ECU LAND ROVER DEFENDER 1996 Workshop Manual

01INTRODUCTION
6
INFORMATION 3.Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1.Position cup of hydraulic arm under differential
casing.
2.Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3.Lower jack until axle sits securely on axle
stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a 'drive on' type ramp which supports vehicle
on its road wheels. If a 'wheel-free' condition is
required, use a 'drive on' ramp incorporating a
'wheel-free' system providing support beneath axle
casings. Alternatively, place vehicle on a firm, flat floor
and support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using 'Two Post' ramps
that employ four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.DYNAMOMETER TESTING
The front and rear axles cannot be driven
independently.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal workshop
safety standards are applied, there is no speed
restriction during testing except any that may apply to
the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.

INTRODUCTION
7
INFORMATION TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1.Turn ignition key to position '1' to release
steering lock.
2.Select neutral in main gearbox and transfer
gearbox.
3.Secure tow rope, chain or cable to front towing
eyes (alternative types shown).
4.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions, 'snatch' recovery
should be avoided.Rear suspended tow by breakdown vehicle
1.If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
2.Select neutral in main gearbox and transfer box.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.
TRANSPORTING THE VEHICLE BY TRAILER
Lashing/towing eyes are provided on front and rear of
the chassis side members, see J6085, to facilitate the
securing of the vehicle to a trailer or other means of
transportation.
CAUTION: Underbody components must
not be used as lashing points.
Install vehicle on trailer and apply park brake. Select
neutral in main gearbox.

INTRODUCTION
9
INFORMATION ABBREVIATIONS AND SYMBOLS USED IN THIS
MANUAL
Across flats (bolt size) AF............................................
After bottom dead centre ABDC...................................
After top dead centre ATDC.........................................
Alternating current a.c..................................................
Ampere amp................................................................
Ampere hour amp hr....................................................
Before bottom dead centre BBDC................................
Before top dead centre BTDC......................................
Bottom dead centre BDC.............................................
Brake horse power bhp................................................
British Standards BS....................................................
Carbon monoxide CO..................................................
Centimetre cm.............................................................
Centigrade (Celsius) C................................................
Cubic centimetre cm
3...................................................
Cubic inch in3...............................................................
Degree (angle) deg or° ...............................................
Degree (temperature) deg or° .....................................
Diameter dia................................................................
Direct current d.c..........................................................
Electronic Control Unit ECU........................................
Fahrenheit F.................................................................
Feet ft...........................................................................
Feet per minute ft/min..................................................
Fifth 5th........................................................................
First 1st........................................................................
Fluid ounce fl oz..........................................................
Foot pounds (torque) lbf ft............................................
Fourth 4th.....................................................................
Gramme (force) gf........................................................
Gramme (mass) g........................................................
Gallons gal...................................................................
High tension (electrical) H.T.........................................
Internal diameter I.D....................................................
Inches of mercury in. Hg..............................................
Inches in......................................................................
Kilogramme (force) kgf.................................................
Kilogramme (mass.) kg................................................
Kilogramme centimetre (torque) kgf.cm.......................
Kilogramme per square millimetre kgf/mm
2.................
Kilogramme per square centimetre kgf/cm2.................
Kilogramme metres (torque) kgf.m..............................
Kilometres km..............................................................
Kilometres per hour km/h.............................................
Kilovolts kV...................................................................
Left-hand LH................................................................
Left-hand steering LHStg.............................................
Left-hand thread LHThd...............................................
Litres litre.....................................................................Low tension l.t..............................................................
Maximum max.............................................................
Metre m........................................................................
Millilitre ml....................................................................
Millimetre mm...............................................................
Miles per gallon mpg....................................................
Miles per hour mph......................................................
Minute (angle) '............................................................
Minus (of tolerance) -...................................................
Negative (electrical) -...................................................
Newton metres (torque) Nm........................................
Number No..................................................................
Ohms ohm...................................................................
Ounces (force) ozf.......................................................
Ounces (mass) oz........................................................
Ounce inch (torque) ozf.in...........................................
Outside diameter O.D..................................................
Part number Part No....................................................
Percentage %...............................................................
Pints pt.........................................................................
Plus (tolerance) +.........................................................
Positive (electrical) +....................................................
Pound (force) lbf..........................................................
Pounds inch (torque) in.lbf...........................................
Pound (mass) lb...........................................................
Pounds per square inch P.S.I......................................
Ratio :...........................................................................
Reference ref...............................................................
Revolution per minute rev/min.....................................
Right-hand RH.............................................................
Second (angle) "...........................................................
Second (numerical order) 2nd......................................
Specific gravity sp.gr....................................................
Square centimetres cm
2...............................................
Square inches in2.........................................................
Standard wire gauge s.w.g..........................................
Synchroniser/Synchromesh synchro...........................
Third 3rd.......................................................................
Top dead centre TDC..................................................
United Kingdom UK......................................................
Vehicle Identification Number VIN...............................
Volts V.........................................................................
Watts W.......................................................................
SCREW THREADS
British Standard Pipe BSP...........................................
Unified Coarse UNC....................................................
Unified Fine UNF.........................................................

