battery LAND ROVER DEFENDER 1996 Service Manual

26COOLING SYSTEM
4
REPAIRREV: 05/99 AUXILIARY MOUNTING BRACKET AND GASKET
Service repair no - 26.50.04
Remove
1.Disconnect battery.
2.Drain cooling system
See Adjustment, Drain
and refill cooling system
.
3.Remove radiator top hose.
4.Remove intercooler top hose.
5.Remove viscous fan unit.
See Viscous
coupling and fan
6.Remove fan cowl.See Fan cowl
7.Slacken power steering pump pulley retaining
bolts.
8.Remove drive belt.
See ELECTRICAL, Repair,
Auxiliary Drive belt
9.Unscrew 3 bolts and remove power steering
pump pulley.
10.Remove 4 bolts securing power steering pump
mounting bracket.
11.Lower pump and bracket. Do not disconnect fluid
pipes.
12.Remove generator.
See ELECTRICAL, Repair,
Generator
13.Unscrew retaining nut and remove drive belt
tensioner.
14.Release hose clip from bracket above water
pump.15.Disconnect bottom hose/heater return hose at
water pump and heater rail.
16.Disconnect by-pass hose from water pump and
thermostat housing.
17.Remove 5 bolts (one with nut) and single
retaining nut, securing auxiliary mounting
bracket to cylinder block.
18.Withdraw mounting bracket, complete with water
pump.
19.Remove gasket and clean mating faces.
Refit
20.Using 2 slave studs, fit new gasket.
NOTE: All fixing bolts and nuts should be
tightened to
25 Nm (18 lbf/ft)unless
otherwise stated.
21.Locate mounting bracket, complete with water
pump on slave studs and secure with 4 other
fixings.
22.Remove slave studs and fit remaining bolts/nuts.
23.Fit by-pass hose to thermostat housing and
water pump.
24.Fit bottom hose/heater return hose to water
pump and heater rail.
25.Fit heater hose clip to mounting bracket.
26.Fit drive belt tensioner. Tighten nut to
45 Nm (33
lbf/ft).
27.Fit generator.See ELECTRICAL, Repair,
Generator
Do not fit drive belt at this stage.

COOLING SYSTEM
5
REPAIR 28.Secure steering pump and bracket to auxiliary
mounting bracket.
29.Fit steering pump pulley.
30.Fit drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
31.Fit fan cowl
See Fan cowl.
32.Fit viscous fan unit
See Viscous coupling and
fan
.
33.Fit intercooler top hose.
34.Fit radiator top hose.
35.Refill cooling system.
See Adjustment, Drain
and refill cooling system
36.Reconnect battery.THERMOSTAT
Service repair no - 26.45.01
Remove
1.Partially drain cooling system, until coolant level
is below thermostat housing.
2.Disconnect top hose from outlet elbow.
3.Disconnect electrical connections to water
temperature switch.
4.Unscrew 2 bolts and remove outlet elbow.
5.Withdraw thermostat. Note 88°C rating of
thermostat.
6.Place thermostat in a container half full of water.
Heat water and observe temperature at which
thermostat begins to open. Thermostat is
satisfactory if it opens between 85°-89°C.
Refit
7.Fit thermostat with jiggle pin/vent hole upwards.
8.Secure outlet elbow to thermostat housing.
Tighten bolts to
25 Nm (18 lbf/ft).
9.Fit water temperature switch connections.
10.Fit top hose to outlet elbow.
11.Refill cooling system.
See Adjustment, Drain
and refill cooling system

