Oil LAND ROVER DEFENDER 1996 Owners Manual

FRONT SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The front suspension design allows maximum wheel
travel and axle articulation providing good ground
clearance without loss of traction or directional
stability.
Long radius arms are fitted to the front axle and
provide maximum axle articulation which is vital for off
road performance. The radius arms are secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arms to mountings on
the chassis cross member.
A panhard rod, which ensures that the front axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations.Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar to the chassis
mountings, while bushed links support the front of the
bar to the front axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement
in all conditions. The shock absorbers are secured to
fabricated towers which are bolted to the chassis. The
upper and lower fixings use a single location stud with
flexible rubber bushes, support washers and securing
nuts. Retaining plates are used to secure the coil
springs to the fabricated towers and axle mountings.
Rubber bump stops are fitted underneath the chassis,
adjacent to the front road springs, and prevent
possible damage that could occur should there be
excessive axle to chassis movement.
Front suspension
1.Panhard rod
2.Radius arms
3.Coil springs
4.Shock absorber
5.Anti-roll bar

REAR SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The rear suspension design locates the rear axle with
two round section steel lower link arms and a forged
'A' frame, upper link assembly. This system allows
maximum axle articulation and wheel travel while
maintaining roll stiffness and directional stability.
The link arm is secured by a single retaining nut to the
chassis mounting, comprising a rubber bushed
bracket, which is retained by three fixings. A ferrule
rubber bush with a single retaining bolt is used to
secure the link arm to its axle mounting.
The upper link assembly is located on the rear
differential housing by a pivot ball-pin assembly. Two
brackets bolted to the chassis crossmember support
both sides of the 'A' frame of the link assembly,
secured by single retaining bolts.A Boge Hydromat self levelling unit can be fitted, as
an option, on 110/130 models to give additional
support when the vehicle is used to carry heavier
loads.
Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar, if fitted, to the
chassis mountings, while bushed links support the
front of the anti-roll bar to the axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement.
The shock absorbers are secured to chassis mounting
brackets and fabricated lower mountings welded to to
the rear axle. Retaining plates are used to secure the
coil springs to the axle mounting while fabricated
brackets, welded to the chassis, are used for the
upper spring location.
Rear axle suspension
1.'A' frame, upper link assembly
2.Lower link
3.Coil springs
4.Shock absorber

REAR SUSPENSION
1
REPAIR REV: 05/99 REAR ROAD SPRING
Service repair no - 64.20.01.
Remove
1.Loosen rear road wheel retaining nuts.
2.Support chassis on stands and remove wheels.
3.Support rear axle weight with jack.
4.Disconnect shock absorbers at one end.
5.Position coil spring compressor correctly on road
spring.
6.Compress spring evenly to facilitate removal.
7.Lower axle to free road spring from upper seat.
CAUTION: Avoid lowering axle further than
rear brake flexible hose will allow.
8.Remove spring retainer plate.
9.Withdraw road spring.
10.Collect spring seat.
Refit
11.Position spring seat on axle location.
12.Fit road spring into chassis location and, using a
turning motion, fit to spring seat.
13.Fit spring retainer plate. Tighten bolts to
14 Nm
(10 lbf/ft).
14.Secure shock absorber. Tighten fixing to37 Nm
(27 lbf/ft).
15.Fit road wheels, remove chassis stands and
jack. Tighten wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
REAR SHOCK ABSORBER
Service repair no - 64.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands. Remove road wheel
and support rear axle weight with jack.
3.Remove fixings and withdraw shock absorber
from axle bracket.
4.Remove upper fixings.
5.Withdraw shock absorber.
6.If required, remove mounting bracket
7.If required, remove mounting rubbers.
Refit
8.Position shock absorber and fit upper fixings.
9.Secure shock absorber with lower fixings to axle
bracket. Tighten upper and lower fixings to
37
Nm (27 lbf/ft).
10.Fit road wheels, remove chassis stands and
jack. Tighten wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)