01INTRODUCTION
10
INFORMATION CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (AC)....................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine coolant temperature sensor (ECTS)................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Intake air temperature (IAT).........................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAFS).......................................
Open loop (OL)............................................................
Relay module (RM)......................................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TPS)......................................
Transmission range (TR)..............................................
Wide open throttle (WOT)............................................OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Intake temperature/ambient temperature (-)................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Relay (-).......................................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Transmission gear (-)...................................................
Full throttle, wide open throttle (WOT).........................

GENERAL FITTING REMINDERS
5
INFORMATION JOINTS AND JOINT FACES
1.Always use correct gaskets where they are
specified.
2.Use jointing compound only when
recommended. Otherwise fit joints dry.
3.When jointing compound is used, apply in a thin
uniform film to metal surfaces; take great care to
prevent it from entering oilways, pipes or blind
tapped holes.
4.Remove all traces of old jointing materials prior
to reassembly. Do not use a tool which could
damage joint faces.
5.Inspect joint faces for scratches or burrs and
remove with a fine file or oil stone; do not allow
removed material or dirt to enter tapped holes or
enclosed parts.
6.Blow out any pipes, channels or crevices with
compressed air, fit new 'O' rings or seals
displaced by air blast.FLEXIBLE HYDRAULIC PIPES, HOSES
1.Before removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
2.Obtain appropriate plugs or caps before
detaching hose end fittings, so that ports can be
immediately covered to exclude dirt.
3.Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any hose found faulty.
4.When refitting hose, ensure that no unnecessary
bends are introduced, and that hose is not
twisted before or during tightening of union nuts.
5.Containers for hydraulic fluid must be kept
absolutely clean.
6.Do not store brake fluid in an unsealed
container. It will absorb water, and fluid in this
condition would be dangerous to use due to a
lowering of its boiling point.
7.Do not allow brake fluid to be contaminated with
mineral oil, or use a container which has
previously contained mineral oil.
8.Do not re-use brake fluid bled from system.
9.Always use clean brake fluid to clean hydraulic
components.
10.Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of dirt.
11.Absolute cleanliness must be observed with
hydraulic components at all times.
12.After any work on hydraulic systems, inspect
carefully for leaks underneath the vehicle while a
second operator applies maximum pressure to
the brakes (engine running) and operates the
steering.

MAINTENANCE
1
MAINTENANCE SERVICE SCHEDULE
The following section describes the items detailed in
the vehicle Service Schedule. Where required
instructions are given for carrying out the service
procedure, or a cross reference is given to the section
in the manual where the procedure may be found.
Service Maintenance Schedules are published
separately to reflect the needs and intervals for each
vehicle variant. Procedures in the Workshop Manual
must be used in conjunction with the Service
Schedule sheets.
Service Maintenance Schedules are available from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle,
Merseyside, L70 1JL
VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seat belts, seat belt
mountings, seat belt buckles and operation of inertia
seat belts.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear wipers and washers and
condition of wiper blades.CHECK OPERATION OF HANDBRAKE
Handbrake check/adjust
1.Chock road wheels.
2.Raise one rear wheel clear of ground and
support securely with axle stand.
3.Release handbrake lever.
4.Underneath vehicle, tighten adjuster bolt
clockwise to
25 Nm (18 lbf/ft)to fully lock brake
drum.
5.Slacken adjusting bolt by 1.5 turns to give brake
shoes running clearance. Check that the drum is
free to rotate.
6.Adjust handbrake cable locknuts to give pawl
two notches free movement on the rachet before
being fully operational on third notch of rachet.
NOTE: Cable adjustment must ONLY be
used for initial setting and to compensate
for cable stretch. It MUST NOT be used to
take up brake shoe wear, which MUST be adjusted
at brake drum.
7.Operate handbrake to settle brake shoes.
Recheck handbrake is fully operational on third
notch of rachet pawl. Readjust if necessary.
8.Remove axle stand and wheel chocks.

