warning LAND ROVER DEFENDER 1996 Owner's Manual

19FUEL SYSTEM
6
REPAIR SIDE MOUNTED FUEL TANK
Service repair no - 19.55.05
NOTE: This fuel tank is standard on 90
models and an option on 110/130 2 door
vehicles fitted with twin tanks.
Remove
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS are
carefully studied and implemented in the interests
of safety.
See INTRODUCTION, Information, Fuel
Handling Precautions
1.Disconnect battery.
2.Remove fuel filler cap.3.Remove fuel tank drain plug, allow fuel to drain
into a clean container and refit plug.
4.Remove RH seat cushion.
5.Release retaining catch and remove seat base
cover to gain access to fuel tank.
6.Disconnect electrical plug from fuel gauge unit.
7.Disconnect fuel supply pipe from tank.
8.Disconnect spill return pipe from fuel tank.
9.Disconnect breather pipe from fuel filler tube.
10.Slacken hose clip and remove filler hose from
filler tube.
11.From rear of tank, remove 2 nuts and washers
securing tank mounting to captive-headed bolts.
12.Support rear of fuel tank and remove captive
bolts.

FUEL SYSTEM
7
REPAIR REV: 05/99
13.Remove single bolt fixing assembly securing
front of tank to chassis mounted bracket.
14.Remove 3 bolts securing tank mounting bracket
to chassis and release bracket.
15.Lower front of tank while turning anti-clockwise
and remove from vehicle.
16.If required, remove tank gauge unit.
See
INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank
orSee INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130
Refit
17.Fit filler hose and clip to tank but do not fully
tighten. Position clip screw so that it is
accessible when tank is fitted.
18.Fit breather hose and secure with clip.
19.Position fuel tank in vehicle and loosely secure
front mounting bracket to tank with special bolt
and rubber bushes.
20.Secure mounting bracket to chassis with 3 bolts
and fully tighten to
20 Nm (15 lbf/ft).
21.Secure rear of tank to chassis mounting and
tighten captive bolt plate fixings to
20 Nm (15
lbf/ft).
22.Fully tighten front fixing bolt assembly to20 Nm
(15 lbf/ft).
23.Fit spill return and fuel supply pipes and secure
union connections.
24.Fit fuel level unit electrical plug.
25.Fit hose to filler tube and tighten upper and lower
clips.
26.Check that drain plug is secure and fill fuel tank.
27.Reconnect battery.
28.Prime fuel system
See Adjustment, Priming
the fuel system
and start engine.
29.Check system for leaks and operation of fuel
gauge.
30.Fit seat base cover and seat cushion.SIDE MOUNTED FUEL TANK - 5 DOOR VEHICLES
Service repair no - 19.55.01
NOTE: This fuel tank is used on 110/130 5
door vehicles fitted with a twin tank
option.
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS,
See
INTRODUCTION, Information, Fuel handling
precautions
are carefully studied and
implemented in the interests of safety.
Remove
1.Disconnect battery.
2.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
3.Remove RH seat cushion.
4.Remove retaining catch and remove seat base
cover to gain access to fuel tank.
5.Disconnect electrical plug from fuel gauge unit.
6.Disconnect fuel supply pipe from tank.
7.Disconnect spill return pipe from tank.
8.Remove 3 bolts securing tank to front mounting
bracket.
9.Support front of tank and remove single fixing
assembly securing tank to rear mounting
bracket.
10.Remove tank from vehicle.
11.If required, remove fuel gauge unit.
See
INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank
orSee INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130
Refit
12.Position fuel tank in vehicle and loosely secure
to rear mounting bracket with special bolt and
rubber bushes.
13.Secure tank to front mounting bracket and
tighten fixings to
20 Nm (15 lbf/ft).
14.Fully tighten rear fixing bolt assembly to20 Nm
(15 lbf/ft).
15.Fit spill return and fuel supply pipes to fuel tank
and securely tighten union connectios.
16.Fit electrical plug to fuel gauge unit.
17.Check that drain plug is secure and fill fuel tank.
18.Reconnect battery.
19.Prime fuel system.
See Adjustment, Priming
the fuel system
and start engine.
20.Check system for leaks and operation of fuel
gauge.
21.Fit seat base cover and seat cushion.

