Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual
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STEERING 9 FAULT DIAGNOSIS POWER STEERING SYSTEM - EXCESSIVE NOISE 1.Is fluid level correct? YES - go to 3. NO - Refill or drain to correct level. Bleed system, check for leaks See Repair, Power Steering System - Bleed . 2.Is problem resolved? YES - end NO - continue. 3.Is pressure hose from pump to box touching body in a hard foul condition? YES - route hose away from body. NO - go to 5. 4.Does noise remain? YES - continue. NO - end. 5.Is noise a whistle or hiss on full lock? YES - noise is not a fault unless excessive. Compare with other vehicles NO - go to 8. 6.Is noise excessive? YES - continue. NO - end. 7.Change steering box and/or pump. 8.Is noise a squeal on full lock? YES - check drive belt tension and remove belt if necessary See ELECTRICAL, Repair, Auxiliary drive Belt . NO - go to 10. 9.Does squeal remain? YES - drive belt contaminated, change belt. NO - end. 10.Is noise a continuous moan? YES - bleed PAS system See Repair, Power Steering System - Bleed . NO - go to 13. 11.Does moan remain? YES - do figure 8 manoeuvres. NO - end. 12.Does moan remain? YES - continue NO - end.13.Is noise an intermittent grunt? YES - See Power Steering System - Grunt. NO - continue. 14.Is it a clunking noise? YES - check drive belt tension and renew belt if necessary See ELECTRICAL, Repair, Auxiliary drive Belt . NO - contact local technical office. 15.Does noise remain? YES - Suspect suspension or drive train. NO - end. POWER STEERING SYSTEM - GRUNT Steering box grunts intermittently when turning from lock to lock: 1.Is fluid level correct? YES - go to 3. NO - refill or drain to correct level. Bleed system, check for leaks See Repair, Power Steering System - Bleed . 2.Does grunt remain? YES - continue NO - end. 3.Is correct low pressure hose, steering box to reservoir, fitted? YES - go to 5. NO - Fit correct hose. 4.Does grunt remain? YES - continue NO - end. 5.Purge box by doing figure 8 manoeuvres e.g. on car park, followed by 10 minutes normal road use. 6.Does grunt remain? YES - Contact local technical office NO - end.
57STEERING 10 FAULT DIAGNOSISREV: 05/99 VISUAL AND SAFETY CHECKS WARNING: Before taking vehicle out on the public highway for road test, it is important that the following basic visual checks are carried out to ensure that the vehicle complies with legal requirements. Tyres and wheel rims 1.Check and adjust tyre pressures See GENERAL SPECIFICATION DATA, Information, Tyre Pressures . Note that this information refers to standard tyres fitted as original equipment. 2.Check condition of tyres. Inspect for signs of uneven wear, damage and feathering. Check tread depth. 3.Ensure that the tyre make, type and general condition are common across each axle. 4.Check wheel rims for signs of damage and excessive run out. 5.Carry out road test See Road Test Procedure . ROAD TEST PROCEDURE General steering/handling problems can usually be classified into one of the categories listed and ARE GENERALLY RELATED TO THE AGE, CONDITION AND USE OF THE VEHICLE. WARNING: Ensure that all road tests are conducted by suitably qualified drivers in a safe and legal manner, and where local traffic conditions allow. 1.Carry out visual and safety checks See Visual and Safety Checks . Confirm general nature of complaint with customer, simulating where possible the conditions under which the problem occurs. Carry out following road test procedure to establish the problem.2.Steering load assessment - drive at 16 km/h (10 mph). Put 90°turn input into steering wheel, check self centering. The self centering should be equal on each lock but not necessarily return to exactly straight ahead without assistance from the driver. 3.Steering assessment - drive at 64 km/h (40 mph) on a staight FLAT road (no camber), check for steering veer. The vehicle should follow a straight path with NO tendency to follow a curved path. If vehicle veers towards the kerb, vehicle may be camber sensitive. A small amount of veer in direction of camber is acceptable. 4.Directional stability assessment - drive at 112 km/h (70 mph) or maximum legal speed on a straight flat road. Carry out a normal lane change. Vehicle should quickly settle into a new straight path. 5.Braking assessment (medium effort) - drive at 96 km/h (60 mph) on a straight flat road. Apply steady medium braking effort, noting any tendency to veer. Carry out brake test three times, if a veer is consistently noted carry out a braking efficiency test on a rolling road. 6.Braking assessment (full effort) - drive at 96 km/h (60 mph) on a straight flat road. Apply full braking effort, noting any tendency to veer. Carry out brake test three times, if a veer is consistently noted carry out a braking efficiency test on a rolling road. If the symptom described by the customer is stiff steering or steering niggle, carry out stiff steering procedure See Stiff Steering Checklist. If not, proceed with basic checks and adjustments See Visual Check and Basic Adjustments.
