Defender 300Tdi (1996+). Instruction - page 9

07

GENERAL FITTING REMINDERS

6

INFORMATION

FUEL SYSTEM HOSES

CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber outer
sleeve and an inner viton core. If any of

the fuel system hoses have been disconnected, it
is imperative that the internal bore is inspected to
ensure that the viton lining has not become
separated from the amoured outer sleeve. A new
hose must be fitted if separation is evident.

METRIC BOLT IDENTIFICATION

1. An ISO metric bolt or screw, made of steel and

larger than 6 mm in diameter can be identified by
either of the symbols ISO M or M embossed or
indented on top of the head.

2. In addition to marks to identify the manufacture,

the head is also marked with symbols to indicate
the strength grade, e.g. 8.8, 12.9 or 14.9, where
the first figure gives the minimum tensile
strength of the bolt material in tens of kgf/mm

2

.

3. Zinc plated ISO metric bolts and nuts are

chromate passivated, a gold-bronze colour.

METRIC NUT IDENTIFICATION

1. A nut with an ISO metric thread is marked on

one face or on one of the flats of the hexagon
with the strength grade symbol 8, 12 or 14.
Some nuts with a strength 4, 5 or 6 are also
marked and some have the metric symbol M on
the flat opposite the strength grade marking.

2. A clock face system is used as an alternative

method of indicating the strength grade. The
external chamfers or a face of the nut is marked
in a position relative to the appropriate hour
mark on a clock face to indicate the strength
grade.

3. A dot is used to locate the 12 O’clock position

and a dash to indicate the strength grade. If the
grade is above 12, two dots identify the 12
O’clock position.

KEYS AND KEYWAYS

1. Remove burrs from edges of keyways with a fine

file and clean thoroughly before attempting to
refit key.

2. Clean and inspect key closely; keys are suitable

for refitting only if indistinguishable from new, as
any indentation may indicate the onset of wear.

TAB WASHERS

1. Fit new washers in all places where they are

used. Always fit a new tab washer.

2. Ensure that the new tab washer is of the same

design as that replaced.

GENERAL FITTING REMINDERS

7

INFORMATION

COTTER PINS

1. Fit new cotter pins throughout when replacing

any unit.

2. Always fit cotter pins where cotter pins were

originally used. Do not substitute spring
washers: there is always a good reason for the
use of a cotter pin.

3. All cotter pins should be fitted as shown unless

otherwise stated.

NUTS

1. When tightening a slotted or castellated nut

never loosen it to insert cotter pin or locking wire
except in those recommended cases where this
forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should
be selected, or washer thickness reduced.

2. Where self-locking nuts have been removed it is

advisable to replace them with new ones of the
same type.

NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.

LOCKING WIRE

1. Fit new locking wire of the correct type for all

assemblies incorporating it.

2. Arrange wire so that its tension tends to tighten

the bolt heads, or nuts, to which it is fitted.

SCREW THREADS

1. Both UNF and Metric threads to ISO standards

are used. See below for thread identification.

2. Damaged threads must always be discarded.

Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and
is not recommended.

3. Always ensure that replacement bolts are at

least equal in strength to those replaced.

4. Do not allow oil, grease or jointing compound to

enter blind threaded holes. The hydraulic action
on screwing in the bolt or stud could split the
housing.

5. Always tighten a nut or bolt to the recommended

torque value. Damaged or corroded threads can
affect the torque reading.

6. To check or re-tighten a bolt or screw to a

specified torque value first loosen a quarter of a
turn, then re-tighten to the correct value.

7. Oil thread lightly before tightening to ensure a

free running thread, except in the case of
threads treated with sealant/lubricant, and
self-locking nuts.

UNIFIED THREAD IDENTIFICATION

1. Bolts

A circular recess is stamped in the upper surface
of the bolt head.

2. Nuts

A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.

3. Studs, Brake Rods, etc.

The component is reduced to the core diameter
for a short length at its extremity.

LUBRICANTS, FLUIDS AND CAPACITIES

1

INFORMATION

RECOMMENDED LUBRICANTS AND FLUIDS

All climates and conditions

AMBIENT TEMPERATURE

°

C

COMPONENT

SPECIFICATION

VISCOSITY

-30

-20

-10

0

10

20

30

40

50

Diesel

RES.22.OL.PD-2

15W/40

Engine sump

or CCMC PD-2
or API CD

Main Gearbox
manual

ATF Dexron IID

Final drive units

API or GL5

90 EP

Swivel pin housings

MIL - L - 2105 or
MIL - L - 2105B

80 EP *

C or D

Power steering

ATF Dexron IID

Transfer box

API GL4 or GL5

90 EP

LT230T

MIL - L - 2105 or
MIL - L - 2105B

80 EP

C or D

NOTE: * Molytex EP 00 grease on later vehicles with filler plug only in swivel pin housing.

09

LUBRICANTS, FLUIDS AND CAPACITIES

2

INFORMATION

Propeller shaft Front
and Rear

NLGI - 2 Multi-purpose Lithium based GREASE

Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker

Brake and clutch
reservoirs

Brake fluids having a minimum boiling point of 260

°

C (500

°

F) and complying with

FMVSS 116 DOT4

Engine coolant

Use an ethylene glycol based anti-freeze (containing no methanol)
with non-phosphate corrosion inhibitors suitable for use in aluminium engines to ensure
the protection of the cooling system against frost and corrosion in all seasons. Use one
part anti-freeze to one part water for protection down to -36

°

C (-33

°

F).

IMPORTANT: Coolant solution must not fall below proportions one part
anti-freeze to three parts water, i.e. minimum 25% anti-freeze in coolant otherwise
damage to engine is liable to occur. Or a maximum of 60%.

Battery lugs,

Petroleum jelly.

Earthing surfaces

NOTE: Do not use Silicone Grease

where paint has
been removed

Air Conditioning
System Refrigerant

Use only refrigerant R134a

Compressor Oil

Sanden oil

LUBRICATION PRACTICE

Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.

Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.

WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze, windscreen washer additives, lubricants and various adhesives.

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