torque LAND ROVER DEFENDER 1996 Service Manual

REAR SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Anti-roll bar
- Strap nyloc nuts 30..............................................................................
- Ball link self lock nut 68........................................................................
- Castellated nut 40................................................................................
Top link to mounting bracket 176.....................................................................
Bottom link to axle 176.....................................................................................
Bottom link to chassis 176...............................................................................
Top link bracket to rear cross member 47......................................................
Shock absorber to axle 37 N............................................................................

BRAKES
7
REPAIR REV: 05/99 FRONT BRAKE PADS - ALL MODELS
Service repair no - 70.40.02
Remove
1.Remove front road wheels .
2.Clean exterior of calipers.
3.Remove split pin from retaining pins.
4.Remove pad retaining pins and anti-rattle
springs.
5.Remove brake pads.
6.Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
7.Using piston clampLRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8.Fit brake pads.
9.Fit pad retaining pins and anti-rattle springs.
Secure with new split pins.
10.Apply service brake pedal several times to locate
pads.
11.Fit road wheels. 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)
12.Check fluid reservoir. Top up if necessary, using
correct grade of fluid
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
.

70BRAKES
8
REPAIRREV: 05/99 REAR BRAKE PADS
Service repair no - 70.40.03
Service tool:
Remove
1.Remove rear road wheels.
2.Clean exterior of calipers.
3.Remove pad retaining pins and anti-rattle
springs. Note differences between 90 and
110/130 models.
4.Remove brake pads.
5.Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
6.Using piston clampLRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
7.Insert brake pads.
8.Fit anti-rattle springs and secure with retaining
pins.
9.Apply service brake pedal several times to locate
pads.
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)
11.Check fluid reservoir, top up if necessary, using
correct grade of fluid
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
.
90 Models
110/130 Models

BRAKES
11
REPAIR REV: 05/99 Assemble outboard pistons
13.Coat new fluid seal with brake fluid. Ease seal
into groove in bore using only fingers, ensuring it
is properly seated. Fluid seal and groove are not
same in section, so when seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat appropriate piston with brake fluid. Insert it
squarely into bore by hand only. Do not tilt piston
during insertion, leave approximately 8mm
projecting from bore.
15.Coat new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston and into bore recess. Use
piston clamp to press home seal retainer and
piston.
Mounting inboard pistons
16.Clamp outboard pistons and carry out same
procedure for removing and fitting outboard
pistons and seals, instructions 8 to 15.
Fit calipers and pads
17.Fit caliper, tighten bolts evenly to
82 Nm (60
lbf/ft).
18.Connect brake flexible hoses to caliper. Tighten
to
15 Nm (11 lbf/ft).
19.Remove hose clamps.
20.Insert pads. Fit pins and springs, secure using
new split pin.
21.Bleed brake system
See Brake System Bleed
.
22.Press brake pedal firmly several times to locate
friction pads.
23.Fit road wheels, remove axle stands. Finally
tighten road 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)
24.Road test vehicle. Note that new friction pads
require 'bedding-in', this may take several
hundred miles before brakes are at maximum
efficiency.FRONT BRAKE DISCS
Service repair no - 70.10.10.
Remove
1.Remove hub assembly
See FRONT AXLE AND
FINAL DRIVE, Repair, Front hub assembly
.
2.Remove 5 hub to disc bolts.
3.Tap disc to separate from hub.
NOTE: On 110/130 vehicles ventilated
discs are fitted as standard.
Refit
4.Locate disc to hub.
5.Apply Loctite 270 to disc bolts and tighten to
73
Nm (54 lbf/ft).
6.Check total disc runout with a dial indicator, this
must not exceed 0,15 mm, 0.006 in. If necessary
reposition disc.
7.Fit hub assembly
See FRONT AXLE AND
FINAL DRIVE, Repair, Front hub assembly
.
Disc reclamation
8.Check disc thickness. This dimension may be
machined to minimum thickness of 12 mm (0.47
in.) - solid discs, 22 mm (0.90 in) - ventilated
discs. Machine equal amount off each face.
NOTE: The disc MUST BE renewed if the
minimum running thickness stamped on
the disc is recorded.

