ECO mode LAND ROVER DEFENDER 1996 Workshop Manual

INTRODUCTION
11
INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number and the
recommended maximum vehicle weights are stamped
on a plate riveted to the brake pedal box in the engine
compartment. The VIN is also stamped on a plate
visible through the LH side of the windscreen, see
J6088.
A.Type approval
B.Identification
C.Maximum permitted laden weight for vehicle
D.Maximum vehicle and trailer weight
E.Maximum road weight-front axle
F.Maximum road weight-rear axle
The number is also stamped on the RH side of the
chassis to the rear of the front lashing eye, see J6089.
The Vehicle Identification Number identifies the
manufacturer, model range, wheel base, body type,
engine, steering, transmission, model year and place
of manufacture. The following example shows the
coding process.
SALLDHMF7TA
SAL= World manufacturer identifier
LD= Land Rover Defender
H= 110 inch,V= 90inch,K= 130 inch
M= 4 door Station Wagon,A= 90 Soft Top, Hard Top,
Pick-up,B= 2 door Station Wagon,E= 2 door 130
Crew cab,F= 4 door 130 Crew cab,H= 130 High
Capacity Pick-up
F= 2.5L (300Tdi)
7= RH drive, 5 speed manaul,8= LH drive, 5 speed
manual
T= 1996 MY, volume build,N= 1996 MY, non-volume
build
A= Solihull build,F= CKD, assembled locally from kit

09LUBRICANTS, FLUIDS AND CAPACITIES
4
INFORMATIONREV: 05/99 RECOMMENDED FUEL
300 Tdi Vehicles
Diesel fuel oil, distillate, diesel fuel, automotive gas or Derv to British standard 2869, Class A1 or A2. Using diesel
fuel with a lower class rating could seriously impair vehicle performance.
Td5 Vehicles
Refer to Defender Workshop Manual VDR 100350.
V8i Vehicles
Refer to Defender Workshop Manual LRL 0185.
FUEL TANK CAPACITY
Side tank:
90 models 54,6 litres (12 gallons)........................................................................
110 models * 68,2 litres (15 gallons)....................................................................
110 Station wagon 45,5 litres (10 gallons)...........................................................
* Except Station wagon
Rear tank:
110 and 130 models 79,5 litres (17,5 gallons).........................................................

MAINTENANCE
11
MAINTENANCE REV: 05/99 RENEW FRONT AND REAR AXLE OIL
1.Ensure vehicle is level and place suitable tray
under axle to be drained.
2.Using 13mm square drive wrench, remove drain
and filler/level plugs from axle and allow oil to
drain completely.
3.Clean and refit drain plug.
A- Front and rear axle, 90 models, front, 110/130
models.B- Rear axle, 110/130 models.
4.Inject new oil,
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended lubricants and fluids
until it
runs out from filler/level hole. Allow excess oil to
drain and wipe clean.
5.Clean and refit filler/level plug.
CHECK/TOP UP FRONT AND REAR AXLE
1.Ensure vehicle is level.
2.Using 13 mm square drive wrench, remove
filler/level plug.3.If necessary inject new oil until oil runs out from
filler/level hole. Allow excess oil to drain and
wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
4.Clean and refit filler/level plug.
RENEW SWIVEL PIN HOUSING OIL
1.Ensure vehicle is level and place suitable tray
under swivel to be drained.
2.Remove drain and level plugs, allow oil to drain
completely. Clean and refit drain plug.
3.Remove filler plug and inject new oil until oil runs
out from level hole.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
Allow
excess oil to drain and wipe clean.
4.Clean and refit filler and level plugs.
NOTE: On later vehicles, the level and
drain plugs have been deleted. The swivel
pin housing is filled with grease on
manufacture, for life service, and maintenance is
not required.
CHECK/TOP UP SWIVEL PIN HOUSING OIL
1.Ensure vehicle is level.
2.Remove level and filler plug, check oil level and
top up if necessary with new oil until oil runs out
from level hole. Allow excess oil to drain and
wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
3.Clean and refit filler and level plugs.