STEERING 11 FAULT DIAGNOSIS STIFF STEERING CHECKLIST NOTE: Having completed visual checks and steering assessment and confirmed that vehicle steering load is incorrect carry out the following procedure in order shown. Steering wheel torque to turn loads 1.Raise vehicle so both front wheels free. 2.With engine off, centralise steering wheel, and remove steering wheel decal. Using torque wrench on column nut, check torque required to turn the steering wheel one turn in each direction. 3.Record readings obtained in each direction. Reading should be 4.40 Nm (3.5 lbf/ft). NOTE: If figures are in excess of that specified carry out steering box tie bar reset below. If figures are as specified See Visual Check and Basic Adjustments . Steering box tie bar reset 1.Loosen the tie bar fixings one complete turn. 2.Drive vehicle carefully a short distance (within the dealership) applying full lock in both directions in order to settle steering components. Drive vehicle over speed bumps and include harsh braking if possible. WARNING: Do not drive on public highway. 3.Near end of operation 2. ensure vehicle is driven in a straight line on level ground and halted. 4.Tighten panhard rod mounting arm nut to 110 Nm (81 lbf/ft). 5.Tighten the 2 fixings, tie bar to steering box, to 81 Nm (60 lbf/ft). 6.Recheck steering wheel torque to turn. If torque reading is still greater than specified, carry out steering shaft universal joint lubrication.Lower steering shaft universal joint lubrication 1.Check lower steering shaft is correctly phased See Repair, Lower Steering Shaft and Universal Joints . 2.Lubricate universal joints with an anti-seizure type penetrating spray. Work the joints to ensure full penetration of the spray by driving vehicle and steering from lock to lock. 3.If steering stiffness still persists carry out swivel pin preload setting. Swivel pin preload setting 1.The swivel pin preload setting must be checked and set See FRONT AXLE AND FINAL DRIVE, Overhaul, Front Stub Axle, Constant Velocity Joint and Swivel Pin Housing . Note that a pull load of 1.16 - 1.46 kg is required after the axle shaft and swivel housing seal have been removed. Steering box adjustment 1.Check steering box adjustment See Adjustment, Power Steering Box . Steering damper check 1.Check condition of steering damper See Steering Damper .
57STEERING 12 FAULT DIAGNOSISREV: 05/99 VISUAL CHECK AND BASIC ADJUSTMENTS NOTE: It is important that the following instructions are carried out in the sequence shown and the results recorded. 1.Road springs - check that road springs are correctly seated and are to correct specification for vehicle. For spring specification See GENERAL SPECIFICATION DATA, Information, Road Spring Data . 2.Ride height - measure trim height from wheel centre to wheelarch eyebrow. Record results on data sheet. 3.Check/top up power steering fluid See Repair, Power Steering Fluid Reservoir . 4.Check tension and condition of drive belt See ELECTRICAL, Repair, Auxiliary drive belt . 5.Track rod/drag link - check condition of track rod, drag link and ball joints See Repair, Drag Link and Drag Link Ends . If either component is damaged, check operation of steering damper and steering box for smoothness. Replace all damaged or worn components that impair the operation of the steering system. 6.Suspension bushes - examine all steering and suspension bushes for signs of wear and deterioration. Also check all fixings for torque relaxation. Tighten to correct torque value See FRONT SUSPENSION, Specifications, torque, Torque Values . 7.Oil leaks - check front and rear axle hubs for leak and repair as necessary. 8.Brake system - check brake system for leaks, pipe condition, pad wear/contamination, disc wear/condition. 9.Hub end float - check movement in the hubs by rocking the wheels. 10.Check front wheel alignment. Vehicles displaying a tendency to veer more than considered allowable, it is permissible to set the front track to parallel.11.Having completed all the above checks and adjustments, road test vehicle See Road Test Procedure . Attempt to reproduce the symptoms established earlier. If symptoms still exist refer to relevant Diagnostic Chart. STEERING LINKAGE INSPECT NOTE: When inspecting steering linkages and ball joints for wear the following items must be checked. Steering ball joints 1.Check ball joint rubber boots for security, signs of cracking or deterioration. 2.Check ball joint assemblies for seizure i.e. no movement on ball joint and associated assemblies. 3.Check for excessive wear. This will be evident as extreme movement on track rod and steering linkages. Renew parts as necessary See Repair, Track Rod and Linkage ,See Repair, Drag Link and Drag Link Ends . Steering linkages 1.Check all linkages for wear, deterioration and damage. Renew parts as necessary See Repair, Track Rod and Linkage ,See Repair, Drag Link and Drag Link Ends .
