air suspension LAND ROVER DEFENDER 1996 Workshop Manual

Section Discard Existing
PagesInsert New Pages Reason for Amendment
41 - Transfer Gearbox -
Specifications, TorquePage 1 Page 1 Page layout amended.
47 - Propeller Shafts Contents page Contents page Introduction of overhaul section.
47 - Propeller Shafts -
RepairPage 1 Page 1 Introduction of overhaul section.
47 - Propeller Shafts -
OverhaulPage 1 Introduction of overhaul section.
51 - Rear Axle and
Final DriveContents page Contents page Page number amended.
51 - Rear Axle and
Final Drive - RepairPages 1 to 6 Pages 1 to 6 Clarification of wheel nut torque figures.
51 - Rear Axle and
Final Drive -
Specifications, TorquePage 1 Page 1 Page layout amended.
54 - Front Axle and
Final DriveContents page Contents page Correction of typographical error.
54 - Front Axle and
Final Drive - RepairPages 1 to 3 Pages 1 to 3 Clarification of wheel nut torque figures.
54 - Front Axle and
Final Drive -
Specifications, TorquePage 1 Page 1 Page layout amended.
57 - Steering - Fault
DiagnosisPages 5, 10, and
12Pages 5, 10, and
12Cross references amended.
57 - Steering - Repair Pages 3, 5, 8, 9,
13, and 14Pages 3, 5, 8, 9,
13, 14 and 15Torque figures updated, typographical errors
and page layout amended.
57 - Steering -
Specifications, TorquePage 1 Page 1 Torque figure amended.
60 - Front Suspension -
RepairPages 1 to 4 Pages 1 to 4 Clarification of wheel nut torque figures.
64 - Rear Suspension -
RepairPage 1 Page 1 Clarification of wheel nut torque figures.
70 - Brakes -
Description and
OperationPage 2 Page 2 Correction of typographical error.
70 - Brakes - Repair Pages 7, 8, 11, 14,
and 16Pages 7, 8, 11, 14,
and 16Clarification of wheel nut torque figures.
70 - Brakes - Overhaul Page 1 Page 1 Page layout amended.
74 - Wheels and Tyres Contents page Contents page Additional page in repair section.

01
04
05
07
09
10
12
17
19
26
30
33
37
41
47
51
54
57
60
64
74
70
75
76
80
82
84
86
88Workshop manual
DEFENDER 300Tdi
This manual covers vehicles from
1996 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
19 FUEL SYSTEM Tdi
26 COOLING SYSTEM Tdi
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS AND TYRES
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
88 INSTRUMENTS
Publication Part No. LRL 0097 ENG (3rd Edition)
Published by Rover Technical Communication
Ó1999 Rover Group Limited

INTRODUCTION
1
INFORMATION REV: 05/99 INTRODUCTION
This workshop manual covers vehicles from 1996
model year onwards. Amendments and additional
pages will be issued to ensure that the manual covers
latest models. Amendments and additions will be
identified by the addition of a dated footer at the
bottom of the page.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover Defender 300Tdi, Td5, and V8i vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system should
be carried out by a Land Rover Dealer. Repairs to
such items should NEVER be attempted by untrained
individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft end of the engine is referred to as the front.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out, particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer's specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.

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.

10MAINTENANCE
14
MAINTENANCEREV: 05/99 ADDITIONAL MAINTENANCE SCHEDULES
Camshaft drive belt
The engine timing gears are driven by a toothed
rubber belt which must be renewed at intervals
determined by the severity of operating conditions. In
reasonable, temperate climate operation, the belt
should be renewed every 120,000 km (72,000 miles)
or every six years whichever occurs earlier.
In adverse operating conditions, such as work in dusty
atmospheres, high ambient temperatures, desert and
tropical zones, renew the belt every 60,000 km
(36,000 miles) or every three years, whichever occurs
earlier.
CAUTION: If the drive belt is not renewed
at the correct interval, it could fail,
resulting in serious engine damage.
Oil change diesel engines
If the vehicle is operated on fuel with a high sulphur
content (over 1%) the oil change intervals must not
exceed 5000 km (3000 miles).
Anti-freeze
At two yearly intervals or at the onset of the second
winter, the cooling system should be drained, flushed
and refilled with the required water and anti-freeze
solution.
Hydraulic brake fluid.
It is recommended that at 40,000 km (24,000 miles)
intervals or every two years, whichever is the earlier,
the hydraulic brake fluid should be completely
renewed.
At 80,000 km (48,000 miles) intervals or every four
years, whichever is the earlier, all hydraulic brake fluid
seals and flexible hoses should be renewed. All
working surfaces of the master cylinder and caliper
cylinders should be examined and renewed where
necessary.Air cleaner
When the vehicle is used in dusty or field conditions or
deep wading, frequent attention to the air cleaner may
be required.
Dampers
At 60,000 km (36,000 miles) intervals remove all
suspension dampers, test for correct operation, refit or
renew as necessary.
SPECIAL OPERATING CONDITIONS
When the vehicle is operated in extremely arduous
conditions or on dusty, wet or muddy terrain, more
frequent attention should be paid to all servicing
requirements.
Additional daily or weekly attention depending on
operating conditions:
Check/top-up transfer box oil.
Check steering rubber boots for security and
condition. Renew if damaged.
Check brake fluid level: Investigate cause if any fluid
loss is suspected.
Clean brake discs and calipers.
Lubricate front and rear propeller shaft
universal/sliding joints. Under tropical or severe
conditions, particularly where sand is encountered,
the sliding joints must be lubricated very frequently to
prevent ingress of abrasive material.
Every week and every maintenance inspection check
tyre pressures and inspect tyre treads and side walls.
Under arduous cross-country conditions the tyre
pressures should be checked much more frequently,
even to the extent of a daily check.
Monthly
Renew gearbox oil.
Renew transfer box oil.
Check air cleaner element and renew every 6 months
or as necessary.