MANIFOLD AND EXHAUST SYSTEM
1
REPAIR INDUCTION MANIFOLD
Service repair no - 30.15.02
Remove
1.Disconnect battery.
2.Remove oil filler cap and remove rocker cover
insulation.
3.Remove hose intercooler to induction manifold. If
fitted, remove EGR valve.
See FUEL SYSTEM,
Repair, EGR valve
4.Remove 2 screws and release heat shield from
induction manifold.
5.Slacken induction manifold lower securing nuts,
located below exhaust manifold.
6.Remove induction manifold upper securing bolts.
7.Remove induction manifold. Plug apertures in
cylinder head with clean rag to prevent any items
falling into engine.
8.Check gasket is satisfactory for further use.
Refit
9.Clean induction manifold mating face.
10.Position induction manifold and secure with
upper and lower fixings.
11.Tighten securing nuts and bolts to
25 Nm (18
lbf/ft).
12.Fit manifold heat shield.
13.Fit hose intercooler to induction manifold.
14.Fit rocker cover insulation.
15.Reconnect battery.INDUCTION/EXHAUST MANIFOLD GASKET
Service repair no - 30.15.15
Remove
1.Remove induction manifold
See Induction
manifold
.
2.Remove turbocharger outlet hose.
3.Raise vehicle and slacken exhaust front pipe to
intermediate silencer flange nuts. Ensure pipe is
free to turn.
NOTE: If removing exhaust manifold and
turbocharger assembly from vehicle,
remove manifold to exhaust front pipe
nuts while working under vehicle.
4.Remove exhaust manifold securing nuts,
removing centre lower nut first.
5.Move heater rail clear of exhaust manifold.
6.With exhaust manifold and turbocharger still
attached to exhaust front pipe, withdraw from
head by turning front pipe until sufficient access
is gained to remove gasket.
7.Suitably support exhaust manifold and
turbocharger assembly to prevent damage.
8.Remove induction manifold lower nuts.
9.Remove gasket.
10.Clean mating faces.

MANIFOLD AND EXHAUST SYSTEM
3
REPAIR EXHAUST FRONT PIPE
Service repair no - 30.10.09
Remove
1.Disconnect battery.
2.Raise vehicle on ramp.
3.Remove 3 securing nuts at exhaust manifold
flange.
4.Remove through bolt securing front pipe
mounting bracket to chassis.
5.Remove bracket and rubber mounting from
exhaust pipe.
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
.
6.Remove flange nuts securing front pipe to
intermediate silencer assembly and separate
flanges.
7.Release front pipe at manifold and remove
gasket.
8.Move front pipe rearwards, lower front end and
at the same time twist toward propeller shaft.
Move pipe forward and withdraw from under
vehicle.
Refit
9.Manouvre front pipe into position and secure to
intermediate silencer flange. Do not fully tighten
fixings at this stage.
10.Fit new gasket and secure front pipe to exhaust
manifold. Tighten fixings to
50 Nm (37 lbf/ft).
11.Fit front pipe bracket and mounting rubber to
chassis.
12.Fully tighten front pipe to intermediate silencer
flange nuts to
30 Nm (22 lbf/ft).
13.Lower vehicle ramp and reconnect battery.

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.

37MANUAL GEARBOX
4
REPAIR
37.Pull handbrake cable through heel board and tie
aside.
38.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer box.
39.Release speedometer cable from retaining clip
on transfer box.
40.Remove retaining nut and release battery earth
strap from transfer box.
41.Secure manufactured cradleLRT-99-007to a
suitable hydraulic hoist.
42.Raise hoist and secure to gearbox with 3 bolts in
location provided.
43.Lower hoist sufficiently to allow transfer lever to
clear transmission tunnel aperture.
44.Disconnect differential lock switch and reverse
light connectors.
45.Remove bolt and release earth leads from RH
side of transfer box.
46.Support engine under sump with a jack.
47.Remove 14 bell housing to engine fixings.
48.Withdraw transmission whilst ensuring all
connections to engine and chassis are released.
49.Lower hoist and remove gearbox assembly.