19FUEL SYSTEM
8
REPAIR REAR MOUNTED FUEL TANK - 110/130
Service repair no - 19.55.26
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS
See
INTRODUCTION, Information, FUEL HANDLING
PRECAUTIONS
are carefully studied and
implemented in the interests of safety.
Remove
1.Disconnect battery.
2.Remove fuel filler cap.
3.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
4.Slacken retaining clips and disconnect fuel filler
hose from rear tank.5.Disconnect breather hose from filler tube.
6.Disconnect electrical plug and fuel supply pipe
from outlet pipe union on fuel gauge unit.
7.If the vehicle is fitted with a tow ball drop-plate
with support bars, the bars must be removed.
8.Remove anti-roll bar chassis mountings.
See
REAR SUSPENSION, Repair, Anti-roll bar
and push roll bar down to provide access to the
tank.
9.Remove LH lashing eye to assist access to tank.
10.Position a support under the tank, preferably one
that can be progressively lowered.

COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL COOLING SYSTEM
Service repair no - 26.10.01
Draining
WARNING: DO NOT remove caps or plugs
when the engine is hot. The cooling
system is pressurised and personal
scalding could result.
1.Remove expansion tank filler cap.
2.Position a clean container under radiator if
coolant is to be reused.
3.Disconnect radiator bottom hose and allow
coolant to drain.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray and/or
integral access panels.
See CHASSIS AND BODY,
Repair, Front undertray
orSee CHASSIS AND
BODY, Repair, Rear undertray
4.When expansion tank has emptied remove
thermostat housing plug to assist drainage.
5.Similarly when coolant is below top of radiator,
remove radiator plug.
6.Fit radiator bottom hose and fully tighten hose
clip.Refill
CAUTION: It is important that the correct
procedure is followed when refilling or
topping up the cooling system to avoid
trapping air in the system.
7.Fill cooling system with 50% - 50% of
water/anti-freeze mixture
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
8.Fill through expansion tank until radiator is full,
with level in expansion tank the same as
radiator.
NOTE: Care should be taken to avoid
excess coolant spillage.
9.Fit plastic plug in radiator.
10.Add a further 1 litre (1.76 pints) of coolant into
expansion tank and allow to settle.
11.Refit expansion tank cap and thermostat
housing plug.
12.Run engine at idle speed for 5 minutes.
13.Switch off engine and allow to cool.
14.Check that coolant in expansion tank is level
with top of indicator post. Top up if necessary.

MANUAL GEARBOX
1
REPAIR REV: 05/99 R380 GEARBOX
Service repair no - 37.20.51
Remove
The R380 gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
support plateLRT-99-007.
WARNING: Where the use of a
transmission hoist is necessary, it is
absolutely essential to follow the
manufacturer's instructions to ensure safe and
effective use of equipment.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
.
1.Install vehicle on a ramp.
2.Disconnect battery.
3.Remove gearbox carpet.
4.Remove gear lever and transfer box lever knobs.
5.Remove gear lever cover.
6.Remove nut and washer securing gear lever.
7.Mark gear lever spline setting and remove lever
and gaiter from the splined lower gear lever.
8.Release insulation pad from tunnel cover and
gear levers and remove.
9.Select low range on transfer box lever to prevent
lever from fouling tunnel when removing
gearbox.

