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Defender 90 Labor Operation Times - 2nd Edition - NAS

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1. DIFFERENTIAL ASSEMBLY Differential assembly replace OIL SEALS amp GASKETS Oil seal pinion replace pp REAR AXLE amp FINAL DRIVE UNIT Axle assembly replace Casing replace cnn coran WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE DRT2 54 FRONT AXLE amp FINAL DRIVE 54 10 54 10 01 54 10 20 54 15 54 15 01 54 15 03 54 15 04 54 15 06 54 20 54 20 07 54 20 08 54 20 11 54 20 12 54 20 13 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE DIFFERENTIAL ASSEMBLY DEFENDER 90 Differential assembly replace Oil seal pinion replace 1 FRONT AXLE ASSEMBLY Axle assembly replace pp Casirig replace ii Oil seal axle case replace
2. POWER STEERING OIL SYSTEM Power steering system test nenn Power steering system bleed Reservoir power steering oil replace Hose feed steering pump replace Pipe hose feed steering rack box replace Pipe hose return steering rack box replace POWER STEERING PUMP Pump steering replace Pulley eterne tte tere Pump steering overhaul pp STEERING ADJUSTMENT Steering box adjust EE Steering rack box centralise ppp WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE DRT45 61 57 STEERING DEFENDER 90 57 40 STEERING COLUMN 57 40 01 Column assembly inner 8 outer replace 57 40 10 Column assembly 57 40 16 Shaft column lower replace pp 57 40 26 Universal joint column upper re
3. Rotor shield s rear each replace Rotor shields front axle set Back plates rear both sides replace Back plate rear each replace Rotor shields rear axle set replace HOSES amp CONNECTORS Includes bleeding system Hoses complete set Hose front primary LH each replace Hose center intermediate replace Hoses front set replace nn HYDRAULIC SYSTEM Brakes complete system bleed IT EE Seals brake system set replace Seals amp hoses brake system set replace Valve pressure reducing WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLI
4. WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT L JUDDER POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE LO gt 44 15 20 DRT42 49 44 AUTOMATIC TRANSMISSION DEFENDER 90 Operations include adjustments to cables where necessary 44 17 CONVERTER HOUSING amp PRIMARY DRIVE 44 17 07 Converter assembly replace pp 44 17 11 Oil seal converter replarce cnn 44 20 TRANSMISSION ASSEMBLY amp CASINGS 44 20 02 Transmission 8 converter replace 44 20 04 99 Transmission converter amp transfer gearbox assembly remove for access and reinstall 44 20 11 Gasket intermediate plate 44 20 18 Oil seal rear extension housing replace 44 20 19 Gasket rear extension housing WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCK
5. EXTERIOR MOULDINGS Finisher extension front wheel arch each replace Finisher extension rear wheel arch LH each arch set replace Wide coach line decal each per panel replace Wide coach line decal extra each per panel WRONGLY ADJUSTED J WORN STRETCHED POROUS ADRIFT NOISY CHAFED C BAD FIT D BROKEN CRACKED SP F SEIZED STIFF L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT LIT CUT N LEAKS NOT COOLANT LOSS P DIFFICULT ENGAGEMENT G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED H CORRODED PLATING FAILURE R FACTORY DAMAGE S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE ND ROVER DRT14 76 BODY DEFENDER 90 76 46 DASHBOARD 76 46 03 Panel dashboard side 76 46 04 Top rail crash roll complete replace 76 46 05 Panel lower dashboard 76 46 05 20 Panel lower dashboard replace air conditioning fitted 76 46 08 Panel dashboard side passenger side replace 76 46 27 Panel clos
6. Oil seal crankshaft rear replace Oil seal crankshaft rear replace engine removed 1 Crankshaft replace includes mains bearings Bearings main engine Set CYLINDER BLOCK CGompressiOr test e peti E Mon e rrr bete Bracket alternator mounting replace 12 21 20 12 21 01 12 17 16 DRT28 12 ENGINE DEFENDER 90 Operations include adjust ignition fuel system or kick down cable 12 29 12 29 01 12 29 02 12 29 02 01 12 29 03 12 29 03 01 12 29 10 12 29 11 12 29 12 12 29 29 12 29 30 12 29 31 12 29 32 12 29 39 12 29 40 12 29 41 12 29 49 12 29 50 12 29 54 12 29 55 12 29 57 12 29 58 12 29 58 01 12 29 60 12 29 61 12 29 62 12 29 82 12 29 83 BAD FIT BROKEN Zonmoou gt WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE CYLINDER HEAD Cylinder heads remove and reinstall including gaskets engine Cylinder head remove amp reinstall LH front each includes gasket Cylinder head remove amp reinstall LH front each includes gasket engine removed Cylinder head remove and reinstall RH rear includes gasket Cylinder he
7. TESTING AND CHARGING Air conditioning system depressurise evacuate capture amp recharge Air conditioning system depressurise evacuate capture amp recharge vehicle in shop WRONGLY ADJUSTED J WORN STRETCHED POROUS ADRIFT NOISY CHAFED C BAD FIT D BROKEN L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS F SEIZED STIFF P DIFFICULT ENGAGEMENT G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED H CORRODED PLATING FAILURE R FACTORY DAMAGE DEFENDER 90 S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE ES 2 82 25 03 82 25 20 84 WINDSHIELD WIPERS amp WASHERS 84 10 84 10 01 84 10 09 84 10 15 84 10 21 84 15 84 15 01 84 15 02 84 15 05 84 15 06 84 15 09 84 15 18 84 15 25 84 15 34 84 15 41 84 30 84 30 09 84 30 21 84 30 27 84 35 84 35 01 84 35 02 84 35 12 84 35 33 84 35 38 BAD FIT BROKEN Zonmoou gt WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WINDSHIELD WASHERS DEFENDER 90 Tank washer replace Ne Jets washer set replace pp Tubes washer each section replace
8. GE 2 Oil pan to engine reseal or fit new gasket 3 Oil pan to engine reseal or fit new gasket with engine removed Pan oil eene nnns Switch oil pressure replace pp Valve oil pressure relief replace Hose s feed oil cooler replace Hose return oil cooler replace WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 12 60 56 N 12 53 19 12 60 26 DRT31 17 12 ENGINE DEFENDER 90 Operations include adjust ignition fuel system or kick down cable 12 65 TIMING GEARS CHAINS TENSIONERS amp GUIDES 12 65 01 Cover timing gears replace 12 65 04 Gasket timing gear cover replace 12 65 04 01 Gasket timing gear cover replace with unit removed 12 65 06 Oil seal amp gasket timing gear cover replace
9. Shaft reverse idler gear replace Gear reverse idler replace Shaft input replace pp Bearing s input shaft replace Countershaft replace pp Synchronizer assembly 3rd 4th gear replace Shaft output replace ee Bearings countershaft Gear s 5th speed Synchronizer assembly 5th reverse replace Synchronizer assembly 5th reverse overhaul 5th gear layshaft Synchronizer 1st 2nd speed Main transmission and transfer gearbox assembly replace Bearing main shaft rear support replace Retaining collars mainshaft 5th gear replace Reverse gear mainshaft replace Bearing layshaft rear support replace Reverse gear layshaft Baffle plate reverse
10. Bulbs warning light each replace Bulbs warning light each extra replace AUDIO Radio replace exchange pp Speaker rear Speaker front replace pp WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 86 45 61 86 45 61 01 86 ELECTRICAL DEFENDER 90 86 55 RELAYS FLASHERS amp MODULES 86 55 12 Flasher unit hazard warning replace 86 55 17 Relay headlamps replace 86 55 19 Relay heated backlight replace 86 55 38 Relay gearshift illumination replace 86 55 74 Module front wipers amp side lights replace 86 55 90 Relay instrument illumination replace 86 60 STARTER MOTOR 86 60 01 Starter motor replace pp
11. 16 11 BODY GENERAL cont 76 11 15 Acoustic cover transmission LH side replace 76 11 16 Turret cover damper front both sides replace 76 11 28 Panel mounting inner door front remove for access 8 reinstall 76 11 39 Roll over bar exterior replace 76 11 40 Roll over bar interior 76 11 41 Tow nnns 76 11 42 Roll over bar interior rear replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC 76 10 13 2 76 10 51 7 76 10 69 DRT7 79 76 BODY DEFENDER 90 76 13 BODY TRIM INTERIOR 76 13 11 Trim casing radio speaker rear 76 1
12. Hose heater to return pipe replace Hose manifold to throttle housing replace RADIATOR Radiator assembly replace THERMOSTAT Thermostat Gasket thermostat housing LH single Thermostat test includes install new thermostat if necessary WATER PUMP Pump water replace esee nnns WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 26 30 50 26 45 01 30 MANIFOLD amp EXHAUST SYSTEM DEFENDER 90 30 10 30 10 01 30 10 09 30 10 11 30 10 22 30 10 28 30 15 30 15 02 30 15 08 30 15 08 01 30 15 10 30 15 11 30 15 16 30 15 16 01 30 15 17 30 15 17 01 30 20 30 20 02 30 20 03 30 20 04 30 20 06 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE EXHAUST S
13. Oil seals axle case both sides replace SHAFTS Half shaft LH each replace AAA Half shaft both replace Half shaft RH replace on ide End float axle shaft LH each check and adjust End float axle shaft both check and adjust WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE DRT3 57 STEERING 57 10 57 10 01 57 10 07 57 10 13 57 15 57 15 01 57 15 02 57 15 08 57 15 20 57 15 21 57 15 22 57 20 57 20 14 57 20 15 57 20 20 57 35 57 35 01 57 35 05 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE POWER STEERING RACK BOX ASSEMBLY DEFENDER 90 Power steering rack box replace Power steering rack box Power steering rack box
14. 19 55 12 Hose filler neck to tank replace 19 55 26 Tank fuel rear replace 19 60 INJECTORS 19 60 04 Fuel rail replace oti 19 60 10 Injector one only replace 19 60 12 Injectors set replace pp 19 70 VENTURVAIR INTAKE 19 70 04 Housing assembly ram pipe WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC 1 N 19 60 10 19 60 12 DRT36 27 19 FUEL SYSTEM DEFENDER 90 19 80 ROUGH ROAD DETECTION SYSTEM 19 80 01 Sensor wheel speed front each replace 19 80 02 Sensor wheel speed rear each 19 80 03 Electronic Control Module ECM replace 19 90 DIAGNOSIS Operations are based on the proce
