Positioning:
The Land Rover Defender is an iconic, utilitarian off-road vehicle renowned for its robustness and go-anywhere capability. This manual targets owners and independent workshops seeking to maintain and repair this highly capable machine.
Competition:
Competed against other heavy-duty off-roaders like the Jeep Wrangler and Toyota Land Cruiser, but with a distinct British character and focus on utility.
Vehicle Identity:
The 2002 Defender represents a highly durable and adaptable platform, often chosen for demanding work or recreational off-roading.
Primary Coverage:
Maintenance, Repair, Diagnostics, Specifications for Land Rover Defender 2002
Estimated Pages:
Extensive (typical for a factory service manual, likely 800-1500 pages in printed equivalent)
Type:
Factory Service Repair Manual
Engine Systems:
Tdi Engine (including tuning data, fuel system, cooling system)
Powertrain:
Clutch, Manual Gearbox, Transfer Gearbox, Propeller Shafts, Rear Axle and Final Drive, Front Axle and Final Drive
Chassis And Suspension:
Steering, Front Suspension, Rear Suspension, Brakes, Wheels and Tyres, Chassis and Body
Body And Comfort:
Heating and Ventilation, Air Conditioning, Wipers and Washers
Electrical And Electronics:
Electrical Systems, Instruments
Maintenance Procedures:
Scheduled Maintenance, Fluid Changes, Component Inspections
Repair Procedures:
Detailed step-by-step repair instructions for all covered systems
Diagnostic Procedures:
Troubleshooting guides and fault finding for common issues
Engine Tuning:
Engine tuning data, ignition timing, fuel injection timing, idle speed adjustments.
Fitting Reminders:
General fitting reminders for proper assembly and torque specifications.
Cooling System Service:
Coolant flush and replacement, radiator and fan assembly inspection and repair.
Exhaust System Repair:
Manifold removal and replacement, exhaust pipe and silencer repair/replacement.
Axle And Drive Service:
Front and rear axle disassembly, inspection, repair, and final drive unit servicing, including hub maintenance.
Suspension Repair:
Spring replacement, shock absorber replacement, bush replacement, alignment procedures.
Brake System Overhaul:
Brake pad and disc replacement, caliper overhaul, brake line replacement, bleeding procedures.
Electrical Diagnostics:
Wiring diagrams, component testing, fault code interpretation, fuse and relay identification.
Depth:
Comprehensive: From basic fluid checks and maintenance schedules to complete engine and transmission overhauls, including electrical system diagnostics.
Body Styles:
Station Wagon (Hard Top), Soft Top, Pickup Truck (110/90 wheelbase variants)
Wheelbase Options:
90 inches, 110 inches
Gross Vehicle Weight Rating:
Varies by model, typically around 5,000-6,000 lbs
Oil Change Interval:
Typically every 6,000 - 12,000 miles (10,000 - 20,000 km) or 12 months, depending on usage and oil specification.
Fuel Filter Replacement:
Recommended every 12,000 - 24,000 miles (20,000 - 40,000 km) or annually.
Air Filter Replacement:
Inspect every service, replace as needed based on operating conditions, typically every 12,000 - 18,000 miles.
Engine Oil Specification:
API CG-4/CH-4 or ACEA E2/B3 specification, typically 15W-40 or 5W-40 diesel engine oil.
Coolant Specification:
Ethylene Glycol based antifreeze, typically a 50/50 mix with de-ionised water. Specific Land Rover approved coolant recommended.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid
Gearbox Oil Specification:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil for manual gearbox and transfer box.
Differential Oil Specification:
API GL-5, SAE 80W-90 gear oil for front and rear axles.
Common Wear Items:
Clutch wear, gearbox synchromesh issues, driveshaft universal joints, shock absorbers, wheel bearings, injector seals (Td5).
Electrical Problems:
Wiring loom chafing, sensor failures, ECU issues (especially on Td5).
Body Corrosion:
Rust can be an issue, particularly on chassis, bulkheads, and wheel arches.
Brand Identity:
Land Rover has a long-standing heritage in producing robust and capable off-road vehicles since its inception post-WWII.
Defender Lineage:
The Defender is the direct descendant of the original Land Rover Series I, II, and III, evolving with powertrain and chassis updates while retaining its core design philosophy.
Manufacturing Period:
The Defender nameplate was introduced in 1983, with the 2002 model representing the later iteration of this generation which ceased production in 2016.
Manufacturing Location:
Solihull, England
Off Road Reputation:
Consistently recognized for its unparalleled off-road capability and durability, often winning accolades in expedition and military vehicle categories.
Reliability Perception:
While mechanically robust, perceived reliability can be mixed due to its rugged, utilitarian design and the specific complexities of the Td5 engine management system.