TRANSFER GEARBOX
1
REPAIR TRANSFER GEARBOX
Service repair no - 41.20.25
Remove
The transfer gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
adaptor plateLRT-99-010.
WARNING: Where use of a transmission
hoist is necessary, it is absolutely
essential to follow the manufacturers'
instructions to ensure safe and effective use of
the equipment.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
.
1.Position vehicle on a ramp.
2.Select LOW range gear and leave vehicle in
neutral.
3.Disconnect battery.
4.Remove front, centre, seat cushion, or cubby
box
See CHASSIS AND BODY, Repair,
Cubby box
.
5.If fitted, disconnect multi-plug from EGR control
unit located on base of seat cushion or cubby
box.
6.Remove 4 screws securing centre access panel
to seat or cubby box base.
7.Release EGR and alarm system diagnostic
connector mounting bracket.
8.Lift up access panel, complete with diagnostic
connector harness, and place aside.
9.Remove breather pipe union from transfer
gearbox high/low cross-shaft housing.
10.Remove retaining clip and disconnect high/low
lever from operating rod.

REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect shock absorbers.
6.Disconnect flexible brake hose at RH chassis
side member and breather hose at banjo
connection on axle casing.
7.Disconnect lower links at axle.8.Mark differential and propeller shaft flanges with
identification marks for assembly.
9.Remove 4 nuts and bolts, lower propeller shaft
and tie to one side.
10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.If applicable, remove anti-roll bar links at axle
See REAR SUSPENSION, Repair, anti-roll
bar
.
14.Remove axle assembly.

REAR AXLE AND FINAL DRIVE
3
REPAIR REAR HUB ASSEMBLY - 90
Service repair no - 64.15.01
Remove
1.Place rear axle onto axle stands and remove
road wheel.
2.Release brake hose clips and remove brake
caliper bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.
3.Remove 5 bolts and withdraw axle shaft.
4.Remove joint washer.
5.Bend back lock washer tabs.
6.Remove locknut and lock washer.
7.Remove hub adjusting nut.
8.Remove spacing washer.
9.Remove hub and brake disc assembly complete
with bearings.
Rear hub components - 90
1.Axle shaft.
2.Axle shaft joint washer.
3.Axle shaft retaining bolt.
4.Lock nut.
5.Lock washer.
6.Hub adjusting nut.
7.Spacing washer.8.Outer bearing.
9.Hub.
10.Inner bearing.
11.Grease seal.
12.Brake disc.
13.Disc retaining bolt.

REAR AXLE AND FINAL DRIVE
5
REPAIR REAR HUB ASSEMBLY - 110/130
Service repair no - 64.15.01
Remove
1.Loosen rear wheel nuts, jack up vehicle and
lower onto axle stands. Remove road wheel.
2.Release brake pipe clips, remove brake caliper
and brake disc shield bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.3.Lever off dust cap.
4.Remove circlip from driveshaft.
5.Remove 5 bolts and withdraw driving member
and joint washer.
6.Bend back lock washer tabs.
7.Remove locknut and lock washer.
8.Remove hub adjusting nut.
9.Remove spacing washer.
10.Remove hub and brake disc assembly complete
with bearings.
Hub components
1.Dust cap.
2.Drive shaft circlip.
3.Drive member.
4.Drive member joint washer.
5.Drive member retaining bolt.
6.Lock nut.
7.Lock washer.
8.Hub adjusting nut.9.Spacing washer.
10.Outer bearing.
11.Hub.
12.Inner bearing.
13.Grease seal.
14.Brake disc
15.Disc retaining bolt.

51REAR AXLE AND FINAL DRIVE
10
OVERHAUL REAR HUB ASSEMBLY - 90
Service repair no - 64.15.13.
1.Remove rear hub
See Repair, Rear hub
assembly
.
2.Remove outer bearing.
3.Mark, for reassembly, position of hub to brake
disc.4.Remove 5 bolts and separate hub from brake
disc.
WARNING: A maximum of two road wheel
retaining studs can be renewed. Should
more studs be unserviceable fit new hub
with studs.
5.Remove grease seal and inner bearing from
hub.
6.Remove inner and outer bearing tracks.
REAR HUB COMPONENTS - 90
1.Axle shaft.
2.Axle shaft joint washer.
3.Axle shaft retaining bolt.
4.Lock nut.
5.Lock washer.
6.Hub adjusting nut.
7.Spacing washer.8.Outer bearing.
9.Hub.
10.Inner bearing.
11.Grease seal.
12.Brake disc.
13.Disc retaining bolt.