15. Selector fork 5th reverse speed replace Gate selector replace pp Stop cam reverse gear replace WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC 37 16 69 37 12 38 37 16 02 DRT119 39 37 MANUAL TRANSMISSION DEFENDER 90 37 20 37 20 02 37 20 02 99 37 20 04 37 20 06 37 20 07 37 20 13 37 20 15 37 20 16 37 20 17 37 20 19 37 20 23 37 20 25 37 20 27 37 20 36 37 20 38 37 20 39 37 20 43 37 20 49 37 20 51 37 20 55 37 20 56 37 20 57 37 20 58 37 20 59 37 20 60 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE TRANSMISSION ASSEMBLY Transmission replace na Transmission remove for access amp reinstall Transmission assembly overhaul includes final drive Transmission assembly overhaul includes transfer gearbox Synchronizer assemblies replace
16. 41 20 08 Bearing front output shaft replace 41 20 09 Output shaft front pp 41 20 10 Intermediate gear assembly replace 41 20 13 Differential assembly replace 41 20 14 Drive flange rear output shaft replace 41 20 15 Drive flange front output shaft 41 20 16 Differential assembly overhaul 41 20 17 Bearings differential assembly replace 41 20 18 Output shaft rear replace pp 41 20 19 Bearing rear output shaft replace 41 20 21 Intermediate shaft rear bearing 41 20 22 Gear drive intermediate shaft replace 41 20 23 Dog clutch differential lock 41 20 25 Transfer gearbox replace pp 41 20 25 99 Transfer gearbox remove for access amp reinstall 41 20 28 Transfer gearbox overhaul ppp WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATI
17. 80 20 HEATER UNIT 80 20 01 Heater unit een een 80 20 01 20 Heater unit replace conditioning fitted 5 80 20 15 Meter fan eire trei 80 20 17 Resistor unit fan motor replace 80 20 29 80 20 29 20 Core replace air conditioning 80 20 31 Duct air inlet sioc EG 80 25 PIPES 8 HOSES 80 25 04 Hose thermostat housing to heater return pipe replace 80 25 05 Hose feed pipe to heater replace 80 25 12 Hose heater to engine return pipe replace 1 B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC 106 80 10 22 80 10 05 80 15 08
18. Oil seals hub amp swivel assembly both sides replace WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC 15 41 Bie So 222 60 15 48 BT 60 15 49 60 15 50 60 15 33 60 15 34 60 15 35 60 15 41 60 15 54 60 15 55 60 15 56 60 15 54 60 15 55 60 15 56 DRT5 67 60 FRONT SUSPENSION DEFENDER 90 Operations do not include wheel alignment 60 20 60 20 02 60 20 03 60 20 04 60 20 11 60 25 60 25 01 60 25 03 60 25 12 60 25 13 60 25 14 60 25 15 60 25 16 60 25 17 60 25 21 60 25 22 60 25 37 60 25 38 60 30 60 30 01 60 30 02 60 30 03 60 30 06 60 30 08 60 30 09 60 30 10 BAD FIT BROKEN WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE ROAD SPRINGS Spring assemblies both sides replace Spring seats lower both sides Spring seats lower one side replace Road spring e
19. Relay blower motor replace Relay compressor magnetic clutch Diode relay condensor fan motor replace Motor vacuum dashboard duct each replace Switch trinary replace WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC f een E a 82 20 27 je 82 20 09 82 AIR CONDITIONING Operations DO NOT include depressurize evacuate flush amp recharge system 82 25 82 25 01 82 25 02 82 25 03 82 25 14 82 25 20 82 25 26 82 30 82 30 02 82 30 02 01 COOLING UNIT Valve thermostatic expansion TXV replace Hose evaporator to compressor replace Hose receiver drier to evaporator replace Blower assembly replace pp Evaporator Hoses evaporator replace
20. TRANSMISSION Hand lever transmission brake replace Transmission brake aduet Back plate transmission brake replace Drum transmission brake replace Shoes transmission brake replace VACUUM SYSTEM Servo assembly replace pp Hose manifold to servo Valve non return replace WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 70 30 08 PI 70 30 09 70 50 01 70 60 17 70 60 19 70 60 25 70 60 26 70 55 02 70 55 05 70 55 13 70 55 16 75 70 BRAKES Operations include bleeding brakes where necessary 70 55 70 55 01 70 55 02 70 55 03 70 55 05 70 55 06 70 55 12 70 55 13 70 55 14 70 55 16 70 55 17 70 60 70 60 17 70 60 19 70 60 25 70 60 26 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROU
21. 44 28 PARKING BRAKE PARK LOCK 44 28 07 Parking brake pawl assembly park lock mechanism replace 44 30 PRESSURE amp ADJUSTMENT CHECKS 44 30 02 Cable linkage downshift control check amp adjust 44 30 04 Cable rod gearshift check amp adjust 44 30 13 Stall test E 44 32 PUMPS 44 32 01 Pump main replace aeea aE nn 44 32 07 Oil seal main pump replace 44 40 VALVE BODIES 44 40 01 Valve body assembly replace 44 90 DIAGNOSIS Operations are based on the procedures in the shop manual trouble shooting manuals and or using TestBook 44 90 01 01 Automatic transmission test procedure includes pressure test WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE Zonmoou gt DOUZZFAC 3 58 3 33 i 4 24 13 44
22. Pump washer replace Ne WINDSHIELD WIPERS Arms wiper set replace pp Arm wiper each replace pp Blades wiper set replace Blade wiper each Motor amp drive wiper replace pp Motor wiper OverhadUl enne Wheelbox drive pivot set replace Switch wiper washer replace Relay wiper motor TAILGATE GLASS BACKLIGHT WASHERS Jet s washer replace en Pump washer replace Switch washer rear replace pp TAILGATE GLASS BACKLIGHT WIPER Arm wiper replace Blade wiper replace Motor wiper rear replace Switch wiper rear replace 1 Relay tailgate wipe replace WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X
23. 12 65 12 Timing belt chain amp gears replace WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT L JUDDER POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE Een 12 65 04 e AQ ING 12 65 01 YA 14 A 12 65 06 12 65 12 DRT32 17 EMISSION CONTROL 17 15 EVAPORATIVE LOSS CONTROL SYSTEMS 17 15 13 Charcoal canister replace pp 17 15 19 Expansion tank vapour seperator replace 17 50 CATALYTIC CONVERTOR 17 50 09 Catalytic converter down pipe LH each replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT D BROKEN E CRACKED SPLIT CUT F SEIZED STIFF G LOOSE SEAK SYNCHROMESH H CORRODED PLATING FAILURE J WORN STRETCHED K NOISY CHAFED L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT N LEAKS NOT COOLANT LOSS P DIFFICULT ENGAGEMENT Q FADED STAINED DISCOLOURED R FACTORY DAMAGE DEFENDER 90 S OPEN CIRCUIT BLOCKED T SHORT
24. 76 49 09 DRT15 95 76 BODY DEFENDER 90 76 58 HANDLES PULLS amp COAT HANGERS 76 58 07 Handle outside front door 76 58 21 Handle glass regulator replace 76 58 22 Finisher front door inside handle replace 76 58 25 Door pe ae 76 58 26 Door pull tail door replace 76 58 34 Handle grab tail door replace 16 61 HARD SOFT TOPS 8 TONNEAU COVERS 76 61 11 Outer cover canopy replace 16 64 HEADLININGS 76 64 10 Headlining front replace Ne 76 64 11 Headlining rear replace 76 64 12 Finisher headlining rear replace 76 64 15 Headlining sun sliding roof fitted replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W
25. 86 60 08 Solenoid starter replace 86 60 10 Relay starter replace Ne e WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC 120 To SEN 9 86 60 01 b 86 ELECTRICAL DEFENDER 90 86 65 SWITCHES amp CIGAR LIGHTERS 86 65 03 Switch only steering lock replace 86 65 09 Switch master lighting replace 86 65 12 Switch panel light 86 65 15 Switch door pillar interior lights 86 65 36 Switch backlight heater 86 65 50 Switch hazard warning replace 86 65 55 Switch combined turn signal headlight horn replace 86 65 60 Cigar
26. transmission removed LUBRICATION Cooler transmission oil fluid replace Pipe hose oil fluid cooler feed radiator to front oil cooler replace Pipe hose oil fluid cooler return from front oil cooler replace Pipe hose oil fluid cooler feed transmission to radiator replace Pipe hose oil fluid cooler return to transmission replace Thermostat transmission oil cooler Seals thermostat housing transmission oil cooler replace SPEEDOMETER DRIVE Pinion speedometer drive SWITCHES Switch back up light replace nennen Switch hi lo warning replace pp WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC UA A AR ei SY 37 25 05 un 37 24 05 37 24 04 DRT120 43 41 TRANSFER GEARBOX DEFENDER 90 41 20 TRANSFER GEARBOX 41 20 05 Bottom cover transfer gearbox replace 41 20 06 Gasket bottom cover transfer gearbox replace
27. BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 84 35 01 84 10 09 84 15 05 84 15 06 84 15 01 84 15 02 84 30 09 84 15 09 84 15 18 84 30 27 84 15 41 84 35 38 84 30 21 84 10 21 84 10 15 DRT19 113 86 ELECTRICAL DEFENDER 90 86 10 ALTERNATOR amp CONTROL UNIT 86 10 01 Test charging system battery load amp generator output 86 10 02 Alternator replace scanneri adai eaaa 86 10 03 Drive belt alternator replace 86 10 04 Pulley alternator replace 2 86 10 09 Automatic tensioner alternator drive belt replace 86 15 86 15 01 Battery s each replace RN 86 15 17 Battery lead positive replace 86 15 19 Battery lead negative replace 86 30 5 86 30 09 Horns set replace n aite ir ue 86 30 10 Horn each era WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAK
28. L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT N LEAKS NOT COOLANT LOSS P DIFFICULT ENGAGEMENT Q FADED STAINED DISCOLOURED R FACTORY DAMAGE S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE DRT10 76 BODY DEFENDER 90 76 31 DOOR GLASSES FRAMES amp SEALS for electrically operated window switches see 86 25 76 31 01 Glass front door replace pp 76 31 13 Rubber felt glass channel front door replace 76 31 21 Glass tail door single replace 76 31 45 Glass regulator front door 76 31 72 Weather strip front door glass exterior replace 76 31 73 Weather strip front door glass interior replace WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT L JUDDER POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED
