ESP LAND ROVER DEFENDER 1996 User Guide

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.

BRAKES
13
REPAIR REAR BRAKE CALIPERS
Service repair no - 70.55.06
Service repair no - 70.55.17
Before starting repair refer to General brake service
practice
See General Brake Service Practice.
Remove caliper
1.Remove rear road wheels.
2.Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
90 Models
110/130 Models
3.Remove brake pipe from rear brake caliper.4.Seal pipe ends to prevent ingress of dirt.
5.Remove retaining pins and springs and withdraw
pads. If same pads are to be refitted, identify
them for assembly in original positions.
6.Remove 2 bolts and withdraw caliper from rear
axle.
Repair
WARNING: Do not separate caliper halves.
7.Clean outer surfaces of caliper with aerosol
brake cleaner.
8. WITH CAUTIONexpel pistons from their bores
by applying air pressure to fluid inlet port. It is
unlikely both pistons will expel at same time,
regulate rate with a suitable piece of wood
inserted between two pistons.
9.Finally, remove pistons keeping them identified
with their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal and 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 particularly seal
grooves using clean brake fluid only. If caliper or
pistons are corroded or their condition is not
perfect new parts must be fitted.
13.Apply brake fluid to new seal. Fit seal into
groove in bore. When seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat piston with brake fluid. Insert it squarely
into bore. Do not tilt piston during insertion and
leave 8mm projecting from bore.

70BRAKES
4
OVERHAUL Assembling master cylinder
CAUTION: It is important that the following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
NOTE: Thoroughly check that no debris is
lodged in fluid passageways and drillings.
If debris is found, carefully remove,
re-clean cylinder and re-check.
16.Fit new swirl tube to bottom of cylinder bore.
17.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
18.Fit primary plunger assembly using same
method as for secondary plunger, push plunger
down bore.
19.Fit original guide ring to support primary plunger.
20.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: 'O' ring should not be rolled
down outer location surface of master
cylinder but should be slightly stretched
and eased down cylinder and into its groove. Do
not over stretch seal.21.Fit a new retaining ring on outer surface of
master cylinder ensuring that serrations of ring
are facing mounting flange.
22.Fit two new reservoir seals in their respective
ports.
23.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger guide ring.
24.Lubricate vacuum seal with brake fluid, fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange. Do
not adjust transfer housing after fitting.
25.Lubricate a new water ingress seal with brake
fluid, slightly stretch seal and ease it down
housing until seal is in correct position between
housing and flange.
26.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 3.
27.Fit master cylinder to servo
See Repair,
Master cylinder
.
28.Reconnect battery, and road test vehicle.

AIR CONDITIONING
1
ADJUSTMENT GENERAL PRECAUTIONS
The refrigerant used in the air conditioning system is
HFC (Hydrofluorocarbon) R134a.
WARNING: R134a is a hazardous liquid
and when handled incorrectly can cause
serious injury. Suitable protective clothing
must be worn when carrying out servicing
operations on the air conditioning system.
WARNING: R134a is odourless and
colourless. Do not handle or discharge in
an enclosed area, or in any area where the
vapour or liquid can come in contact with naked
flame or hot metal. R134a is not flammable, but
can form a highly toxic gas.
WARNING: Do not smoke or weld in areas
where R134a is in use. Inhalation of
concentrations of the vapour can cause
dizziness, disorientation. uncoordination,
narcosis, nausea or vomiting.
WARNING: Do not allow fluids other than
R134a or compressor lubricant to enter the
air conditioning system. Spontaneous
combustion may occur.
WARNING: R134a splashed on any part of
the body will cause immediate freezing of
that area. Also refrigerant cylinders and
replenishment trolleys when discharging will
freeze skin to them if contact is made.
WARNING: The refrigerant used in an air
conditioning system must be reclaimed in
accordance with the recommendations
given with a Refrigerant Recovery Recycling
Recharging Station.
NOTE: Suitable protective clothing
comprises: Wrap around safety glasses or
helmet, heatproof gloves, rubber apron or
waterproof overalls and rubber boots.REMEDIAL ACTIONS
1.If liquid R134a strikes the eye, do not rub it.
Gently run large quantities of eyewash over the
eye to raise the temperature. If eyewash is not
available cool, clean water may be used. Cover
eye with clean pad and seek immediate medical
attention.
2.If liquid R134a is splashed on the skin run large
quantities of water over the area as soon as
possible to raise the temperature. Carry out the
same actions if skin comes into contact with
discharging cylinders. Wrap affected parts in
blankets or similar material and seek immediate
medical attention.
3.If suspected of being overcome by inhalation of
R134a vapour seek fresh air. If unconscious
remove to fresh air. Apply artificial respiration
and/or oxygen and seek immediate medical
attention.
NOTE: Due to its low evaporating
temperature of -30°C, R134a should be
handled with care.
WARNING: Do not allow a refrigerant
container to be heated by a direct flame or
to be placed near any heating appliance. A
refrigerant container must not be heated above
50°C.
WARNING: Do not leave a container of
refrigerant without its cap fitted. Do not
transport a container of refrigerant that is
unrestrained, especially in the boot of a car.