10MAINTENANCE
12
MAINTENANCEREV: 05/99 LUBRICATE PROPELLER SHAFT UNIVERSAL
AND SLIDING JOINTS
1.Clean all grease nipples on front and rear
propeller shafts.
2.Using a low pressure hand grease gun, apply
recommended grease
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
to grease
nipples at front and rear propeller shaft universal
and sliding joints.
VISUALLY CHECK BRAKE, FUEL, CLUTCH
HOSES/PIPES/UNIONS FOR CHAFING, LEAKS
AND CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
RENEW CATALYTIC CONVERTERS
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
manifolds and exhaust system
CHECK FOR FLUID LEAKS FROM POWER
STEERING AND SUSPENSION SYSTEMS,
HYDRAULIC PIPES AND UNIONS FOR CHAFING
AND CORROSION
CHECK/TIGHTEN STEERING UNIT AND STEERING
ROD BALL JOINT FIXINGS, CHECK CONDITION
OF BALL JOINTS AND DUST COVERSBall joints are lubricated for life during manufacture
and require no further lubrication unless the rubber
boot has been dislodged or damaged. All joints should
be checked at specified service intervals, but more
frequently if vehicle is used under arduous conditions.
1.Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent, fit a new joint assembly.
See
STEERING, Repair, Drop arm ball See
STEERING, Repair, Track rod and See
STEERING, Repair, Drag link and drag link
ends
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN AND CLEAN FUEL SEDIMENTER, IF
FITTED
The fuel sedimenter is located on a chassis side
member on the RH side of vehicle near rear wheel. It
increases the working life of the fuel filter by removing
larger droplets of water and other matter from fuel.
NOTE: On 110/130 models with a twin tank
fuel system, two sedimenters may be
fitted, one on each side of the vehicle
chassis.
1.Slacken drain plug and allow any water to drain
off.

FUEL SYSTEM
11
REPAIR HEATER PLUGS
Service repair no - 19.60.31
Remove
1.Disconnect battery.
No.1 heater plug - air conditioning models:
2.Release drive belt from compressor pulley.See
AIR CONDITIONING, Repair, Compressor
drive belt
3.Remove 4 bolts securing compressor to front
cover, move compressor aside.
No.3 heater plug:
4.Remove retaining bolt and withdraw breather
valve from rocker cover. Remove and discard 'O'
ring.
All heater plugs:
5.Remove terminal nut and disconnect wire from
heater plug terminal.
6.Unscrew heater plug.
Refit
7.Clean heater plug and seating.
8.Coat threads of heater plug with suitable
anti-seize compound operational to a
temperature of 1000°C.
9.Fit heater plug, tighten to
23 Nm (17 lbf/ft).
10.Connect wire to heater plug terminal and secure
with nut.
NOTE: Feed wire must be connected to
No. 4 heater plug terminal.
No. 3 heater plug:
11.Lubricate new 'O' ring with engine oil and fit to
breather valve.
12.Fit valve to rocker cover, tighten to bolt to
15 Nm
(11 lbf/ft).
No. 1 heater plug - air conditioning models
13.Position compressor to front cover, fit bolts and
tighten to
25 Nm (18 lbf/ft).
14.Fit drive belt to compressor pulley and adjust
tension.
See AIR CONDITIONING, Repair,
Compressor drive belt
All models:
15.Reconnect battery.

FRONT AXLE AND FINAL DRIVE
1
OVERHAUL FRONT DIFFERENTIAL
Service repair no - 54.10.07.
Overhaul
NOTE: The front axle differential, for all
models, is the same as that fitted to the 90
rear axle and can only be serviced as a
complete assembly
See REAR AXLE AND FINAL
DRIVE, Repair, Differential assembly - 90
.
FRONT HUB
Service repair no - 60.25.14.
Overhaul
1.Remove hub assembly
See Repair, Front hub
assembly
.
2.Remove outer bearing.
3.Mark, for reassembly, relationship between hub
and brake disc, if original hub is to be refitted.
4.Remove 5 bolts and separate hub from brake
disc.
5.Drift out grease seal and inner bearing from hub
and discard seal.
6.Drift out inner and outer bearing tracks.
7.Clean hub and drift in inner and outer bearing
tracks.
8.Pack hub inner bearing with recommended
grease and fit to hub.
9.With lip side leading fit new seal to hub using
special toolLST 137seal replacer and drift18G
134. Drive in seal flush with rear face of hub.
Apply grease between seal lips.
10.Fit brake disc to hub, lining up to marks made
during dismantling. Applying Loctite 270, fit
retaining bolts. Tighten to
73 Nm (54 lbf/ft).
11.Grease and fit outer bearing to hub.
12.Fit hub assembly
See Repair, Front hub
assembly
.