29. adjust Fork hi lo selector replace pp Gasket input gear support plate replace Input gear bearings Oil seal input shaft replace pp Oil seal input shaft replace transfer gearbox removed i Oil seal s front output shaft replace 2 Gasket front output shaft housing Oil seal s rear output shaft replace Gasket rear output shaft housing replace Hi lo selector hub amp sleeve assembly replace Input gear bearing nen Input gear bearing replace with unit removed High gear central differential Low gear centre differential replace Solenoid hi lo gearshift interlock Switch audible alarm gearshift neutral replace Knob hi lo selector lever WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION
30. 0 05 7A0 B P0328 1 005 7A0 B B B N 19 22 0306 Misfire on cylinder 6 P0306 0 05 761 C 19 22 0307 Misfire on cylinder 7 P0307 0 05 7G1 C 19 22 0331 Continuous knock on bank 2 B P0331 N 0 05 7A0 19 22 0332 Knock background noise low bank 2 B P0332 0 05 19 22 0336 CKP sensor inaccurate tooth count P0336 Y 0 05 7E7 A 19 22 0340 CMP sensor signal inaccurate compared to CKP signal P0340 0 05 7 8 19 22 0420 Catalyst efficiency low bank 1 420 0 05 282 19 22 0430 Catalyst efficiency low bank 2 B 430 0 05 254 19 22 0441 cannister purge valve incorrect flow fault 19 22 0442 system small leak detected 19 22 0443 EVAP cannister purge valve circuit malfunction 443 0 05 2N4 19 22 0446 cannister vent valve circuit malfunction 446 0 05 2N4 A N N 19 22 0308 Misfire on cylinder 8 P0308 N 0 05 761 19 22 0326 Continuous knock on bank 1 26 N 0 05 N N 19 22 0333 Knock background noise high bank 2 B P0333 N 0 05 7A0 B 19 22 0335 CKP sensor circuit fault no signal P0335 Y 0 05 7E A Y Y Y Y 19 22 0451 EVAP fuel tank pressure sensor performance 451 Y 0 05 2N6 19 22 0452 fuel tank pressure sensor low input P0452 0 05 2N6 C 19 22 0453 fuel tank pressure sensor high input P0453 0 05 2N6 C 19 22 0460 Fuel level sensor circuit malfunction
31. 1176 LTFT too lean banks 1 A and 2 B FMFR P1176 Y 0 05 7W2 C 2 Page edition 2 Re check with TestBook after a full power down REPAIR PCM DIAGNOSTIC TROUBLE CODES DTC MIL CLAIM WTY rens CODE CODE CYCLE 19 22 1177 LTFT too rich banks 1 A and 2 B FMFR 1177 Y 00 7W2 C 19 22 1178 too rich banks 1 A and 2 B AMFR 1178 005 7 2 Rasta ee e 19 22 1185 H02S ECM circuitry detects open circuit upstream sensors 1185 005 215 eat 19 22 1187 HO2S one heater open circuit upstream sensors 1187 Y 005 SCHU 19 22 1189 HO2S htr circuit type 1 low resistance upstream 1189 005 215 19 22 1191 H02S ECM circuitry detects open circuit downstream sensors 1191 Y 005 215 enge 0 05 215 19 22 1193 HO2S one heater open circuit downstream sensors P1193 Y 0 05 EN EIC et 19 22 1195 HO2S htr circuit type 1 low resistance downstream 1195 Y 005 275 en 0 05 215 19 22 1199 Fuel level sensor circuit malfunction pre 97 1199 Y 005 79 C Ken O 19 22 1202 Injector circuit open circuit or ground short cylinder 2 1202 005 2 2 Injector circuit open circuit or ground short cylinder 3 P1203 MEETS
32. 19 22 0130 HO2S switching cycle bank 1 A upstream P0130 19 22 0131 HO2S circuit low volt upstream sensor bank 1 A P0131 0 05 2T5 0 05 2T5 19 22 0132 025 circuit high volt upstream sensor bank 1 A P0132 19 22 0133 HO2S circuit slow response upstream bank 1 A P0133 0 05 2T5 0 05 2T5 19 22 0136 HO2S switching cycle bank 1 A downstream P0136 19 22 0137 HO2S circuit low volt downstream sensor bank 1 A P0137 0 05 2T5 0 05 2T5 19 22 0138 HO2S circuit high volt downstream sensor bank 1 A P0138 19 22 0139 HO2S circuit slow response downstream bank 1 A P0139 0 05 2T5 0 05 2T5 19 22 0150 025 switching cycle bank 2 B upstream P0150 19 22 0151 HO2S circuit low volt upstream sensor bank 2 B P0151 0 05 2T6 0 05 2T6 19 22 0152 HO2S circuit high volt upstream sensor bank 2 B P0152 19 22 0153 HO2S circuit slow response upstream bank 2 B P0153 0 05 2T6 0 05 2T6 19 22 0156 025 switching cycle bank 2 B downstream P0156 19 22 0157 HO2S circuit low volt downstream sensor bank 2 B P0157 0 05 2T6 0 05 2T6 19 22 0158 H025 circuit high volt downstream sensor bank 2 B P0158 19 22 0159 H025 circuit slow response downstream bank 2 B P0159 0 05 2T6 0 05 2T6 19 22 0171 System too lean bank 1 A P0171 19 22 0172 System too rich bank 1 A P0172 0 05 215 0 05 215 19 22 0174 System too lean bank 2 B P0174 19 22 0175 S
33. 24 14 44 24 15 T 44 32 0 44 32 07 DRT44 53 47 DRIVE SHAFTS DEFENDER 90 47 15 PROPELLER SHAFT 47 15 02 Propeller shaft front replace 47 15 03 Propeller shaft rear replace nennen 47 15 11 Universal joint s propeller shaft front 47 15 12 Universal joint s propeller shaft rear replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT D BROKEN E CRACKED SPLIT CUT F SEIZED STIFF G LOOSE SEAK SYNCHROMESH H CORRODED PLATING FAILURE J WORN STRETCHED K NOISY CHAFED L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT N LEAKS NOT COOLANT LOSS P DIFFICULT ENGAGEMENT Q FADED STAINED DISCOLOURED R FACTORY DAMAGE S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE DRT1 51 REAR AXLE amp FINAL DRIVE 51 10 51 10 01 51 10 03 51 15 51 15 01 51 20 51 20 01 51 25 51 25 01 51 25 04 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE AXLE HALF SHAFTS DEFENDER 90 Half shaft LH each replace Half shafts both replace
34. 25 06 Boot gear shift lever replace 76 25 24 Lock glove box lid replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT D BROKEN E CRACKED SPLIT CUT F SEIZED STIFF G LOOSE SEAK SYNCHROMESH H CORRODED PLATING FAILURE J WORN STRETCHED K NOISY CHAFED L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT N LEAKS NOT COOLANT LOSS P DIFFICULT ENGAGEMENT Q FADED STAINED DISCOLOURED R FACTORY DAMAGE S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 76 BODY DEFENDER 90 76 28 DOORS 76 28 01 Door assembly front each replace 76 28 07 Door front align on hinges includes adjust striker 76 28 19 Door tail assembly LH single replace 76 28 24 Door s tail adjust on striker s pp 76 28 27 Door tail align on hinges pp 76 28 42 Hinges side door front single upper pair replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT D BROKEN E CRACKED SPLIT CUT F SEIZED STIFF G LOOSE SEAK SYNCHROMESH H CORRODED PLATING FAILURE J WORN STRETCHED K NOISY CHAFED
35. C BAD FIT L JUDDER POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE 102 DRT50 78 SEATS DEFENDER 90 78 10 78 10 18 99 78 10 44 99 78 10 50 99 78 30 78 30 01 78 30 16 78 30 30 78 40 78 40 02 78 40 15 78 40 34 78 40 50 78 50 78 50 03 78 80 78 80 27 78 85 78 85 41 78 90 78 90 08 78 90 12 78 90 21 78 90 22 78 90 26 78 90 50 78 90 53 78 90 82 BAD FIT BROKEN Zonmoou gt 104 WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE ACCESS REMOVE amp REINSTALL SEAT ASSEMBLIES Cushion rear seat side remove for access 4 reinstall Front seat remove for access amp reinstall Seat back front seat remove for access 4 reinstall CUSHIONS FRONT SEATS Cover one piece front seat cushion replace Frame front seat cushion replace Pad one piece front seat cushion replace CUSHION
36. CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE ar 18 20 02 18 30 01 18 30 09 18 20 11 AAA 19 FUEL SYSTEM DEFENDER 90 19 10 19 10 01 19 10 10 19 10 17 19 20 19 20 01 19 20 06 19 20 23 19 22 19 22 08 19 22 09 19 22 16 19 22 17 19 22 25 19 22 46 19 22 49 19 22 54 19 25 19 25 02 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE AIR CLEANERS amp HOSES Air cleaner s replace pp Element air cleaner Hose intake single replace CONTROLS Pedal throttle replace Cable throttle replace Return spring throttle pedal replace i ELECTRONIC FUEL DISTRIBUTION EQUIPMENT Sensor engine fuel temperature EFTS replace Switch inertia fuel cut off Sensor heated oxygen HO2S front LH each rep
37. LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE Zonmoou gt DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 86 40 33 86 40 32 86 40 61 86 40 42 86 40 60 86 40 70 86 40 91 86 40 45 86 40 89 86 41 32 67 86 41 31 DRT22 117 86 ELECTRICAL 86 45 86 45 01 86 45 02 86 45 49 86 45 51 86 45 52 86 45 56 86 45 60 86 45 61 86 45 61 01 86 50 86 50 03 86 50 12 86 50 15 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE LAMPS INTERIOR DEFENDER 90 Bulb roof lamp replace Ne Lamp assembly roof replace Bulb illumination speedometer replace Bulb illumination temperature gauge replace Bulb illumination fuel gauge replace 2 Bulb illumination ammeter battery condition gauge replace Lamp assembly warning
38. RH Housing swivel pin bearing both sides replace Oil seals swivel housing outer both sides replace Oil seal swivel housing outer LH replace Oil seal swivel housing outer RH replace Constant velocity joint swivel housing both sides replace Constant velocity joint swivel pin housing one side replace Constant velocity joint swivel pin housing RH remove amp reinstall Bearings swivel pin both sides replace o Bearings swivel pin LH Bearings swivel pin RH replace Bearings swivel pin both sides adjust Bearings swivel pin LH Bearings swivel pin RH Gaskets swivel bearing housing both sides replace Gasket swivel bearing housing LH replace Gasket swivel bearing housing RH replace Oil seals hub amp swivel assembly replace Oil seals hub and swivel assembly RH replace
39. VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC 76 64 11 FF n pp 76 58 26 76 58 21 O 76 58 22 76 61 11 DRT16 97 76 BODY DEFENDER 90 76 73 SEAT BELTS amp RESTRAINT SYSTEMS 76 73 11 Non passive belt assemblies front set replace 76 73 13 Non passive belt assembly front each replace 76 73 18 Seat belt side rear replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT D BROKEN E CRACKED SPLIT CUT F SEIZED STIFF G LOOSE SEAK SYNCHROMESH H CORRODED PLATING FAILURE J WORN STRETCHED K NOISY CHAFED L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT N LEAKS NOT COOLANT LOSS P DIFFICULT ENGAGEMENT Q FADED STAINED DISCOLOURED R FACTORY DAMAGE S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 76 BODY DEFENDER 90 76 81 WINDSHIELD amp BODY GLASSES 76 81 01 Glass sealing rubber windshield 76 81 18 Glass body side rear replace 76 81 28 Catch s
40. Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE 76 BODY DEFENDER 90 76 34 DOOR INTERIOR TRIM 76 34 01 Trim casing front door 76 34 01 99 Trim casing front door remove for access reinstall 76 34 09 Trim pad tail door replace pp WRONGLY ADJUSTED POROUS ADRIFT BAD FIT D BROKEN E CRACKED SPLIT CUT F SEIZED STIFF G LOOSE SEAK SYNCHROMESH H CORRODED PLATING FAILURE J WORN STRETCHED K NOISY CHAFED L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT N LEAKS NOT COOLANT LOSS P DIFFICULT ENGAGEMENT Q FADED STAINED DISCOLOURED R FACTORY DAMAGE S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 76 BODY DEFENDER 90 76 37 DOOR LOCKS amp LATCHES for electrically operated locks see 86 26 76 37 12 Latch front door replace nenn 76 37 16 Latch tail door replace A 76 37 23 Striker plate front door replace includes adjustment 76 37 25 Striker plate tail door replace includes adjustment 76 37 27 Door front or rear adjust on striker 76 37 29 Lever remote control locking fr
41. set Valve guides engine set replace includes reface seats amp grind in valves Valves engine set replace includes reface seats grind in valves amp replace head gaskets Valves LH front each bank head set replace includes reface seats grind in valves amp replace head gasket Valves RH rear bank head set replace includes reface seats grind in valves amp replace head gasket WORN STRETCHED OPEN CIRCUIT BLOCKED NOISY CHAFED SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION INACCURATE SLIPPING BODY COOLANT LEAKS BURNT BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED INOPERATIVE FACTORY DAMAGE DOUZZFAC 12 29 58 12 29 61 12 29 82 12 29 88 12 ENGINE DEFENDER 90 Operations include adjust ignition fuel system or kick down cable 12 29 CYLINDER HEAD 12 29 88 Valve guides LH front each bank set replace 12 29 89 Valve guides RH rear bank set 12 29 90 Oil seal valve stem inlet engine set replace 12 29 93 Oil seal valve stem inlet amp exhaust engine set replace 12 29 98 Valve guide one only cylinder head RH rear replace includes reface s
42. 19 22 1204 Injector circuit open circuit or ground short cylinder 4 1204 Y 005 2 2 ERI Injector circuit open circuit or ground short cylinder 5 P1205 PET 19 22 1206 Injector circuit open circuit or ground short cylinder 6 1206 Y 005 2 2 E Injector circuit open circuit or ground short cylinder 7 P1207 19 22 1208 Injector circuit open circuit or ground short cylinder 8 1208 Y 005 2 2 19 22 1314 Misfire likely to cause damage to catalyst bank 2 B 1314 Y 005 284 C ENDE 0 05 2S0 C 19 22 1317 ABS rough road line low input 1317 Y 0 05 761 C EM 0 05 7G1 A 19 22 1361 No ignition coil activation coil 1 1361 Y 005 EN ignition coil activation coil 2 P1362 19 22 1363 No ignition activation coil 3 1363 Y 005 ERU ignition coil activation coil 4 P1364 MESE IEN 19 22 1371 Early ignition coil activation coil 1 1371 Y 005 EET ignition coil activation coil 2 P1372 MEME 19 22 1373 Early ignition coil activation 3 P1373 Y 005 748 Barren ignition coil activation coil 4 1374 Y 005 748 A 19 22 1440 cannister purge valve stuck open 1440 Y 005 2N4 esee e RC n 19 22 1448 EVAP system major leak detected 1448 Y 005 2N4 D Kos Ki 19 22 1508 circuit open 1508 Y 005 w 19 22 1509 circuit sho
43. 3 13 Trim casing rear quarter upper replace 76 13 26 Trim finisher A pillar upper replace 76 13 57 Trim casing body side rear LH each replace 16 16 HOOD 8 LATCHES 76 16 01 99 Hood remove for access amp 76 16 20 Latch s 88 10 een 76 16 21 LalChs Teplace iude 76 16 29 Cable rod latch control replace WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT L JUDDER POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE 76 16 01 99 76 13 26 76 BODY DEFENDER 90 76 22 BUMPERS 76 22 08 Bumper assembly front 76 25 CONTROL PANELS amp CONSOLES 76 25 01 Console assembly front center upper replace 76
44. 605 44 90 12 P1120 FDKT Throttle position malfunction 12 Y 0 05 605 44 90 13 P0743 FMVWK Torque converter solenoid circuit malfunction 13 Y 005 605 B San eut 20 Y 0 05 605 B 44 90 21 727 726 MOT Engine speed signal performance m Y 005 6U5 B 44 90 22 P0748 P0745 FDR Pressure control regulator circuit malfunction 22 Y 0 05 605 44 90 23 P1609 FME Engine torque reduction 23 Y 0 05 605 B E 24 Y 065 605 B 44 90 26 P1608 FT T Engine Torque signal 26 Y 005 6U5 B aas erre C Dem RN eet aca ga 27 Y 005 605 B 44 90 28 P1607 FEPROM TCM data corrupted 28 005 605 A SE 30 Y 005 605 B 44 90 31 P0705 FPOSST Gear position switch failure whilst starting 31 Y 0 05 605 A 40 Y 065 605 B 144 90 41 P0730 FGANG2 2nd gear malfunction 97 onwards 41 0 05 605 B Se MM 42 005 605 B 44 90 43 P0730 FGANGA 4th gear malfunction 97 onwards 43 Y 005 605 B EMEN 44 Y 005 605 B Terminology for above is P code number Fault name Fault description 4 Page edition 2 Re check with TestBook after a full power down OBD CODES 14CUX 19 22 01 MFI TESTING 19 22 01 02 MFI Dynnamic Expert Tool Box Test 0 20 19 22 01 12 MFI Initial Test Access OBD Code 12 0 40 19 22 01 14 Initial Test Access OBD Co
45. 80 25 04 80 25 05 80 10 12 80 25 12 80 20 15 80 15 15 80 15 03 80 15 29 80 20 31 DRT52 107 82 AIR CONDITIONING DEFENDER 90 Operations DO NOT include depressurize evacuate flush amp recharge system 82 10 82 10 20 82 10 21 82 15 82 15 01 82 15 07 82 17 82 17 01 82 20 82 20 04 82 20 08 82 20 09 82 20 10 82 20 11 82 20 26 82 20 27 82 20 51 82 20 74 82 20 79 82 20 86 BAD FIT BROKEN A B C D E F G H 108 WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE COMPRESSOR amp DRIVE Compressor replace pp Hose compressor to condenser CONDENSER Motor condenser fan Condenser replace LIQUID RECEIVER DRIER ACCUMULATOR Liquid receiver drier replace CONTROLS Switch pressure liquid receiver drier replace Relay main replace Relay condenser fan motor replace Switch temperature control Switch air flow control replace pp Resistance unit blower motor
46. 97MY onwards 460 0 05 7F9 A 19 22 0461 Fuel level sensor signal not changing 461 0 05 7F9 A 19 22 0500 VSS malfunction P0500 0 05 7T2 B 19 22 0506 IAC system RPM low 19 22 0507 system RPM high N Y Y Y P0441 0 05 2N4 C P0442 0 05 2N4 D Y Y Y Y 506 Y 005 7W1 A P0507 Y 0 05 7W1 A 19 22 0560 System voltage low with high engine speed A 19 22 0562 System voltage low A P0560 0 05 781 62 0 05 761 N 19 22 0563 System voltage high P0563 0 05 761 A 19 22 0605 data corrupted P0605 0 05 7G1 A 19 22 1137 HO2S failed to switch to rich upstream bank 1 19 22 1137 HO2S failed to switch to rich downstream bank 1 Y P1137 Y 0 05 2T5 A P1137 0 05 215 N 19 22 1138 HO2S failed to switch to lean upstream bank 1 P1138 0 05 215 19 22 1138 HO2S failed to switch to lean downstream bank 1 P1138 N 0 05 215 19 22 1157 25 failed to switch to rich upstream bank 2 P1157 Y 0 05 2T6 C 19 22 1157 HO2S failed to switch to rich downstream bank 2 B P1157 N 0 05 2T6 19 22 1158 HO2S failed to switch to lean upstream bank 2 B P1158 Y 0 05 216 19 22 1158 HO2S failed to switch to lean downstream bank 2 P1158 N 0 05 2T6 19 22 1171 System too lean bank 1 and bank 2 B P1171 Y 0 05 215 19 22 1172 System too rich bank 1 and bank 2 B 1172 0 05 216 19 22
47. CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE DRT53 18 ENGINE MANAGEMENT SYSTEM 18 20 18 20 02 18 20 11 18 20 45 18 30 18 30 01 18 30 09 18 30 10 18 30 12 18 30 24 18 30 28 18 30 30 18 30 71 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE IGNITION SYSTEM DEFENDER 90 Spark plugs replace See normal wear limits Wire spark plug engine set replace Ignition coils multiple set SENSORS SWITCHES RELAYS amp VALVES Engine control module ECM combined ignition amp fuel replace Sensor intake air temperature IAT replace Sensor engine coolant temperature ECTS Sensor crankshaft position Sensor camshaft position CMP replace Sensor knock KS LH each replace Sensor knock KS RH replace Relay module replace pp WORN STRETCHED NOISY CHAFED JUDDER POOR
48. DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC 64 15 15 64 15 16 64 15 12 64 15 13 64 15 14 64 15 17 64 15 19 64 15 20 64 15 15 64 15 16 64 30 13 64 30 15 WS T O 64 35 05 64 35 07 64 20 01 64 20 02 64 35 02 64 35 12 64 30 06 64 30 07 64 30 01 64 30 02 64 35 04 64 35 06 DRT47 71 70 BRAKES Operations include bleeding brakes where necessary 70 10 70 10 03 70 10 05 70 10 09 70 10 10 70 10 12 70 10 13 70 10 17 70 10 18 70 10 19 70 10 21 70 10 24 70 10 28 70 10 29 70 15 70 15 01 70 15 02 70 15 04 70 15 10 70 25 70 25 02 70 25 03 70 25 16 70 25 18 70 25 21 BAD FIT BROKEN Zonmoou gt WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE ROTORS amp DRUMS Includes check new rotor s for runout DEFENDER 90 Drum rear each replace Drums rear set replace Rotors vehicle set replace Rotor front each pp Rotors front set replace Rotors rear set replace Rotor shields vehicle set Rotor shield s front each replace