BRAKES
1
REPAIR GENERAL BRAKE SERVICE PRACTICE
Brake fluid precautions
WARNING: Do not allow brake fluid to
come into contact with eyes or skin.
CAUTION: Brake fluid can damage
paintwork, if spilled wash off immediately
with plenty of clean water.
CAUTION: Use only correct grade of brake
fluid. If an assembly fluid is required use
ONLY brake fluid. Do NOT use mineral oil,
i.e. engine oil etc.
CAUTION: Thoroughly clean all brake
calipers, pipes and fittings before
commencing work on any part of the brake
system. Failure to do so could cause foreign
matter to enter the system and cause damage to
seals and pistons which will seriously impair the
efficiency of the brake system. To ensure the
brake system efficiency is not impaired the
following warnings must be adhered to :-
·DO NOT use any petroleum based cleaning
fluids or any proprietary fluids containing
petrol.
·DO NOT use brake fluid previously bled from
the system.
·DO NOT flush the brake system with any fluid
other than the recommended brake fluid.
The brake system should be drained and flushed
at the recommended service intervals.
Cover all electrical terminals carefully to make
absolutely certain that no fluid enters the
terminals and plugs.FLUID LEVEL CHECK/TOP UP
WARNING: Clean reservoir body and filler
cap before removing cap. Use only fluid
from a sealed container.
1.Park vehicle on level ground.
2.Check level is between 'MIN' and 'MAX' marks.
3.If level is below 'MIN' mark top up fluid level to
'MAX' mark on reservoir, using correct fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
CAUTION: Do not fill reservoir above
maximum line.

70BRAKES
10
REPAIR FRONT BRAKE CALIPERS
Service repair no - 70.55.05
Service repair no - 70.55.16
Before starting repair refer to general brake service
practice
See General Brake Service Practice.
Remove
1.Remove front road wheels.
2.Expose flexible brake hose by moving coiled
protective covering.
3.Using a recognised hose clamp, clamp hose to
prevent loss of brake fluid.
4.Disconnect rigid brake pipe from flexible hose,
seal exposed ends to prevent ingress of dirt.
5.Remove split pin, retaining pins and springs,
withdraw pads. If refitting pads, identify them for
assembly to original locations.
6.Remove 2 bolts and withdraw caliper from swivel
housing.
WARNING: Do not separate caliper halves
7.Clean outer surfaces of caliper using aerosol
brake cleaner.
8.Using special toolLRT-70-500, clamp pistons in
inboard half of caliper. Gently, keeping fingers
clear, and withCAUTION, apply air pressure to
fluid inlet port to expel pistons. It is unlikely that
pistons will expel at same time, regulate rate
with a suitable piece of wood between
appropriate piston and caliper.
9.Finally remove pistons, identifying them with
their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal. Pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and seal grooves using
clean brake fluid only. If caliper or pistons are
corroded, or their condition is not perfect, new
parts must be fitted.

74WHEELS AND TYRES
6
REPAIRREV: 05/99 WHEELS
Remove
WARNING: The parking brake acts on
transmission, not rear wheels, and may
not hold vehicle when jacking unless
following procedure is used. If one front wheel
and one rear wheel is raised no vehicle holding or
braking effect is possible. Wheels MUST be
chocked in all circumstances.
Apply parking brake, select a gear in main
gearbox and engage low gear in transfer box.
1.Loosen 5 wheel nuts.
2.Using a suitable trolley jack, raise vehicle and
place on axle stands
See INTRODUCTION,
Information, Jacking
.
3.Remove wheel nuts and carefully withdraw
wheel over studs.
Refit
4.Ensure that retaining studs and nuts are clean.
5.Alloy wheels: Lightly coat wheel mounting spigot
face with a suitable anti-seize compound to
minimise possibility of adhesion between wheel
and spigot face.
6.Refit wheel taking care not to damage stud
threads. (Do not apply oil).
7.Fit wheel nuts and turn by hand for at least three
full threads before using any form of wheel
wrench.
8.Tighten nuts as much as possible using a
suitable wrench.
9.Lower vehicle and finally tighten nuts to correct
torque sequence shown.
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)