BRAKES
1
DESCRIPTION AND OPERATION DESCRIPTION
The mechanical components of the hydraulic braking
system consists of four piston caliper disc brakes at
the front and two piston caliper disc brakes at the rear.
Vented front brake discs are fitted as standard on
110/130 models, while 90 models have solid discs.
However, on 90 models with a heavy duty chassis,
vented front discs may also be fitted.A cable controlled parking brake operates a single
drum brake mounted on the output shaft of the
transfer gearbox and is completely independent of the
main braking system.
The basic hydraulic system involves 2 separate and
independent primary and secondary circuits which
permits a degree of braking should a fault occur in
one of the circuits. The primary circuit operates the
rear brake calipers and the secondary circuit the front
brake calipers.
Master cylinder components
1.Secondary plunger
2.Secondary spring
3.Recuperation seal4.Primary spring
5.Recuperation seal
6.Primary plunger

70BRAKES
2
DESCRIPTION AND OPERATION REV: 05/99 OPERATION
Master cylinder
A tandem master cylinder, which is assisted by a light
weight, short, compact servo, is fed by a divided fluid
reservoir. The rear section supplies fluid for the
primary circuit and the front section the secondary
circuit.
When the brakes are off, the fluid can move
unrestricted between the dual line system and the
separate reservoirs in the fluid supply tank.
When the footbrake is applied, the primary plunger
assembly moves up the cylinder bore and the
pressure created acts in conjunction with the primary
spring to overcome the secondary springs, thus
moving the secondary plunger assembly up the bore.
At the same time initial movement of both plungers
takes the recuperating seals past the cut-off holes in
the cylinder chambers 'A' and 'C',see J6321, and
applies pressure to the fliud in those chambers, which
is directed to the respective circuits.
The fluid in chambers 'B' and 'D'is unaffected by
movement of the plungers and can move unrestricted
between the separate chambers and respective
reservoirs in the fluid supply tank, both before and
during brake application. When the brakes are
released, the plunger assemblies, aided by the return
springs are retracted faster than the fluid; this creates
a depression between the fluid in chambers 'A' and
'C'and the recuperation seals.
The recuperation seals momentarily collapse allowing
fluid in chambers 'B' and 'D'to flow through the holes
in the plungers, over the collapsed seals and into
chambers 'A' and 'C'respectively. The movement of
fluid from one set of chambers to the other, is
compensated for by fluid from the separate reservoirs
in the supply tank moving through the feed holes in
the cylinder. Conversely, the final return movement of
the plunger assemblies causes the extra fluid in
chambers 'A' and 'C'to move through the cut off holes
into the fluid reservoir.The servo unit provides controlled power assistance
to to the brake pedal when pressure is applied. Power
is obtained from a vacuum pump located on the RH
side of the engine cylinder block. The vacuum is
applied to both sides of a flexing diaphragm, and by
admitting atmosheric pressure to the rear diaphragm,
assistance is obtained. The servo unit is mounted
between the brake pedal and master cylinder and is
linked to these by push rods. Should a vacuum failure
occur, the two push rods will act as a single rod
allowing the brakes to function in the normal way,
although more effort will be required to operate the
brake pedal.
Hydraulic system
A brake fluid loss switch is fitted to the master cylinder
reservoir filler cap. The switch is wired to a warning
light on the vehicle fascia and will illuminate as a bulb
check when the ignition is switched on and
extinguishes when the engine is running and the
handbrake is released. A hydraulic failure in the
system will result in fluid loss, causing the warning
light to illuminate.
On 90 models a pressure reducing valve (PRV), fitted
to the RH bulkhead in the engine compartment,
maintains the braking balance, see J6322. Pressure
to the rear calipers is regulated by the PRV, this valve
is of the failure by-pass type, allowing full system
pressure to the rear brake calipers in the event of a
front (secondary) circuit failure.
NOTE: In some countries, a pressure
reducing valve may be fitted to 110 models
to conform to legal requirements.

BRAKES
3
DESCRIPTION AND OPERATION
90 Models
110/130 Models
Hydraulic system
A- Primary circuit
B- Secondary circuit
C- Pressure reducing valve (PRV)1.LH rear brake caliper
2.T connector
3.RH rear brake caliper
4.Brake servo
5.Master cylinder and reservoir
6.LH front brake caliper
7.RH front brake caliper

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
.