STEERING 1 ADJUSTMENT POWER STEERING BOX - ADJUST Service repair no - 57.35.01 WARNING: Adjustments of steering box should not be required while in warranty period. If box is stiff or tight and within warranty, it must be returned to manufacturer. No attempt must be made to introduce backlash. 1.Apply park brake brake, chock wheels and Jack up front of vehicle until wheels are clear of ground. 2.Support chassis front on axle stands. 3.Disconnect drag link from steering drop arm. 4.Check torque to turn See Fault diagnosis, Stiff Steering Checklist . 5.Centralise steering box See Centralise Steering Box . NOTE: Only check for no backlash when steering box is in central position. NOTE: If steering wheel is not straight, it should be repositioned See Repair, Steering Wheel . 6.Adjustment is obtained by rocking the drop arm about centre whilst an assistant slowly tightens the steering box adjuster screw. 7.Tighten locknut when all backlash has been removed.8.Repeat the check for backlash. If backlash exists loosen locknut and repeat adjustment procedure. 9.Turn steering wheel lock to lock and check no tightness exists. 10.Ensure front wheels are aligned and in straight ahead position. 11.Adjust drag link 924 mm between ball joint centres. 12.Connect drag link and tighten to 40 Nm (30 lbf/ft). 13.Lower vehicle to ground level and remove chocks. 14.Road test vehicle See Fault diagnosis, Road Test Procedure . Drag link adjust 1.RH drive vehicles - if steering wheel is to right, drag link is too long. If steering wheel is to left drag link is too short. LH drive vehicles - if steering wheel is to right, drag link is too short. If steering wheel is to left drag link is too long. 2.Adjust drag link until steering wheel points straight ahead when vehicle is travelling in a straight line. CENTRALISE STEERING BOX Service repair no - 57.35.05 LH drive vehicle 1.Disconnect drag link from drop arm See Repair, Drag link and drag link ends . 2.Turn steering wheel on full RH lock. 3.Turn steering wheel back exactly two turns. 4.Fit drag link See Repair, Drag link and drag link ends . RH drive vehicle 1.Repeat operation for LH drive vehicle but turn steering wheel on full LH lock.
57STEERING 2 ADJUSTMENT STEERING LOCK STOPS Service repair no - 57.65.03 Check 1.Measure clearance between tyre wall and radius arm at full lock. This must be not less than 20 mm. Adjust 2.Loosen stop bolt locknut. 3.Turn stop bolt as required. 4.Tighten locknut. 5.Check clearance between tyre wall and radius arm on each lock. NOTE: Alternatively lock stop adjustment may be carried out using following procedure. Check 1.Measure stop bolt protrusion A. Refer to table for correct setting. Adjust 2.Loosen stop bolt locknut. 3.Turn stop bolt as required. 4.Tighten locknut. 5.Check wheel position at full lock.LOCK STOP SETTINGS Tyre & wheel size - alloys Make Size Setting BF Goodrich Mud Terrain 265 59,7 mm Goodyear GT+4 235 55,7 mm Michelin M+S 4x4 235 54,2 mm Tyre & wheel size - steel Make Size Setting Goodyear 205 52,2 mm Michelin 205 52,2 mm Avon 7.50 56 mm Michelin 7.50 56 mm Goodyear 7.50 56 mm
STEERING 3 ADJUSTMENT FRONT WHEEL ALIGNMENT Service repair no - 57.65.01 Checking Toe-out dimensions NOTE: Recognised front wheel alignment and tracking equipment should be used for this operation. Only the use of basic equipment is described below. No Adjustment is provided for castor, camber or swivel pin inclinations. 1.Set vehicle on level ground with road wheels positioned straight ahead. 2.Push vehicle back and forwards to settle linkage. 3.Set up the equipment to manufacturers instructions and check alignment as advised by equipment supplier. 4.Position trammel probes on inner face of wheel, not the rims, if the latter are damaged. 5.Measure toe-out at horizontal centre-line of wheels. 6.Check tightness of clamp bolt fixings. Tighten to 14 Nm (10lbf/ft). Adjust 7.Slacken clamps at both ends of track rod. 8.Rotate track rod to increase or decrease its effective length until correct toe-out is obtained See GENERAL SPECIFICATION DATA, Information, Steering . 9.Push vehicle rearwards turning steering wheel from side to side to settle ball joints. With road wheels set in straight ahead position, push vehicle forward a short distance. 10.Recheck track and adjust if necessary. 11.When alignment is correct, tap ball joints in direction of arrows to maximum of travel, to ensure full unrestricted movement of track rod. 12.Tighten clamp bolts to 14 Nm (10 lbf/ft). POWER STEERING PUMP DRIVE BELT Service repair no - 57.20.01 Adjust NOTE: For details of drive belt adjust procedure. See ELECTRICAL, Repair, Auxiliary Drive Belt
STEERING 1 REPAIR STEERING COLUMN Service repair no - 57.40.01 Remove 1.Remove bonnet. 2.Set road wheels and steering wheel in straight ahead position. 3.Mark relationship of steering column inner shaft to top universal joint. NOTE: collapsible shaft can be disconnected from steering column only, if required, by removing bolts from top universal joint and slackening top bolt of lower universal joint. 4.Remove 2 bolts from top universal joint and lower bolt of bottom universal joint. Slacken top bolt of lower universal joint and withdraw shaft.5.Prise centre cap from steering wheel. 6.Remove steering wheel retaining nut and withdraw wheel from column spline. 7.Disconnect battery. 8.Remove 4 screws securing instrument panel and pull panel away from facia to enable speedometer cable to be disconnected. 9.Disconnect multi-plugs, electrical leads and connections to vehicle alarm system, if fitted. See ELECTRICAL, Repair, Vehicle immobilisation and alarm system . 10.Withdraw panel complete with instruments. 11.Remove 5 screws and 2 self-tapping screws to remove top half of nacelle. 12.Ease bottom half of nacelle from switch gaiters/grommets and remove.