CHASSIS AND BODY
39
REPAIR ACCESS PANEL - FRONT UNDERTRAY
Service repair no - 76.11.85 - Access panel
Service repair no - 76.11.83 - Acoustic pad
The access panel is provided in the front undertray to
enable fitment of the wading plug into the engine
timing cover.
Remove
1.Raise vehicle on ramp.
2.Remove 5 bolts securing access panel to front
undertray.
3.Remove access panel.
4.If necessary, remove 5 fasteners and release
acoustic pad from access panel.
Refit
5.If applicable, fit acoustic pad to access panel.
6.Fit access panel to front undertray, Tighten
fixings to
14 Nm (10 lbf/ft).
7.Lower ramp.ACCESS PANEL - REAR UNDERTRAY
Service repair no - 76.11.84
The access panel is provided in the rear undertray to
enable fitment of the wading plug or timing tool
LRT-12-044in the flywheel housing, and access to
the engine oil sump drain plug.
Remove
1.Raise vehicle on ramp.
2.Rotate access panel anti-clockwise to release
locking flanges.
3.Remove access panel from undertray.
Refit
4.Locate access panel flanges in undertray
apertures.
5.Rotate panel clockwise to secure in undertray.
6.Lower ramp.

82AIR CONDITIONING
2
DESCRIPTION AND OPERATION Operation
Evaporator unit and expansion valve
High pressure liquid refrigerant is delivered to the
expansion valve which is the controlling device for the
air conditioning system. A severe pressure drop
occurs across the valve and as the refrigerant flows
through the evaporator it picks up heat from the
ambient air, boils and vaporizes. As this change of
state occurs, a large amount of latent heat is
absorbed. The evaporator is therefore cooled and as
a result heat is extracted from the air flowing across
the evaporator. The refrigerant leaves the evaporator,
on its way to the compressor, as a low pressure gas.
An evaporator sensor measures the air temperature at
the evaporator and engages or disengages the
compressor clutch to prevent icing of the air ways.
Compressor
The compressor, a pump specially designed to raise
the pressure of the refrigerant, is mounted on the front
of the engine and is driven by an independent drive
belt from the crankshaft pulley. The compressor draws
vaporized refrigerant from the evaporator. It is
compressed with a resulting rise in temperature and
passed on to the condenser as a hot, high pressure
vapour.
Condenser
The condenser is mounted directly in front of the
radiator and consists of a refrigerant coil mounted in a
series of thin cooling fins to provide the maximum
heat transfer. Air flow across the condenser is induced
by vehicle movement and assisted by two electric fans
attached to the frame of the condenser. The
refrigerant high pressure vapour enters the condenser
inlet on the RH side. As the vapour passes through
the condenser coils the air flow, assisted by the two
fans, carries the latent heat away from the condenser.
This induces a change of state resulting in the
refrigerant condensing into a high pressure warm
liquid. From the condenser, the refrigerant continues
to the receiver/ drier.
Receiver/drier
This component acts as a reservoir and is used to
hold extra refrigerant until it is needed by the
evaporator. The drier within the receiver unit contains
a filter and dessicant (drying material) which absorb
moisture and prevent dessicant dust from being
carried with the refrigerant into the system.AIR CONDITIONING AND HEATER CONTROLS -
LH DRIVE
1. Temperature control
Move the lever upwards (RED) to increase air
temperature, or downwards (BLUE) to reduce air
temperature.
2. Air conditioning switch
Press the switch (indicator lamp illuminates) to
activate the air conditioning. Press again to switch off.
3. Air recirculation control
Move the lever fully upwards to activate air
recirculation. Move the lever fully downwards to
cancel recirculation.
NOTE: Prolonged recirculation may cause
the windows to mist up.
4. Air distribution control
Lever fully up - air to windscreen vents (also provides
some air to the footwell).
Lever midway - air to fascia vents (also provides some
air to the footwell).
Lever fully down - air to footwell vents (also provides
some air to the windscreen).