49. ED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT L JUDDER POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE 44 20 04 99 Ka N DRT43 51 44 AUTOMATIC TRANSMISSION DEFENDER 90 Operations include adjustments to cables where necessary 44 22 GOVERNOR 44 22 01 Governor assembly replace pp 44 22 04 Governor assembly 44 24 LUBRICATION SYSTEM 44 24 01 Tube fluid filler replace en 44 24 02 Lubrication system drain amp refil 44 24 04 Pan Tula replace uerit erede ate 44 24 05 Gasket oil fluid pan replace 44 24 07 Filter fluid replace 44 24 10 Cooler oil fluid replace pp 44 24 13 Hose supply fluid cooler replace 44 24 14 Hose return fluid cooler replace 44 24 15 Hoses pipes oil fluid cooler set
50. FIT D BROKEN L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS F SEIZED STIFF P DIFFICULT ENGAGEMENT G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED H CORRODED PLATING FAILURE R FACTORY DAMAGE S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE DRT37 31 26 COOLING SYSTEM Operations include drain refill bleed system and pressure test where necessary 26 30 26 30 01 26 30 04 26 30 07 26 30 29 26 30 30 26 30 33 26 30 44 26 30 50 26 40 26 40 01 26 45 26 45 01 26 45 06 26 45 09 26 50 26 50 01 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE HOSES amp PIPES DEFENDER 90 Hose top radiator replace Hose radiator to throttle housing Hose bottom radiator replace Hose manifold to heater pipe Hose manifold to heater valve heater replace Hose radiator to expansion tank
51. LIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC ADLA S 60 10 01 AD PAN ar eme Ti 60 10 03 60 10 04 60 FRONT SUSPENSION DEFENDER 90 Operations do not include wheel alignment 60 15 60 15 20 60 15 21 60 15 22 60 15 33 60 15 34 60 15 35 60 15 39 60 15 40 60 15 41 60 15 42 60 15 43 60 15 46 60 15 48 60 15 49 60 15 50 60 15 54 60 15 55 60 15 56 60 15 57 60 15 58 60 15 59 60 15 63 60 15 64 60 15 65 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE BALL JOINTS amp KNUCKLES Housing swivel pin LH replace Housing swivel pin RH replace Housings swivel pins both sides Housing swivel bearing LH replace Housing swivel pin bearing
52. Labor Operation Times ao a a e LAND ROFER DEFENDER 90 LABOR OPERATION TIMES 1994 MODEL YEAR ONWARDS Part No LRL 0109NAS Page Edition 2 EFFECTIVE DATE 10 97 Published by Rover Technical Communication 1997 Rover Group Limited ENGINE tme dei 12 EMISSION CONTROL 17 ENGINE MANAGEMENT SYSTEM 18 FUEL SYSTEM mee 19 COOLING SYSTEM 26 MANIFOLD AND EXHAUST SYSTEM 30 CLUTCH mes 33 MANUAL TRANSMISSION 37 TRANSFER GEARBOX 41 AUTOMATIC TRANSMISSION 44 DRIVE SHAFTS esee 47 REAR AXLE 8 FINAL DRIVE 51 FRONT AXLE FINAL DRIVE 54 STEERING tees 57 FRONT SUSPENSION 60 REAR SUSPENSION 64 BRAKES ipm 70 BODY LO 76 SEA TS voii pa 78 HEATING AND VENTILATION 80 AIR CONDITIONING eene 82 WINDSHIELD WIPERS WASHERS 84 ELECTRICAL u ee 86 INSTRUMENTS senes 88 INTRODUCTION LABOR TIMES AND ALLOWANCES All operation times are given in DECIMAL HOURS Minimum time is 0 10 hour with the exception of operations with numbers having an additional pair of digits e g 12 60 32 01 The times listed in this publication are the result of careful study of the operations concerned They reflect the averag
53. N OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 70 30 08 PI 70 30 09 70 50 01 70 60 17 70 60 19 70 60 25 70 60 26 70 55 02 70 55 05 70 55 13 70 55 16 77 76 BODY DEFENDER 90 76 10 BODY GENERAL 76 10 13 Panel roof replace a EAE RS EE 76 10 17 Sun visors pair replace 76 10 24 Fender front LH each remove for access amp reinstall 76 10 47 Sun visor each replace pp 76 10 51 Mirror interior replace AA 76 10 52 Mirror exterior each replace 76 10 55 Panel fender outer front RH replace 76 10 56 Panel fender outer front LH replace 76 10 63 Panel fender inner front LH replace 76 10 64 Panel fender inner front RH replace 76 10 68 Panel front floor passenger side 76 10 69 Panel front floor drivers side 76 10 70 Panel cover transmission replace 76 10 71 Panel cover transmission bell housing replace 76 10 92 Cross member chassis remove and reinstall
54. NG FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE Zonmoou gt DOUZZFAC 41 20 33 a 41 20 34 DRT40 45 41 TRANSFER GEARBOX DEFENDER 90 41 20 41 20 30 41 20 33 41 20 34 41 20 40 41 20 41 41 20 44 41 20 46 41 20 47 41 20 48 41 20 49 41 20 50 41 20 50 01 41 20 51 41 20 52 41 20 54 41 20 55 41 20 58 41 20 60 41 20 60 01 41 20 61 41 20 62 41 20 63 41 20 64 41 20 65 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE TRANSFER GEARBOX Gasket rear cover plate replace Switch differential lock actuator adjust Switch differential lock actuator replace Housing selector lever replace Housing selector lever overhaul Gasket hi lo selector housing replace Linkage cable hi lo selector
55. NT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC 30 10 22 Er 30 20 03 e NP 30 20 04 30 20 02 6 30 20 06 DRT39 35 33 CLUTCH Operations include bleeding hydraulic system where necessary 33 10 33 10 01 33 10 01 01 33 10 02 33 10 07 33 15 33 15 01 33 20 33 20 01 33 20 07 33 25 33 25 12 33 25 13 33 30 33 30 02 33 30 08 33 35 33 35 01 33 35 07 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE CLUTCH ASSEMBLY DEFENDER 90 Clutch assembly replace Clutch assembly replace transmission removed Clutch disc replace sess Pressure plate clutch disc amp throw out bearing replace HYDRAULIC SYSTEM Hydraulic system bleed MASTER CYLINDER Cylinder master replace pp Cylinder master overhaul cc MECHANICAL LINKAGE amp RELEASE Bearing throw out replace Arm clutch throw out replace pp PEDAL ASSEMBLIES Pedal clutch replace E a a Pad cover clut
56. PPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE gt 70 15 02 70 15 01 70 15 10 70 15 04 Lad HHG at 70 10 29 70 10 17 70 10 19 70 10 18 70 10 09 DRT48 73 70 BRAKES Operations include bleeding brakes where necessary 70 30 70 30 08 70 30 09 70 35 70 35 01 70 35 03 70 35 10 70 35 25 70 35 42 70 35 60 70 40 70 40 01 70 40 02 70 40 03 70 45 70 45 01 70 45 09 70 45 15 70 45 17 70 45 18 70 50 70 50 01 70 50 14 70 50 15 BAD FIT BROKEN gt 2 WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE MASTER CYLINDER DEFENDER 90 Cylinder master tandem replace Cylinder master tandem MECHANICAL LINKAGE Pedal brake replace on Pedal box replace A Cable s rod s parking brake adjus Cable parking brake each replace Switch stop light replace pp Pad cover brake pedal replace PADS SHOES Pads shoes vehicle set Pads shoes front set Pads shoes rear set replace
57. R POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE 124 86 70 07 e eu NE AS 0 3 H L BACI NS 86 70 23 Se S gt DRT26 125 88 INSTRUMENTS DEFENDER 90 88 15 CLOCK 88 15 07 Glock replace nen 88 20 INSTRUMENT PANEL 88 20 01 Instrument pack replace 88 20 20 Printed circuit warning lamp cluster replace 88 25 OIL amp FUEL GAUGES 88 25 14 Gauge coolant temperature replace 88 25 20 Transmitter coolant temperature 88 25 26 Gauge fuel replace 88 30 SPEEDOMETER 4 TACHOMETER 88 30 01 Speedometer replace A 88 30 14 Transducer speed 88 30 21 Tachometer replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK
58. RE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC DRT46 63 60 FRONT SUSPENSION DEFENDER 90 Operations do not include wheel alignment 60 10 ANTI SWAY BARS STABILISERS 60 10 01 Anti sway bar replace Ne 60 10 03 Ball joint links anti sway bar both sides replace 60 10 04 Ball joint link anti sway bar each 60 10 05 Rubber mountings anti sway bar set replace 60 10 07 Bush s Panhard rod replace 60 10 10 Stabiliser panhard tie rod replace 60 10 16 Radius rod replace an 60 10 17 Radius rods both sides 60 10 19 Bush s radius rod both sides 60 10 20 Bush s radius rod one side replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SP
59. READ DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC DRT57 80 HEATING amp VENTILATION DEFENDER 90 80 10 CONTROLS 80 10 02 Controls heater replace pp 80 10 05 Cable heater temperature control 80 10 12 Cable air distribution control 80 10 17 Cable air recirculation control replace nn 80 10 22 Switch fan front heater replace 80 15 DEFOGGERS amp VENTILATORS 80 15 01 Tube demister LH replace 80 15 03 Duct demister each replace gt 80 15 08 Duct demister driver s side 80 15 14 Outlet foot level ventilator each replace 80 15 15 Tube demister RH replace 80 15 17 Valve foot level ventilator 80 15 29 Grille fresh air intake passenger side replace
60. S 8 OCCASIONAL SEATS Cover rear seat cushion side replace Frame rear seat cushion side Pad rear seat cushion side replace Pad rear seat cushion LH each replace HEAD RESTRAINTS FRONT amp REAR SEATS Head restraint front seat LH each SLIDES amp CONTROLS MANUAL Slides manual front seat set replace SEAT FRAMES 4 FIXINGS Hinges rear seat pair replace SEAT BACKS FRONT amp REAR SEATS Cover seat back front seat replace Cover seat back rear seat side LH each replace Pullmaflex frame front seat back replace Frame seat back front seat replace Frame seat back rear seat side LH each replace Pad seat back front seat center replace Pad seat back rear seat side replace Seat back rear seat LH each replace WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT TH
61. S NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC DRT21 115 86 ELECTRICAL 86 40 LAMPS EXTERIOR Operations do not include headlamp alignment DEFENDER 90 86 40 02 Headlamp assembly outer single replace 86 40 17 Headlamps pair aim beam 86 40 32 Lens side park lamp front 86 40 33 Bulb side park lamp front replace 86 40 34 Lamp assembly side park front 86 40 40 Lens turn signal lamp front 86 40 41 Bulb turn signal lamp front replace 86 40 42 Lamp assembly turn signal front 86 40 43 Lens turn signal lamp rear 86 40 44 Bulb turn signal lamp rear replace 86 40 45 Lamp assembly turn signal rear replace 86 40 58 Bulb side marker front replace 86 40 59 L