37MANUAL GEARBOX
6
REPAIRREV: 05/99 78.Position crossmember and locate over fixing
studs of LH and RH gearbox mounting rubbers.
79.Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
80.Fit intermediate silencer.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 90
orSee MANIFOLD AND EXHAUST
SYSTEM, Repair, Intermediate pipe - 110/130
.
81.Fit front pipe to exhaust manifold
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe
.
82.Fit rear propeller shaft to transmission brake
drum. Tighten nuts to
47 Nm (33 lbf/ft).
83.Remove 3 bolts securing support cradle to
transmission and remove hoist.
84.Reconnect battery earth strap to transfer box
fixing.
85.Connect speedometer cable to transfer box and
secure with retaining clip.
86.Coat both sides of clutch slave clinder backing
plate with Hylomar P232M waterproof sealant.
87.Locate backing plate on slave cylinder.
88.Fit slave cylinder to bell housing, engaging
push-rod through centre of dust cover, and with
bleed screw uppermost. Tighten bolts to
25 Nm
(18 lbf/ft).
89.Fit front propeller shaft to transfer box. Tighten
nuts to
47 Nm (33 lbf/ft).
90.Refill main gearbox and transfer boxSee
MAINTENANCE , Under vehicle maintenance
.
91.Feed transmission brake cable through heel
board and ensure grommet is correctly located.
NOTE: Apply a soap solution to aid fitment
of cable.
92.Lower vehicle on ramp.
93.Fit ties to secure gearbox harness to
transmission breather pipes.
94.Fit breather pipe retaining clip to rear of engine.
95.Reconnect charge air hose at turbocharger.
96.Reconnect intake hose at induction manifold. If
EGR system is fitted, reconnect intake hose at
intercooler.
97.Reconnect radiator top hose at thermostat
housing.
98.Fit viscous fan unit
See COOLING SYSTEM,
Repair, Viscous coupling and fan
.
99.Reconnect battery.100.Refill cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system
.
101.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
102.Locate insulation pad over gear levers and fit to
tunnel cover.
103.Fit gear lever with gaiter to lower lever spline
and secure with retaining nut.
104.Fit gear lever cover.
105.Fit gear lever and transfer box lever knobs.
106.Fit gearbox cover carpet.
107.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Under
vehicle maintenance
.

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.

41TRANSFER GEARBOX
4
REPAIR
36.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer
gearbox.
37.Remove battery earth strap retaining nut, 1 nut
and 4 bolts, securing transfer box to main
gearbox extension case.
38.Remove retaining nut securing earth leads to RH
side of transfer box.
39.Fit three guide studs,LRT-41-009, through
transfer box bolt holes to support it during
removal.
40.Lower hoist and withdraw transfer box from main
gearbox.
41.Remove transfer box.Refit
42.Ensure joint faces of transfer box and main
gearbox are clean and guide studs,LRT-41-009,
are fitted to extension case.
43.Lubricate oil seal in joint face of transfer box.
44.Secure transfer box to adaptor plate on lifting
hoist and raise hoist until transfer box can be
located over guide studs.
45.Remove guide studs, fit battery earth strap, and
secure transfer box to main gearbox extension
case. Tighten fixings to
45 Nm (33 lbf/ft).
46.Fit electrical leads to differential lock switch.
47.Raise hoist and remove wooden block
supporting main gearbox.
48.Secure LH and RH mounting brackets to
gearbox and tighten fixings to
55 Nm (41 lbf/ft).
49.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
50.Position chassis crossmember and locate over
fixing studs of LH and RH gearbox mounting
rubbers .
51.Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
52.Remove body jack.
53.Fit retaining nut to LH and RH mounting rubbers.
Tighten to
21 Nm (15 lbf/ft).
54.Remove 4 bolts securing hoist adaptor plate to
transfer box bottom cover.
55.Lower hoist and move aside.
56.Clean threads of the 4 bolts, coat with Loctite
290, and fit to transfer box bottom cover. Tighten
to
25 Nm (18 lbf/ft).
57.Fit earth leads to RH side of transfer box.
58.Connect differential lock control operating rod to
pivot arm.
59.Fit speedometer cable to transfer box.
60.Fit front and rear propeller shafts to transfer box.
Tighten nuts to
47 Nm (33 lbf/ft).
61.Fit intermediate silencer.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
silencer - 90; Refit
orSee MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 110/130; Refit
.
62.Refill transfer box with recommended oil
See
SECTION 10, Maintenance, Under vehicle
maintenance

TRANSFER GEARBOX
5
REPAIR REV: 05/9963.Feed transmission brake cable through heel
board. Ensure cable grommet is correctly
located.
NOTE: Apply a soap solution to aid fitment
of cable.
64.Lower vehicle ramp.
65.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
66.Connect high/low lever to operating rod.
67.Fit breather pipe banjo union to high/low
cross-shaft housing.
68.Fit centre access panel to seat base. If fitted,
secure EGR and alarm system diagnostic
connector mounting bracket to front of access
panel.
69.If fitted, reconnect multi-plug to EGR control unit
on base of centre seat cushion or cubby box.
70.Fit seat cushion or cubby box
See CHASSIS
AND BODY, Repair, Cubby box
.
71.Reconnect battery.
72.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Handbrake
cable
.