82AIR CONDITIONING
2
ADJUSTMENT SERVICING PRECAUTIONS
Care must be taken when handling refrigeration
system components. Units must not be lifted by their
hoses, pipes or capillary lines. Hoses and lines must
not be subjected to any twist or stress. Ensure that
hoses are positioned in their correct run before fully
tightening the couplings, and ensure that all clips and
supports are used. Torque wrenches of the correct
type must be used when tightening refrigerant
connections to the stated value. An additional spanner
must be used to hold the union to prevent twisting of
the pipe.
Before connecting any hose or pipe ensure that
refrigerant oil is applied to the seat of the new '0' ring
but not to the threads.
Check the oil trap for the amount of oil lost.
All protective plugs on components must be left in
place until immediately prior to connection.
The receiver/drier contains desiccant which absorbs
moisture. It must be positively sealed at all times.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
Use alcohol and a clean cloth to clean dirty
connections.
Ensure that all new parts fitted are marked for use
withR134a.
Refrigerant oil
Use the approved refrigerant lubricating oil - Nippon
Denso ND-OIL 8.
CAUTION: Do not use any other type of
refrigerant oil.
Refrigerant oil easily absorbs water and must not be
stored for long periods. Do not pour unused oil back
into the container.
When renewing system components, add the
following quantities of refrigerant oil:
Condenser 40ml..........................................................
Evaporator 80ml..........................................................
Pipe or hose 20ml........................................................
Receiver/drier 20ml......................................................Total quantity of refrigerant oil in system = 140ml
A new compressor is sealed and pressurised with
Nitrogen gas, slowly release the sealing cap, gas
pressure should be heard to release as the seal is
broken.
NOTE: A new compressor should always
have its sealing caps in place and these
must not be removed until immediately
prior to fitting
A new compressor is supplied with an oil fill of 140ml.
A calculated quantity of oil must be drained from a
new compressor before fitting.
To calculate the quantity of oil to be drained:
1.Remove sealing plugs from the OLD
compressor.
2.Invert compressor and gravity drain oil into
measuring cylinder. Rotating the compressor
clutch plate will assist complete draining.
3.Note the quantity of oil drained (Yml).
4.Calculate the quantity (Qml) of oil to be drained
from the NEW compressor using the following
formula:
Xml - (Yml + 20ml) = Qml
Rapid refrigerant discharge
When the air conditioning system is involved in
accident damage and the circuit is punctured, the
refrigerant is discharged rapidly. The rapid discharge
of refrigerant will also result in the loss of most of the
oil from the system. The compressor must be
removed and all the remaining oil in the compressor
drained and refilled as follows:
1.Gravity drain all the oil, assist by rotating the
clutch plate (not the pulley).
2.Refill the compressor with 90ml of new
refrigerant oil.
3.Plug the inlet and outlet ports.
Servicing Equipment
The following equipment is required for full servicing
of the air conditioning system.
Recovery, recycling and charging station
Leak detector
Thermometer +20°C to -60°C
Safety goggles and gloves

AIR CONDITIONING
3
ADJUSTMENT REFRIGERANT RECOVERY, RECYCLING,
RECHARGING
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
All operations must be carried out in a
well-ventilated area away from open flame and
heat sources.
Always wear safety goggles and gloves when
opening refrigerant connections.
WARNING: Wear eye and hand safety
protection. Open connections slowly in
case liquid or pressure is present. Allow to
bleed off slowly.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover refrigerant R134a from the air conditioning
system, to filter and remove moisture, to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
manufacturers' instructions.
Recovery and recycling
1.Connect a Refrigerant Station to the high and
low pressure servicing connections.
2.Operate the refrigerant recovery system
according to the manufacturers instructions.
3.Measure the amount of oil discharged from the
system. Add an equal amount of new refrigerant
oil to compressor before evacuation sequence.
WARNING: Refrigerant must always be
recycled before reuse, to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system. Recycling
should always be carried out with equipment
which is design certified by Underwriter
Laboratory Inc. for compliance with SAE-J1991.
Other equipment may not recycle refrigerant to
the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and commercial
sources must not be used in motor vehicle air
conditioning systems.
Evacuation and recharging
1.Add refrigerant oil to compressor if necessary.
2.Renew the receiver/drier.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using inert gas.
3.Connect a Refrigerant Station to the high and
low pressure servicing connections.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
4.Operate the refrigerant evacuation system
according to the manufactures instructions.
NOTE: If the vacuum reading is below
700mmHg after 15 minutes, suspect a leak
in the system. Partially recharge the
system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes and then check the high
pressure lines.
CAUTION: The system must be Evacuated
immediately before recharging
commences. Delay between Evacuation
and Recharging is not permitted.