AIR CONDITIONING
7
REPAIR EVAPORATOR - LH DRIVE
Service repair no - 82.25.20
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit.
2.Suitably support unit on a bench to prevent
damage to heater matrix pipes.
3.Release 3 nuts and remove mounting bracket
from underneath unit casing.
4.Remove 7 screws securing outlet duct to
heater/cooler unit.
5.Carefully break sealing compound around edge
of duct and pull ducting from unit.
6.Remove 15 screws located around cover seam.
Break sealing compound from unit body and top
cover.
7.Remove 4 screws and 4 nuts from top of cover.
8.From front of unit remove 2 screws adjacent to
low pressure pipe moulding.
9.At side of unit remove 2 screws adjacent to air
intake aperture.
10.Lift off top cover, release grommet and feed
blower motor wiring and air control flap rod
through respective apertures. Note thermostat
temperature probe which is inserted in
evaporator matrix through top cover.
11.Lift support plate and insulation pad from heater
matrix.
12.From bottom of unit casing, remove 3 screws
adjacent to dump valve outlet, and screws next
to heater matrix pipes.

AIR CONDITIONING
9
REPAIR EXPANSION VALVE - LH DRIVE
Service repair no - 82.25.01
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit.
2.Suitably support unit on a bench to prevent
damage to heater matrix pipes.
3.Remove 7 screws securing outlet duct to
heater/cooler unit.
4.Break sealing compound around edge of duct
and pull duct from unit.
5.Remove all fixing screws securing top cover
seam and cover sides to main casing.
6.Remove 4 screws and 4 nuts from top of cover.
7.Break sealing compound from unit casing and
top cover.
8.Lift off top cover, release grommet and feed
blower motor wiring and air flap operating rod
through respective apertures. Note thermostat
temperature probe which is inserted in top of
evaporator.
9.Release 2 clips securing expansion valve sensor
and lagging to low pressure pipe.
10.Unscrew union securing expansion valve to
evaporator high pressure pipe.
11.Remove expansion valve, complete with high
pressure pipe.
12.Disconnect high pressure pipe from expansion
valve.
13.Discard all pipe connection 'O' rings.
14.Clean sealing compound from all joints of main
casing, top cover and outlet duct.
Refit
15.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
16.Fit high pressure pipe to new expansion valve.
17.Fit expansion valve to evaporator pipe
connector.
18.Position valve sensor at low pressure pipe and
secure with lagging and clips.
19.Apply sealing compound around top edge of
main casing.
20.Feed blower motor wiring through top cover and
fit grommet.
21.Fit top cover to casing. Ensure thermostat
temperature probe is inserted in top of
evaporator. Apply mastic sealant to air flap
operating rod aperture.
22.Apply sealing compound to joint face of blower
motor outlet duct.
23.Locate duct over blower motor outlet and secure
to casing.
24.Fit heater/cooler unit
See Heater/cooler unit.

82AIR CONDITIONING
10
REPAIR HEATER MATRIX - LH DRIVE
Service repair no - 82.25.19
Remove
1.Remove evaporator
See Evaporator.
2.Leaving evaporator in place, remove single
screw securing heater matrix pipe plate to base
of support frame.
3.Remove heater matrix and insulation pad.
Refit
4.Position insulation pad and fit heater matrix to
support frame.
5.Fit heater matrix and evaporator assembly
See
Evaporator.
BLOWER MOTOR ASSEMBLY- LH DRIVE
Service repair no - 82.25.14
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit.
2.Remove 7 screws securing outlet duct to
heater/cooler unit.
3.Carefully break sealing compound around edge
of duct and pull ducting from unit.
4.Remove 15 screws located around cover seam.
Break sealing compound from unit body and top
cover.
5.Remove 4 screws and 4 nuts from top of cover.
6.From front of unit remove 2 screws adjacent to
low pressure pipe moulding.
7.At side of unit remove 2 screws adjacent to air
intake aperture.
8.Lift off top cover, release grommet and feed
blower motor wiring and air control flap rod
through respective apertures. Note thermostat
probe which is inserted in evaporator matrix
through top cover.