62. S ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WHEEL BRAKE CALIPERS DEFENDER 90 Calipers vehicle set replace Caliper front each replace uu Caliper rear each replace Calipers front set replace Calipers rear set replace Calipers vehicle set overhaul A Caliper front each Overhaul Caliper rear each overhaul Calipers front set overhaul Calipers rear set overhaul WHEEL CYLINDERS Wheel cylinders rear both sides replace Wheel cylinder rear each replace Wheel cylinders rear both sides Wheel cylinder rear each overhaul WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATIO
63. SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC 126 88 20 01 DRT27 127 DTC MIL DRIVE REPAIR PCM DIAGNOSTIC TROUBLE CODES CODE CODE CYCLE GEMS CODES 19 22 0101 MAF sensor circuit performance PO101 0 05 7W2 19 22 0102 MAF sensor circuit low input P0102 19 22 0103 sensor circuit high input P0103 lt lt 0 05 7W2 0 05 7W2 19 22 0111 sensor circuit performance 111 19 22 0112 sensor circuit low input P0112 0 05 7G4 0 05 7G4 19 22 0113 sensor circuit high input P0113 19 22 0116 ECT sensor circuit performance falling temp P0116 0 05 7G4 0 05 7G3 19 22 0117 ECT sensor circuit low input PO117 19 22 0118 ECT sensor circuit high input P0118 0 05 7G3 0 05 7G3 19 22 0121 TPS sensor circuit performance P0121 19 22 0122 TPS sensor circuit low input P0122 0 05 7G5 0 05 7G5 19 22 0123 TPS sensor circuit high input P0123 19 22 0125 ECT excessive time to closed loop fuel control P0125 0 05 7G5 0 05 7G3
64. U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC La 41 20 30 gt 41 20 64 e A 41 20 63 41 20 48 aa 41 20 557 50 amp 2 41 20 54 PY pa 6 A A S 8 41 20 44 QS 41 20 17 DRT41 47 44 AUTOMATIC TRANSMISSION DEFENDER 90 Operations include adjustments to cables where necessary 44 15 CONTROLS amp LINKAGE 44 15 01 Cable control downshift replace includes adjustment 44 15 04 Lever gearshift selector assembly replace 44 15 07 Knob gearshift lever replace 44 15 08 Rod cable assembly gearshift replace 44 15 10 Indicator gearshift replace 44 15 19 Switch starter inhibitor replace 44 15 20 Gearshift shaft cams A stop plate replace 44 15 34 Oil seal gearshift shaft replace 44 15 37 Relay s gearshift interlock replace 44 15 38 Relay s gearshift neutral replace
65. YSTEM See 17 50 for three way catalyst Exhaust system replace Ne Front pipe Ee Intermediate pipe amp or muffler replace Tail pipe amp muffler replace Heat shield front pipe replace MANIFOLDS Manifold air intake LH front single replace Gasket s air intake manifold LH each replace Gasket s air intake manifold LH each replace with engine removed Manifold exhaust LH front single replace Manifold exhaust RH rear Gasket s exhaust manifold RH rear replace Gasket s exhaust manifold RH rear replace engine removed Gasket s exhaust manifold LH front single replace Gasket s exhaust manifold LH front single replace engine removed MOUNTINGS Mounting rubber front replace Mounting rubber center replace 2 Mounting rubber rear each replace Mountings set replace Ne WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BUR
66. ach replace HUBS DRIVE FLANGES amp WHEELS Hub each replace Hubs both sides replace pp Bearings hubs both sides check 8 adjust end float Bearings hub one side check 4 adjust end float Bearings hub one side replace Oil seals hub one side replace Bearings hubs both sides Oil seals hubs both sides replace Stub axles both sides replace Stub axle one side replace i Oil seal front hub stub axle one side replace Oil seals front hub stub axle both sides replace SUSPENSION DAMPERS amp STOP RUBBERS Dampers both sides Damper one side replace 2 Dampers front amp rear remove amp Mounting turret front both sides remove amp reinstall Mounting rubber damper one side replace Bump stops b
67. ad remove and reinstall RH rear includes gasket engine removed Cylinder heads engine set replace includes reface amp grind in Cylinder head LH front each replace includes reface amp grind in Cylinder head RH rear replace includes reface amp grind in Rocker shaft assembly LH front each Rocker shaft assembly RH rear replace 3 Push rods set LH Push rods set replace Gaskets covers camshaft valve engine set replace Gasket cover LH front each replace Gasket cover camshaft valve RH rear replace Rocker shaft assembly LH front each overhaul Rocker shaft assembly RH rear overhaul Rocker shaft assembly engine set replace Rocker shaft assembly engine set overhaul Tappets cam followers engine set replace Valve guide one only cylinder head front LH replace includes reface seat amp grind in valve Valve guide extra each cylinder head front LH replace includes reface seat amp grind in valve Pushrods engine
68. amp assembly side marker front replace 86 40 60 Lamp assembly side marker rear 86 40 61 Bulb side rear marker replace 86 40 66 Lens tail lamp each replace 86 40 67 Bulb tail lamp each 86 40 70 Lamp assembly tail LH each replace 86 40 84 Lens license plate lamp replace 86 40 85 Bulb license plate lamp 86 40 86 Lamp assembly license plate replace 86 40 89 Lens back up lamp replace 86 40 90 Bulb back up lamp replace 86 40 91 Lamp assembly back up 86 41 LAMPS EXTERIOR continued Operations do not include headlamp alignment 86 41 31 Bulb s center high mounted stop lamp replace 86 41 32 Lamp assembly center high mounted stop replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF
69. ch pedal replace SLAVE CYLINDER Cylinder slave replace pp Cylinder slave overhaul nn WORN STRETCHED NOISY CHAFED JUDDER POOR CONNECTION BODY COOLANT LEAKS BURNT LEAKS NOT COOLANT LOSS DIFFICULT ENGAGEMENT FADED STAINED DISCOLOURED FACTORY DAMAGE DOUZZFAC S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE 33 10 02 33 30 08 DRT83 37 37 MANUAL TRANSMISSION DEFENDER 90 37 12 37 12 01 37 12 01 01 37 12 07 37 12 09 37 12 33 37 12 33 01 37 12 35 37 12 38 37 12 40 37 12 41 37 12 47 37 12 48 37 16 37 16 02 37 16 04 37 16 09 37 16 10 37 16 11 37 16 14 37 16 15 37 16 26 37 16 27 37 16 29 37 16 37 37 16 37 01 37 16 40 37 16 45 37 16 55 37 16 69 37 16 73 BAD FIT BROKEN Zonmoou gt WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE COVERS CASE amp EXTENSIONS Extension rear replace Ne E Extension rear remove reseal amp reinstall includes replace oil Housing clutch bell replace pp Cover bottom replace pp Cover front replace cc cnn nn Cover front remove reseal amp reinstall includes replace oil seal Pipe oil
70. de 14 0 40 19 22 01 15 MFI Initial Test Access OBD Code 15 0 40 19 22 01 17 MFI Initial Test Access OBD Code 17 0 40 19 22 01 18 MFI Initial Test Access OBD Code 18 0 40 19 22 01 19 MFI Initial Test Access OBD Code 19 0 40 19 22 01 23 MFI Initial Test Access OBD Code 23 0 40 19 22 01 25 Initial Test Access OBD Code 25 0 40 19 22 01 26 MFI Initial Test Access OBD Code 26 0 40 19 22 01 28 MFI Initial Test Access OBD Code 28 0 40 19 22 01 29 MFI Initial Test Access OBD Code 29 0 40 19 22 01 34 MFI Initial Test Access OBD Code 34 0 40 19 22 01 36 MFI Initial Test Access OBD Code 36 0 40 19 22 01 40 Initial Test Access OBD Code 40 0 40 19 22 01 44 MFI Initial Test Access OBD Code 44 0 40 19 22 01 45 Initial Test Access OBD Code 45 0 40 19 22 01 48 MFI Initial Test Access OBD Code 48 0 40 19 22 01 50 MFI Initial Test Access OBD Code 50 0 40 19 22 01 68 MFI Initial Test Access OBD Code 68 0 40 19 22 01 69 Initial Test Access OBD Code 69 0 40 19 22 01 88 MFI Initial Test Access OBD Code 88 0 40 19 22 01 99 MFI Initial Test Light On No OBD Code Stored 0 40 This test procedure may be claimed in addition to an OBD code test only in situations where appropriate Note One and ONLY one of the listed Initial Tests MUST be claimed any time a vehicle is diagnosed with a MIL illuminated If more t
71. dures in the shop manual trouble shooting manuals and or using TestBook 19 90 06 01 Fuel system pressure Test WRONGLY ADJUSTED POROUS ADRIFT BAD FIT D BROKEN E CRACKED SPLIT CUT F SEIZED STIFF G LOOSE SEAK SYNCHROMESH H CORRODED PLATING FAILURE J WORN STRETCHED K NOISY CHAFED L JUDDER POOR CONNECTION M BODY COOLANT LEAKS BURNT N LEAKS NOT COOLANT LOSS P DIFFICULT ENGAGEMENT Q FADED STAINED DISCOLOURED R FACTORY DAMAGE S OPEN CIRCUIT BLOCKED T SHORT CIRCUIT THREAD DAMAGE U INACCURATE SLIPPING V BULB LIGHT UNIT FAILURE W VIBRATION OUT OF BALANCE X BRAKE PULL SURFACE DAMAGE Z INOPERATIVE DRT54 26 COOLING SYSTEM Operations include drain refill bleed system and pressure test where necessary 26 10 26 10 01 26 10 07 26 15 26 15 01 26 25 26 25 03 26 25 06 26 25 11 26 25 19 COOLANT amp SYSTEM DEFENDER 90 Cooling system drain flush and rent System pressure teSt nennen EXPANSION TANKS Tank replace en en ed oed deed d ds FANS Pulley water pump replace Fan blades LH single replace Cowl shroud fan replace pp Coupling unit viscous fan replace WRONGLY ADJUSTED J WORN STRETCHED POROUS ADRIFT NOISY CHAFED C BAD
72. e time a technician should take to carry out the operation in a workshop with average facilities efficiently They do not reflect special familiarity The following items have been allowed for in operation times Wrench Time Spanner Time including time taken to carry out intermediate operations e g opening and closing hood fitting and removing fender covers the use of jacks and lifts draining and refilling units cleaning Time taken to drive vehicle in and out of the shop and place the vehicle in position for repair Repair diagnosis time Includes use of common testers such as volt ohmmeter ammeter timing light or engine analyzer that are included in service manual or technical bulletin publications or instructions Time taken to obtain and return special tools Time taken receiving instruction concerning the operation Time taken to obtain appropriate parts Time taken to carry out associated clerical work Time taken for final test and quality checks No allowance has been included for inaccessibility through damage removing extras or special fitments freeing seized parts removing rusted or broken studs or bolts or subsequent repairs after test Allowances are made within the final time to change over ancillaries from the removed part or component and to fit them onto the new part or component EACH OPERATION IS COMPLETE IN ITSELF UNLESS OTHERWISE STATED e g Brake Master Cylinder Replace time includes al
