Defender 300Tdi (1996+). Manual — part 34
30
MANIFOLD AND EXHAUST SYSTEM
4
REPAIR
INTERMEDIATE PIPE - 90
Service repair no - 30.10.11
Remove
1. Raise vehicle on ramp.
2. Release intermediate pipe from front mounting
rubber, see J6243.
3. Remove 2 flange nuts securing intermediate
pipe to tail pipe.
4. Release intermediate pipe from rear mounting
rubber.
5. Remove 2 flange nuts securing intermediate
pipe to front pipe.
6. Release intermediate pipe from front and tail
pipe and remove.
Refit
7. Fit intermediate pipe to front and tail pipes.
8. Secure intermediate pipe to front and rear
mounting rubbers.
9. Secure intermediate pipe to front pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
10. Secure intermediate pipe to tail pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
11. Lower vehicle.
INTERMEDIATE PIPE - 110/130
Service repair no - 30.10.11
Remove
1. Raise vehicle on ramp.
2. Release intermediate pipe from mounting
rubber, see J6244.
3. Remove 2 flange nuts securing intermediate
pipe to tail pipe.
4. Remove 2 flange nuts securing intermediate
pipe to front pipe.
5. Release intermediate pipe from front and tail
pipe and remove.
Refit
6. Fit intermediate pipe to front and tail pipes.
7. Secure intermediate pipe to mounting rubbers.
8. Secure intermediate pipe to front pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
9. Secure intermediate pipe to tail pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
10. Lower vehicle.
MANIFOLD AND EXHAUST SYSTEM
5
REPAIR
TAILPIPE - 90
Service repair no - 30.10.22
Remove
1. Raise vehicle on ramp.
2. Remove 2 flange nuts securing tail pipe to
intermediate pipe, see J6243.
3. Release tail pipe from inboard mounting rubber.
4. Release tail pipe from outboard mounting rubber
and remove.
Refit
5. Fit tail pipe to intermediate pipe.
6. Secure tail pipe to mounting rubbers.
7. Secure tail pipe to intermediate pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
8. Lower vehicle.
TAILPIPE - 110/130
Service repair no - 30.10.22
Remove
1. Raise vehicle on ramp.
2. Remove 2 flange nuts securing tail pipe to
intermediate pipe, see J6244.
3. Release tail pipe from front mounting rubber.
4. Release tail pipe from rear mounting rubber.
5. Release tail pipe from intermediate pipe and
feed over rear axle.
6. Remove tail pipe.
Refit
7. Feed tail pipe over rear axle and connect to
intermediate pipe.
8. Secure tail pipe to mounting rubbers.
9. Secure tail pipe to intermediate pipe. Tighten
nuts to
30 Nm (22 lbf/ft).
10. Lower vehicle.
CLUTCH
1
DESCRIPTION AND OPERATION
DESCRIPTION
The clutch unit comprises a single dry plate friction
disc and diaphragm spring clutch unit, secured to the
engine flywheel.
OPERATION
The unit is operated hydraulically by the clutch master
cylinder (12) and a slave cylinder (13) attached to the
transmission bell housing.
Clutch components
1. Crankshaft and flywheel
2. Friction plate
3. Clutch cover
4. Diaphragm spring
5. Pressure plate
6. Fulcrum posts (9) for diaphragm spring
7. Bearing rings (2) for diaphragm spring
8. Retraction links and bolts (3) for pressure plate
9. Release bearing
10. Release lever
11. Release lever pivot post
12. Master cylinder
13. Slave cylinder
14. Master cylinder pedal pushrod
15. Primary shaft and taper bearing (in gearbox)
16. Gearbox front cover
17. Primary shaft flywheel bush
18. Pedal pivot and return spring
33
CLUTCH
2
DESCRIPTION AND OPERATION
When the clutch pedal is depressed, hydraulic fluid
transmits the movement via the slave cylinder, release
lever (10), bearing (9), to the inner fingers of the
diaphragm spring (4).
The diaphragm spring (4) pivots on the bearing rings
(7) and fulcrum posts (6) causing the pressure plate
(5) to release the clamping force on the friction plate
and linings (2).
As the the clamping force is removed from the friction
plate (2), the plate slides on the splines of the primary
shaft (15) and takes up a neutral position between the
flywheel (1) and the pressure plate (5), thus
disconnecting the drive between the engine and the
gearbox.
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