70BRAKES
14
REPAIRREV: 05/99 15.Coat a new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston into bore recess.
16.Using special toolLRT-70-500- piston clamp,
press home seal retainer and piston.
Mounting inboard piston
17.Carry out same procedure as for removing and
fitting outboard piston and seals, instructions 8 to
16.
Fit calipers and pads to vehicle
18.Fit caliper to axle, tighten 2 bolts evenly to
82
Nm (60 lbf/ft).
19.Connect brake pipe to caliper. Tighten to15 Nm
(11 lbf/ft).
20.Remove clamp from flexible brake hose.
21.Insert pads and retaining springs, secure in
position with new retaining pins and spread ends
or fit new split pins, depending on vehicle model.
Note correct position of retaining springs on 90
models.
22.Bleed brake system
See Brake System Bleed.
23.Press brake pedal firmly several times to locate
pads.
24.Fit road wheels, remove axle stands. Finally
tighten road 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)
25.Road test vehicle. Note new brake pads require
'bedding-in', for several hundred miles before
brakes are at maximum efficiency.REAR BRAKE DISC
Service repair no - 70.10.11.
Remove
1.Remove rear hub assembly
See REAR AXLE
AND FINAL DRIVE, Repair, Rear hub
assembly
.
2.Remove disc bolts.
3.Remove disc from rear hub.
Refit
4.Fit disc to rear hub.
5.Fit disc bolts. Tighten to
73 Nm (54 lbf/ft).
6.Check total disc run out, this must not exceed
0,15 mm (0.006 in). If necessary reposition disc.
7.Fit rear hub assembly
See REAR AXLE AND
FINAL DRIVE, Repair, Rear Hub Assembly
.
Disc reclamation
8.Check disc thickness. This dimension may be
machined to minimum thickness of 12 mm.
Machine equal amounts off each face.
NOTE: The brake disc MUST BE renewed if
the minimum running thickness stamped
on the disc is recorded.

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)

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

82AIR CONDITIONING
2
REPAIR COMPRESSOR DRIVE BELT
Service repair no - 82.10.02
Remove
1.Disconnect battery.
2.Remove auxiliary drive belt
See ELECTRICAL,
Repair, Auxiliary drive belt.
3.Remove 3 nuts securing drive belt guard to
compressor retaining studs.
4.Slacken 3 belt tensioner retaining bolts.
5.Remove compressor drive belt. Mark direction
on belt if refitting.Refit
6.Fit compressor drive belt.
7.Fit drive belt guard.
8.Fit torque meter to centre of tensioner, apply and
hold a torque of
35 Nm (26 lbf/ft).
9.Tighten tensioner retaining bolts.
10.Rotate crankshaft 2 full turns.
11.Reapply and hold a torque of
35 Nm (26 lbf/ft)
to tensioner, then fully slacken and retighten
tensioner retaining bolts to
25 Nm (18 lbf/ft).
12.Fit auxiliary drive beltSee ELECTRICAL,
Repair, Auxiliary drive belt.
13.Reconnect battery.

WIPERS AND WASHERS
7
REPAIR Refit
NOTE: During reassembly all fixings
related to wiper motor and wheelboxes are
finger tightened only, until all components
are correctly aligned.
12.Fit wheelboxes to bulkhead and secure with
retaining nuts and washers.
13.Fit drive rack tubes to wheelboxes.
14.Apply grease to drive rack and wheelboxes.
15.Align wiper motor and mounting pad, secure with
retaining strap and tighten drive tube nut.
16.Fully tighten wheelbox back plate nuts.
17.Fully tighten both wheelbox spindle nuts.
18.Fit wiper arm adaptors and secure with grub
screw.
19.Before refitting panels fit wiper blades, connect
multi-plug and earth lead, reconnect battery and
check wiper operation.
20.If satisfactory, secure steering column upper and
lower fixings and tighten to correct torque.
21.Fit ventilator grille panel, fascia crash pad,
instrument housing and all other components
removed to gain access to wiper motor and
wheelboxes.

WIPERS AND WASHERS
9
REPAIR 13.Fit wheelboxes to bulkhead.
14.Fit drive tubes to wheelboxes.
15.Feed drive rack through tubes until fully seated
in both wheelboxes.
16.Secure drive tube nut to wiper motor.
17.Fit wiper motor strap and earth lead.
18.When all components are correctly aligned, fully
tighten wheelboxes nuts to secure drive tubes.
Tighten wheelbox to bulkhead nuts.
19.Fully tighten drive tube nut to wiper motor and
motor strap screws.
20.Connect multiplug to wiper motor and earth lead
to strap tag.
21.Fit spacer, where used, early vehicles only.
22.Fit wiper arm adaptors.
23.Reconnect battery and check operation of wiper
motor and drive assembly and wheelboxes.
24.Disconnect battery.
25.Fit steering column upper and lower supports.
Tighten fixings to correct torque.
26.Fit demister vent top duct.
27.Secure RH demister vent and hose.
28.Fit LH and RH demister vents to ducts.
29.Fit centre and LH fascia top crash rail support
brackets.
30.Fit all other components removed to gain access
to wiper motor and wheelboxes.
31.Reconnect battery, check wiper motor operation
again and adjust wiper arms, if necessary.REAR WIPER MOTOR
Service repair no - 84.35.12
Remove
1.With assistance, unscrew 3 retaining nuts and
remove spare wheel from rear door mounting
studs.
2.Lift wiper arm end cap to gain access to securing
nut.
3.Remove nut and withdraw wiper arm from drive
spindle.
4.Remove retaining nut, plain washer and rubber
washer securing wiper motor drive spindle to
door.
5.Remove 2 screws and remove cover from wiper
motor mounting bracket.
6.Disconnect wiper motor harness multi-plug.
7.Remove bolt, with rubber washer, and detach
wiper motor, complete with mounting bracket,
from rear door.