73. earings hub one side check 8 adjust end float Bearing s hub one side replace Oil 5 hub one side replace r Oil seals hubs both sides replace Bearings hubs both sides Stub axles rear both Stub axle each replace Oil seal rear stub axle LH each replace Oil seals rear stub axles both sides ROAD SPRINGS Road spring each replace Spring assemblies both sides SUSPENSION DAMPERS amp RUBBER STOPS Dampers both sides Dampers one side replace Brackets damper top mountings both sides Bracket damper top mounting each replace Bump stop arch spring both sides replace Bump stop one side joints a
74. eat amp grind in valve 12 29 98 01 Valve guide extra each cylinder head RH rear replace includes reface seat amp grind in valve A WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT L JUDDER POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE 12 29 58 12 29 61 12 29 82 12 29 88 12 ENGINE DEFENDER 90 Operations include adjust ignition fuel system or kick down cable 12 41 12 41 01 12 41 02 12 41 03 12 45 12 45 01 12 45 03 12 45 04 12 45 07 12 45 09 12 45 10 ENGINE ASSEMBLY Engine amp ancilliaries replace Stripped engine long block remove engine change over ancillary equipment amp reinstall Short block block with crank and pistons replace ENGINE MOUNTINGS Mounting front LH replace pp Mounting front RH replace Mountings front set replace nn Mounting rear LH A Mounting rear RH replace Mountings rear set rep
75. gear replace WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC amp 37 20 56 DRT 121 41 37 MANUAL TRANSMISSION DEFENDER 90 37 23 37 23 01 37 23 01 01 37 23 03 37 23 06 37 23 06 01 37 23 16 37 23 16 01 37 24 37 24 02 37 24 03 37 24 04 37 24 05 37 24 06 37 24 07 37 24 08 37 25 37 25 05 37 27 37 27 01 37 27 03 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE OIL SEALS Oil seal output shaft replace Cil seal output shaft replace transfer gearbox removed Collar oil seal mainshaft replace Oil seal input shaft replace Oil seal input shaft replace transmission removed Transmission reseal fit new oil seals and O ring s Transmission reseal fit new oil seals and O ring s
76. han one OBD code is accessed claim the test for the first code retrieved enter the code s on a comment line and use fault code Page edition 2 5 Re check with TestBook after a full power down REQUEST FOR LABOR OPERATION TIME REVIEW DEALER CODE DEALER NAME TECHNICIAN TELEPHONE DATE LABOR CODE DESCRIPTION CAR MODEL EXISTING TIME ATTEMPT ACTUAL TIME RO fe NAAA SECOND THRD COMMENTS Return this form with the following supporting documentation to United States Canada Land Rover Warranty Administration Land Rover Warranty Administration 4371 Parliament Place 2425 Skymark Avenue Unit 6 Lanham MD 20706 Mississauga ON LAW 4Y6 1 Copies of 3 repair orders requiring this operation 2 Punch times related to this operation from the same technician for the 3 repair orders referenced above 3 List each step and the time needed to perform it for this procedure on the back of this form Describe in detail any specific problems or procedures you encountered Requests lacking documentation may not be processed Times modified due to a Labor Operation Review are subject to re evaluation with the next printing of the Warranty Codes Manual REQUEST FOR LABOR OPERATION TIME REVIEW ug eU ELE SERVICE MANAGER DATE
77. ic repair or operation replace Operation numbers with an additional pair of digits e g 12 60 32 01 relate to operations which can be performed with the vehicle or major system in different stages of assembly and appear immediately following the operation to which they are related LABOR OPERATION USE Engineers Product Reliability and Warranty Administration Groups utilize repair or fault codes for various reasons For this reason it is extremely important that correct and appropriate labor operation numbers are selected and entered on the warranty claim Each claim must begin with the labor operation that caused the complaint In the case where a failure causes other faults i e axle seal contaminates brake pad linings the first operation number to be entered into the warranty claim system is the labor operation number to replace the axle seal The labor operation to replace the brake pads is second within the same claim number This format allows the LANA Warranty System to assign the appropriate failure code for Land Rover statistical and analysis uses This also puts the repair into perspective NON SCHEDULED TIME If an operation does not exist for a repair use a 00 operation To do this substitute the 5thand 6thcharacters with 00 e g 12 60 32becomes 12 60 00 Only the actual time taken to perform the repair should be claimed All unscheduled labor must be documented by clock times In the event that both scheduled and unschedu
78. ide screen window sliding 76 81 44 Body side glass assembly replace 76 81 52 Glass alpine light replace nn 76 81 53 Sealing rubber alpine light replace WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT L JUDDER POOR CONNECTION U INACCURATE SLIPPING D BROKEN M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE 100 76 81 18 76 81 52 DRT18 101 76 BODY DEFENDER 90 76 83 SLIDING amp SUNROOFS Mechanically operated 76 83 01 Sun sliding roof complete front replace 76 83 03 Glass panel sun sliding roof front replace 76 83 25 Finisher flange to headlining front replace 76 83 40 Handle operating sun sliding roof front replace WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE
79. ing replace seen 76 46 28 Panel closing driver s side replace 76 46 35 Surround instrument pack replace 76 49 FLOOR COVERINGS 76 49 01 Carpet transmission cover front each replace 76 49 03 Carpet rear replace pp 76 49 09 Carpet LH replace 76 49 10 Carpet RH replace 76 49 21 Carpet wheel arch rear RH 76 49 22 Carpet wheel arch rear LH replace 76 55 GRILLES 76 55 03 Grille front 76 55 06 Grille panel radiator front remove and reinstall WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC 76 46 28 76 49 03 76 49 10
80. lace WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT D BROKEN L JUDDER POOR CONNECTION U INACCURATE SLIPPING M BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE E CRACKED SPLIT CUT N LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE F SEIZED STIFF P DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE G LOOSE SEAK SYNCHROMESH Q FADED STAINED DISCOLOURED Z INOPERATIVE H CORRODED PLATING FAILURE R FACTORY DAMAGE 12 ENGINE Operations include adjust ignition fuel system or kick down cable 12 53 12 53 13 12 53 13 01 12 53 19 12 60 12 60 04 12 60 20 12 60 26 12 60 38 12 60 38 01 12 60 44 12 60 50 12 60 56 12 60 74 12 60 76 BAD FIT BROKEN A B C D E F G H WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE FLYWHEEL amp DRIVE PLATE DEFENDER 90 Drive plate automatic replace Drive plate automatic replace with transmission removed Ring gear starter LUBRICATION SYSTEM Filter oil TEDIACES SE cE Strainer oil pick up replace pp 01
81. lace Sensor heated oxygen H02S rear RH replace Sensor mass air flow replace Plenum chamber replace pp Sensor throttle position TPS replace includes adjust Valve IACV idle control stepper motor replace FUEL FILTERS mains replace eter Hee hides WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC N 127 ch AR _N 5 l 1 1227 NINN gt 2 TIN 25 EARS T X AETR se A3 19 22 54 1 N 19 FUEL SYSTEM DEFENDER 90 19 45 FUEL PUMP 19 45 06 Regulator pressure replace 19 45 08 Pump replace u a en 19 50 FUEL SYSTEM 19 50 02 Fuel system depressurise pp 19 55 FUEL TANK 19 55 02 Tank Cran fuels e M ROM iatis 1 19 55 07 Filler neck replace uten ttt teet 19 55 08 Cap fuel filler 19 55 10 Sealing ring fuel filler cap
82. led operations are claimed for a single repair and only one clock time is used no separate time punch used for unscheduled LRNA will allow a maximum of 100 efficiency for the entire job The portion being claimed as unscheduled time shall be equal to the clock time less the allowance for the scheduled labor operation OVERLAP Labor operations that clearly include removal and replacement of one component to replace a different component as outlined in the Workshop Manual cannot be submitted as two separate labor operations For example no additional time is allowed to replace the water pump 26 50 01 if at the same time the front timing gasket 12 65 04 is being replaced CUSTOMER PROBLEM ANALYSIS SYSTEM DIAGNOSIS amp REPAIR TESTING The following are definitions of the terms used in the preceding statement Customer problem analysis The process of transacting the customer s concern complaint or question to a symptom that can effectively be addressed by a technician if needed i e A C insufficient cooling brakes pull engine hesitates etc Customer Problem Analysis includes those conditions which are readily apparent to the normal senses of sight touch sound and smell Customer Problem Analysis is the duty of service management and or the service advisor Symptom Diagnosis The process of finding the source of a problem based on a detailed systematic and logical approach i e finding the source of an electrical problem by follo
83. lighter front replace WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC 122 EE DRT25 86 ELECTRICAL DEFENDER 90 86 70 WIRING amp FUSES 86 70 02 Fuse replace one per repair only 86 70 07 Harness main replace a 86 70 15 Harness rear replace pp 86 70 17 Harness engine replace pp 86 70 19 Harness trunk lid tailgate replace 86 70 23 Harness air conditioning 86 70 50 Harness engine compartment replace 86 77 ALARM SYSTEM 86 77 01 Main module ECU alarm system replace A WRONGLY ADJUSTED J WORN STRETCHED S OPEN CIRCUIT BLOCKED B POROUS ADRIFT K NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE C BAD FIT L JUDDE
84. lowance for bleeding brakes The method given in the Repair Manual describes how the time may be achieved DEFINITIONS The operation Replace refers to the removing of an existing component part and fitting a new component or part Labor operations that indicate replace may not be used when a component or part is removed for its repair and subsequent reinstallation R amp I Times given for Overhaul operations include removing the component from its installed position disassemble clean and inspect all parts rebuild the unit assemble with the same or new parts reinstall and adjust The term Unit refers to an assembly in the state in which it can be most efficiently be removed from the vehicle The term Set applies to the complete car set of the components referred to in an operation unless otherwise defined i e brake set all four wheels NUMBERING Note The labor operations are printed with decimal points for readability only Do not enter them when entering service records The operation numbers comprise six digits arranged in three pairs The first pair indicates the major assembly the second pair the components or part of the major assembly or system and the third pair indicates the operation and any further definition of the parts or component EXAMPLE 12 29 11 Cylinder head replace 12 First digit pair major assembly engine 29 Second digit pair component cylinder head s 11 Third digit pair specif
85. ont door replace 76 37 31 Handle linkage front door replace 76 37 39 Lock cylinder front door replace 76 37 42 Lock cylinder taildoor replace 76 37 44 Lock cylinders vehicle set 76 37 47 Mechanism front door ACjUSt WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE A B C D E F G H DOUZZFAC 76 BODY 76 40 76 40 01 76 40 10 76 40 20 76 40 29 76 43 76 43 54 76 43 55 76 43 72 76 43 72 01 DOOR SEALS amp CHECK STRAPS DEFENDER 90 Seal front door replace pp Seal tailgate tail door aperture replace Door seal front door lower Check strap front door replace
86. oth sides replace Bump stop s one side replace WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE DIFFICULT ENGAGEMENT X BRAKE PULL SURFACE DAMAGE FADED STAINED DISCOLOURED Z INOPERATIVE FACTORY DAMAGE DOUZZFAC 60 30 09 60 30 10 60 30 06 el 60 30 01 60 30 02 60 20 02 2 60 20 11 60 30 08 60 20 03 60 20 04 o c DRT6 69 64 REAR SUSPENSION DEFENDER 90 Operations do not include wheel alignment 64 15 64 15 01 64 15 03 64 15 12 64 15 13 64 15 14 64 15 15 64 15 16 64 15 17 64 15 19 64 15 20 64 15 22 64 15 23 64 20 64 20 01 64 20 02 64 30 64 30 01 64 30 02 64 30 06 64 30 07 64 30 13 64 30 15 64 30 19 64 35 64 35 02 64 35 04 64 35 05 64 35 06 64 35 07 64 35 08 64 35 08 01 64 35 11 64 35 12 64 35 18 64 35 24 64 35 27 64 35 42 64 35 43 64 35 44 BAD FIT BROKEN Zonmoou gt WRONGLY ADJUSTED POROUS ADRIFT CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILURE HUBS Hub each Ce Hubs both sides replace pp Bearings hubs both sides check 8 adjust end float B
87. place 57 40 27 Universal joint column lower 57 40 29 Surround column complete replace 57 40 31 Column lock amp ignition starter switch assembly replace 57 50 STEERING IDLER RELAY UNIT 57 50 14 Drop arm 57 55 STEERING RODS 57 55 07 Ball joint track rod each replace 57 55 08 Ball joints track rod set replace 57 55 09 replace eite Rt etre ah 57 55 15 Ball joint side rod drag link each 1 57 55 17 Side rod drag link replace pp 57 55 21 Damper steering box replace 57 60 STEERING WHEEL 57 60 01 Steering wheel replace pp 57 60 03 Pad steering wheel replace 57 65 WHEEL ALIGNMENT 57 65 01 Front wheel alignment check amp 57 65 03 Lock stops check and WRONGLY ADJUSTED POROUS ADRIFT BAD FIT BROKEN CRACKED SPLIT CUT SEIZED STIFF LOOSE SEAK SYNCHROMESH CORRODED PLATING FAILU
88. pump feed Filter transmission oil replace Main case replace Main case reseal or replace Pump oil i Pump oil overhaul aa GEARSHIFT CONTROLS 8 SELECTORS Bias spring gear shift lever replace Lever gear Shift replace Ball socket gear shift lever Yoke assembly selector shaft replace Knob gear shift lever replace Lever upper gear shift replace Lever lower gear shift replace Bias spring gear shift lever Cover bias spring replace pp Gasket selector mechanism housing replace gt Mechanism amp housing gear selector Housing gear selector mechanism remove amp reinstall Mechanism amp housing gear selector Forks selector shaft replace
89. rted 1509 Y 0 05 7WI 19 22 1514 Neutral detected during high load 1514 Y 005 7 2 C NR 005 7H2 19 22 1517 Drive detected during cranking 1517 Y 005 722 B Page edition 2 3 Re check with TestBook after a full power down REPAIR PCM DIAGNOSTIC TROUBLE CODES WTY DRIVE CODE CODE CYCLE 19 22 1607 MIL line open or short circuited N 7G1 A 19 22 1621 Security ECM communications timeout 1 621 0 05 701 1622 N 0 05 701 19 22 1701 Transfer box fault 1701 Y 005 788 1703 0 05 788 A 19 22 1708 Transfer box line short circuit fault 1708 Y 005 7H8 1775 005 605 19 22 1776 Gearbox ignition retard request duration 1776 Y 0 05 605 19 22 1777 Gearbox ignition retard request line fault P1777 Y 0 05 605 E A T CODES 44 90 01 P1606 FTGR Solenoid supply malfunction 01 Y 0 05 6U5 B 44 90 02 P1607 FEPROMI TCM data corrupted 02 Y 005 605 A 44 90 05 P1121 FDK1 Throttle angle malfunction 05 Y 0 05 605 06 005 605 B 44 90 07 P0758 P0755 FMV2 Gear shift solenoid B malfunction MV2 07 005 605 B 44 90 09 NA FPRGANZ1 Mode indication output 1 malfunction MES 1 09 N 0 05 605 144 90 10 NA FPRGANZE Mode indication output 2 malfunction MES 2 10 N 0 05
90. wing the trouble trees and or diagnostic charts Symptom Diagnosis is the responsibility of the technician and is included in the published labor time guide allowances Repair Testing The checks tests and measurements needed in the repair to find the cause of failure or identify faulty parts Examples are Cleaning and inspection of all parts such as gears clutch plates Use of test equipment classified as LANA essential tools Use of common testers such as volt onmmeter ammeter or timing light that are included in service manuals and technical service publications 12 ENGINE DEFENDER 90 Operations include adjust ignition fuel system or kick down cable 12 13 12 13 02 12 13 24 01 12 17 12 17 03 12 17 08 12 17 16 12 21 12 21 01 12 21 14 12 21 20 12 21 20 01 12 21 33 12 21 39 12 25 12 25 01 12 25 21 CAMSHAFT Camshaft front LH each replace y Cam plug oil gallery plugs reseal with transmission removed CONNECTING RODS amp PISTONS Includes glaze break 8 measure cylinder bores where applicable Piston assemblies engine set replace Piston rings engine set replace Bearings connecting rods engine set replace includes measure journals CRANKSHAFT Pulley crankshaft replace Oil seal crankshaft front replace
91. xle bracket replace SUSPENSION LINKS amp ARMS Suspension link lower Bushing suspension link upper one side replace Bushing suspension link lower one side replace 3 Bushing suspension link upper both sides Bushing suspension link lower both sides replace Anti sway replace eese Anti sway bar replace sess ene Suspension links upper both sides replace Suspension links lower both sides replace Rubber bushing anti sway bar set replace Link anti sway bar replace Links anti sway bar rear both sides replace Flexible mountings lower suspension link both sides replace Flexible mountings lower suspension link one side replace Suspension link upper one side replace WORN STRETCHED S OPEN CIRCUIT BLOCKED NOISY CHAFED T SHORT CIRCUIT THREAD DAMAGE JUDDER POOR CONNECTION U INACCURATE SLIPPING BODY COOLANT LEAKS BURNT V BULB LIGHT UNIT FAILURE LEAKS NOT COOLANT LOSS W VIBRATION OUT OF BALANCE
92. ystem too rich bank 2 B P0175 0 05 2T6 0 05 2T6 19 22 0181 Fuel temperature inaccurate compared to ECT P0181 19 22 0182 Fuel temperature sensor circuit low input P0182 0 05 7G9 0 05 7G9 19 22 0183 Fuel temperature sensor circuit high input P0183 19 22 0201 circuit fault cylinder 1 P0201 0 05 7G9 0 05 2P2 19 22 0202 Injector circuit fault cylinder 2 P0202 19 22 0203 Injector circuit fault cylinder 3 P0203 0 05 2P2 0 05 2P2 19 22 0204 Injector circuit fault cylinder 4 P0204 19 22 0205 Injector circuit fault cylinder 5 P0205 0 05 2P2 0 05 2P2 19 22 0206 Injector circuit fault cylinder 6 P0206 19 22 0207 Injector circuit fault cylinder 7 P0207 4444444444444 5 44 4 4 4 4 4 4 4 444 444545 0 05 2 2 0 05 2 2 19 22 0208 Injector circuit fault cylinder 8 P0208 19 22 0300 Misfire on multiple cylinders P0300 0 05 2P2 0 05 7G1 Z lt lt Ea e eee Page edition 2 1 Re check with TestBook after a full power down CLAIM WTY DRIVE CODE CYCLE 0 05 7G1 C REPAIR PCM DIAGNOSTIC TROUBLE CODES DTC CODE 19 22 0301 Misfire on cylinder 1 P0301 N 19 22 0302 Misfire on cylinder 2 P0302 N 0 05 761 C 19 22 0303 Misfire on cylinder 3 P0303 N 0 05 7G1 C 19 22 0304 Misfire on cylinder 4 04 0 05 7G1 C EC P0305 1 0 05 7G1 C 19 22 0327 Knock background noise low bank 1 A P0327 N

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