MAINTENANCE
5
MAINTENANCE REV: 05/99 CHECK COOLING, INTERCOOLING AND HEATING
SYSTEMS
Check cooling, and heater systems for leaks and
pipes/hoses for security and condition. Refill or top up
as necessary.
CAUTION: It is important that the correct
procedure is followed when refilling or
topping up the cooling system to avoid
trapping air in the system.
WARNING: Do not remove caps and plugs
when engine is hot because cooling
system is pressurised and personal
scalding could result.
1.Remove plastic plugs from thermostat housing
and radiator.
2.Fill cooling system with correct concentration
and specification of anti-freeze.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
3.Fill from expansion tank until radiator is full, with
level in expansion tank the same as in radiator.
NOTE: Care should be taken to avoid
excess coolant spillage from radiator.
4.Fit plastic plug in radiator.
5.Add a further 1 litre (1.76 pints) of coolant to
expansion tank and allow to settle.
6.Refit expansion tank cap and thermostat
housing plug.
7.Run engine at idle speed for five minutes.
8.Switch off engine, check that expansion tank
coolant is level with top of indicator post and top
up as necessary.Check intercooler and turbo-charger system for air
leaks and pipes/hoses for security and condition.
All system hoses should be renewed at first signs of
deterioration.
VALVE CLEARANCES - CHECK/ADJUST
Check/adjust valve clearances.
See ENGINE ,
Adjustment, Valve clearances - check and adjust
RENEW FUEL FILTER ELEMENT
Remove
1.Clean area around filter head and position a
container beneath.
2.Unscrew and remove filter, catch fuel released.
Refit
3.Wet seal of new filter with fuel.
4.Screw new filter into position.
5.Ensure drain tap is fully closed.

10MAINTENANCE
6
MAINTENANCE RENEW AIR CLEANER ELEMENT AND CLEAN
DUMP VALVE
Remove
1.Release 2 retaining clips and lift air cleaner from
its cradle sufficiently to gain access to element.
2.Unscrew wing nut and remove end cover.
3.Unscrew second wing nut and withdraw element
from air cleaner casing.
4.Clean interior and exterior of casing and cover.
5.Squeeze open dump valve and check that
interior is clean. Renew valve, if perished.Refit
6.Fit new element, seal first, into casing and
secure with wing nut.
7.Fit end cover, align mating arrows, and secure
with wing nut.
8.Position air cleaner in mounting cradle and
secure with retaining clips.
CLEAN ENGINE BREATHER FILTER
Remove
1.Disconnect breather top hose.
2.Remove single bolt and ease breather from
rocker cover.
3.Disconnect bottom hose and remove engine
breather.
4.Using suitable flushing solvent, thoroughly clean
breather filter. Remove and discard rubber 'O'
ring from breather pipe.
Refit
5.Fit new rubber 'O' ring to engine breather.
6.Connect breather bottom hose.
7.Locate breather into rocker cover and secure
with retaining bolt, tightening to
9 Nm (7 lbf/ft).
8.Connect breather top hose.

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.

MAINTENANCE
13
MAINTENANCE REV: 05/992.When pure diesel is emitted, retighten drain
plug.
3.Disconnect fuel inlet pipe at sedimenter. Raise
and support pipe above level of fuel tank to
prevent fuel draining from tank.
4.Support sedimenter bowl, unscrew bolt and
remove bowl.
5.Remove sedimenter element.
6.Clean all components in kerosene.
7.Fit new seals.
8.Fit element into sedimenter bowl.
9.Secure bowl to sedimenter head.
10.Fit fuel inlet pipe to sedimenter.
11.Slacken drain plug and when pure diesel is
emitted, retighten plug.
12.If necessary, prime the system.
See FUEL SYSTEM, Adjustment, Priming
the fuel system
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK SECURITY OF TOWING BRACKET
FITTINGSCARRY OUT ROAD OR ROLLER TEST
WARNING: Two wheel roller tests MUST
NOT be carried out.
For details of dynamometer testing.
See
INTRODUCTION, Information, Dynamometer
testing
Check the following components:
1.Engine for excessive noise.
2.Clutch for slip, judder or spin/drag.
3.Gear selection/noise - high/low range.
4.Steering for abnormal noise/effort.
5.Steering for free play.
6.All instruments, gauges and warning indicators.
7.Heater and air conditioning systems.
8.Heated rear screen.
9.Shock absorbers - ride irregularities.
10.Foot brake, on emergency stop, pulling to one
side, binding and pedal effort.
11.Handbrake operation.
12.Seat reclining and latching.
13.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
14.Road wheel balance.
15.Transmissions for vibrations.
16.Body noises, squeaks and rattles.
17.Excessive exhaust smoke.
18.Engine idle speed.
19.Endorse service record.
20.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD