover
Rear Seat Cushion
Rear Seat Cushion Cover
Third Row Seat
Third Row Seat Backrest
Third Row Seat Backrest Cover
Third Row Seat Cushion
Third Row Seat Cushion Cover
501-11: Glass, Frames and Mechanisms
Description and Operation
Glass, Frames and Mechanisms
Removal and Installation
Front Door Window Glass
Front Door Window Regulator and Motor
Heated Windshield Relay
Rear Door Window Glass
Rear Door Window Regulator and Motor
Taildoor Window Glass
Window Control Switch
501-12: Instrument Panel and Console
Specification
Description and Operation
Instrument Panel
Removal and Installation
Instrument Panel
Instrument Panel Console
In-Vehicle Crossbeam
Floor Console
Instrument Panel Switches
501-14: Handles, Locks, Latches and Entry Systems
Specification
Description and Operation
Handles, Locks, Latches and Entry Systems
General Procedures
Latch Cable Adjustment
Removal and Installation
Front Door Latch
Rear Door Latch
Door Lock Cylinder
Exterior Front Door Handle
Exterior Rear Door Handle
Interior Rear Door Handle
Interior Front Door Handle
Hood Latch
Hood Latch Release Handle
Front Door Lock Actuator
Front Door Push Button Rod and Linkage
Rear Door Lock Actuator
Rear Door Push Button Rod and Linkage
Taildoor Latch
Taildoor Lock Cylinder
Taildoor Lock Motor
501-16: Wipers and Washers
Description and Operation
Wipers and Washers
Removal and Installation
Front Wiper Pivot Arm
Rear Window Washer Jet
Rear Window Wiper Motor
Windshield Washer Pump
Windshield Wiper Motor
Windshield Wiper/Washer Switch
Wiper Mounting Arm and Pivot Shaft
501-17: Roof Opening Panel
Removal and Installation
Roof Opening Panel
501-18: Convertible Top
Description and Operation
Convertible Top
501-19: Bumpers
Removal and Installation
Front Bumper
501-20: Safety Belt System
Specification
Description and Operation
Safety Belt System
Removal and Installation
Front Safety Belt Buckle
Front Safety Belt Retractor
Rear Center Safety Belt Buckle
Rear Center Safety Belt Retractor
Rear Safety Belt Retractor
Rear Safety Belt Buckle LH
Rear Safety Belt Buckle RH
Third Row Safety Belt Buckle
Third Row Safety Belt Retractor
501-25A: Body Repairs - General Information
Description and Operation
Body Repairs
501-25B: Body Repairs - Corrosion Protection
Description and Operation
Corrosion Protection
501-25C: Body Repairs - Water Leaks
Description and Operation
Water Leaks
501-26: Body Repairs - Vehicle Specific Information and Tolerance Checks
Description and Operation
Body and Frame
501-27: Front End Sheet Metal Repairs
Removal and Installation
Bulkhead Assembly
Front Fender Side Panel
Front Fender Top Panel LH
Front Fender Top Panel RH
Front Wheelhouse
Hood Latch Panel
Windshield Frame
501-28: Roof Sheet Metal Repairs
Removal and Installation
Roof Panel
501-29: Side Panel Sheet Metal Repairs
Removal and Installation
Front Rocker Panel
Rear Rocker Panel
B and C-Pillar Assembly
501-30: Rear End Sheet Metal Repairs
Removal and Installation
Rear Lamp Mounting Panel
Rear Quarter Upper Panel
Rear Quarter Lower Panel
Rear Crossmember Panel