57STEERING 2 REPAIR 13.Disconnect 3 switch multi-plugs. 14.Slacken clamp screw on top of switch cluster and withdraw switch assembly. 15.Note position of harness leads on back of starter switch and disconnect lucars. If fitted, remove alarm system passive coil from switch See ELECTRICAL, Repair, Vehicle immobilisation and alarm system . 16.Using a punch or stud extractor remove 2 shear bolts securing switch to column. 17.Remove switch and collect 2 plain washers between switch and clamp. 18.Remove brake pedal box See BRAKES, Repair, Brake pedal . 19.Remove bolt securing tie-bar to steering column, behind instrument panel. 20.Remove 2 bolts securing column lower support to mounting bracket. 21.Remove bolts securing two halves of top clamp and bolts that secure top half of clamp to bulkhead. 22.Remove clamp and rubber packing. 23.Remove 2 bolts securing column main support bracket to bulkhead. 24.Remove steering column and main support bracket from vehicle.
STEERING 3 REPAIR REV: 05/99 NOTE: The steering column is a non serviceable component and can only be serviced as a complete assembly. 25.Fit main support bracket and padding to steering column and manoeuvre column into position in vehicle. 26.Loosely secure main support bracket and harness bracket to bulkhead. 27.Loosely fit clamp and rubber packing strip to column. 28.Loosely secure lower end of column to lower support bracket. 29.Loosely secure clamp bracket to main support bracket. 30.Working inside vehicle cab, fit tie-bar to column bracket and secure with single bolt to 22 Nm (16 lbf/ft). 31.Finally, tighten main support bracket, clamp bracket, upper clamp, and lower support bracket nuts and bolts. (M6 bolts 9 Nm (6 lbf/ft),M8 bolts 22 Nm (16 lbf/ft). 32.Fit brake pedal boxSee BRAKES, Repair, Brake pedal . 33.Fit steering lock/switch in position and rotate steering column inner shaft to line up slot with switch plunger. 34.Secure lock to column with clamp and shear bolts. Evenly tighten bolts but do not shear them. 35.Temporarily fit steering wheel and operate switch and lock mechanism several times to ensure it functions correctly. 36.Fully tighten switch retaining bolts until heads shear. 37.Connect electrical leads to rear of switch. Fit alarm system passive coil, if applicable. See ELECTRICAL, Repair, Vehicle immobilisation and alarm system . 38.Fit switch assembly on steering column and tighten clamping screw. 39.Connect switch assembly multi-plugs and electrical leads to main harness. 40.Offer up instrument panel, connect speedometer cable, multi-plugs and electrical leads to main harness. If applicable, fit vehicle alarm system connections. See ELECTRICAL, Repair, Vehicle immobilisation and alarm system . 41.Secure panel with 4 screws. 42.Locate top half of nacelle in position and fit to switch gaiters/grommets.43.Fit lower half of nacelle and loosely tighten fixing screws. 44.Ensure switch gaiters/grommets are correctly located and fully tighten fixings. 45.Turn indicator cancelling ring so that slots are vertical and lug with arrow points to the left, in direction of indicator switch. 46.Fit steering wheel with finisher attachment lug at bottom, ensuring that indicator cancelling forks locate in cancelling ring slots. 47.Secure wheel with nut and new shake-proof washer. Tighten to 43 Nm (32 lbf/ft). 48.Fit steering wheel decal. 49.If necessary, fit new universal joints to support. Note that long joint is fitted to short length of shaft and short joint to long end. Joints can only be fitted one way to shaft. 50.With steering lock engaged and road wheels in straight ahead position, align reassembly marks, and fit collapsible shaft assembly with long leg of shaft to steering box. Fit pinch bolts and tighten to 25 Nm (18 lbf/ft).