86ELECTRICAL
2
DESCRIPTION AND OPERATION VEHICLE IMMOBILISATION AND ALARM SYSTEM
A sophisticated engine immobilisation and anti-theft
alarm system is offered on the Land Rover Defender
300 Tdi vehicle range, which incorporates the
following features:
Perimeter protection
This part of the alarm system protects side doors,
bonnet and rear door against unauthorised entry -
alarm sounding if any one of these apertures is
opened without alarm first being disarmed.
Interior protection
Also known as volumetric protection, this part of the
system protects space inside the vehicle. Once
armed, the alarm will sound if a door is opened, or if
movement is detected inside the vehicle.
Engine immobilisation
The engine is immobilised electronically whenever the
alarm system is armed. Even if the alarm has not
been armed, engine immobilisation will occur
automatically thirty seconds after the driver's door is
opened, or five minutes after the starter switch is
turned to position '0'.
ALARM SYSTEM COMPONENTS
Electronic control unit (ECU)
The ECU is the alarm system brain and controls all
vehicle immobilisation and alarm functions. It
responds to the inputs received, by supplying suitable
outputs to indicate status of the alarm system or
activating relevant warning devices. unit is located
under fascia behind instrument binnacle.
Handset and key
The handset is the primary source of control for the
alarm system i.e. it arms and disarms the alarm
components. The key can be used to override engine
immoblisation if the handset is lost or fails to operate,
seeEngine immobilisation override.The handset battery should last for approximately
three years dependent upon use. The following
symptoms will be noticed when the battery requires
replacement:
1.The handset will only work every other operation
while disarming.
2.The direction indicator lamps will not flash when
the alarm is disarmed.
For battery replacement procedure, seeHandset
Battery.
Passive coil
The passive coil is fitted on the starter switch and
activates a receiving coil in the handset, causing it to
automatically transmit a remobilisation signal to the
ECU.
Aerial
The aerial is integral within the alarm system harness
and supplies the ECU with the signal received from
handset.
Immobilisation spider
The immobilisation spider provides an interface
between ECU and immobilised areas of the vehicle.
This is installed in a sealed (safe) box inside the
vehicle battery box.
Digital diesel shut-off valve - 97 MY
When fitted, the digital diesel shut-off valve
immobilises the fuel injection pump by preventing
power reaching the fuel shut-off solenoid,
See
Immobilisation and alarm system circuit diagram -
with DDS
.

ELECTRICAL
3
DESCRIPTION AND OPERATION Door and bonnet switches
Perimetric protection for the vehicle is provided by
ECU inputs connected to the starter switch, bonnet
switch and door switches.
Ultrasonic sensor
The ultrasonic sensor operates by emitting an air
pressure carrier wave which is subsequently received
by the sensor as it bounces back from objects inside
the vehicle. Once armed, the alarm will sound if wave
is disturbed by a door opening, or if movement is
detected inside the vehicle.
When the volumetric sensor is activated it monitors
movement within the vehicle for 15 seconds before
detecting and responding to intrusions. If the sensor
detects movement it delays arming until a quiet period
has lapsed; if continuous movement is detected, the
alarm will not arm volumetrically.
NOTE: Interior protection will not operate
until 15 seconds after alarm is set.
The ultrasonic sensor is positioned in a different
location, according to vehicle type, as follows:
·90/110 Station Wagon - RH cantrail trim
·90/110 Pick-up - On headlining, between interior
lamp and rear view mirror
·130 Crewcab - On headlining above RH door
Alarm sounder
Two types of alarm sounder can be fitted, one with a
battery back-up facility and or without battery back-up,
both providing an audible warning whenever the alarm
is triggered. The vehicle horn will also operate if the
alarm sounds.
The alarm sounder is fitted to LH inner front wing in
the engine compartment.
NOTE: Disconnecting the battery on
vehicles fitted with the battery backed-up
facility will result in the alarm sounding, if
correct procedure has not been followed.Engine immobilisation warning light
The engine immobilisation warning light is located on
the instrument panel, and provides a visual indication
that the engine is immobilised.
Anti-theft alarm indicator light
The anti-theft alarm indicator light is located on the
instrument panel, between the fuel and coolant
temperature indicators, and provides a visual
indication of the alarm/ immobiliser status.