MAINTENANCE
15
MAINTENANCE ADDITIONAL MAINTENANCE SCHEDULES
Camshaft drive belt
The engine timing gears are driven by a toothed
rubber belt which must be renewed at intervals
determined by the severity of operating conditions. In
reasonable, temperate climate operation, the belt
should be renewed every 120,000 km (72,000 miles)
or every six years whichever occurs earlier.
In adverse operating conditions, such as work in dusty
atmospheres, high ambient temperatures, desert and
tropical zones, renew the belt every 60,000 km
(36,000 miles) or every three years, whichever occurs
earlier.
CAUTION: If the drive belt is not renewed
at the correct interval, it could fail,
resulting in serious engine damage.
Oil change diesel engines
If the vehicle is operated on fuel with a high sulpher
content (over 1%) the oil change intervals must not
exceed 5000 km (3000 miles).
Anti-freeze
At two yearly intervals or at the onset of the second
winter, the cooling system should be drained, flushed
and refilled with the required water and anti-freeze
solution.
Hydraulic brake fluid.
It is recommended that at 40,000 km (24,000 miles)
intervals or every two years, whichever is the earlier,
the hydraulic brake fluid should be completely
renewed.
At 80,000 km (48,000 miles) intervals or every four
years, whichever is the earlier, all hydraulic brake fluid
seals and flexible hoses should be renewed. All
working surfaces of the master cylinder and caliper
cylinders should be examined and renewed where
necessary.Air cleaner
When the vehicle is used in dusty or field conditions or
deep wading, frequent attention to the air cleaner may
be required.
Dampers
At 60,000 km (36,000 miles) intervals remove all
suspension dampers, test for correct operation, refit or
renew as necessary.
SPECIAL OPERATING CONDITIONS
When the vehicle is operated in extremely arduous
conditions or on dusty, wet or muddy terrain, more
frequent attention should be paid to all servicing
requirements.
Additional daily or weekly attention depending on
operating conditions:
Check/top-up transfer box oil.
Check steering rubber boots for security and
condition. Renew if damaged.
Check brake fluid level: Investigate cause if any fluid
loss is suspected.
Clean brake discs and calipers.
Lubricate front and rear propeller shaft
universal/sliding joints. Under tropical or severe
conditions, particularly where sand is encountered,
the sliding joints must be lubricated very frequently to
prevent ingress of abrasive material.
Every week and every maintenance inspection check
tyre pressures and inspect tyre treads and side walls.
Under arduous cross-country conditions the tyre
pressures should be checked much more frequently,
even to the extent of a daily check.
Monthly
Renew gearbox oil.
Renew transfer box oil.
Check air cleaner element and renew every 6 months
or as necessary.

19FUEL SYSTEM
8
REPAIR REAR MOUNTED FUEL TANK - 110/130
Service repair no - 19.55.26
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS
See
INTRODUCTION, Information, FUEL HANDLING
PRECAUTIONS
are carefully studied and
implemented in the interests of safety.
Remove
1.Disconnect battery.
2.Remove fuel filler cap.
3.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
4.Slacken retaining clips and disconnect fuel filler
hose from rear tank.5.Disconnect breather hose from filler tube.
6.Disconnect electrical plug and fuel supply pipe
from outlet pipe union on fuel gauge unit.
7.If the vehicle is fitted with a tow ball drop-plate
with support bars, the bars must be removed.
8.Remove anti-roll bar chassis mountings.
See
REAR SUSPENSION, Repair, Anti-roll bar
and push roll bar down to provide access to the
tank.
9.Remove LH lashing eye to assist access to tank.
10.Position a support under the tank, preferably one
that can be progressively lowered.

FUEL SYSTEM
9
REPAIR REV: 05/99
11.Remove 2 nuts that secure front fixing assembly
of the tank to chassis mounting bracket.
12.Remove tank rear mounting nuts.
13.With care, lower tank sufficiently to enable nut
and olive of spill return to be disconnected from
elbow in centre of tank.
14.Continue to lower tank until it can be removed
from vehicle.
NOTE: On later vehicles a separate stone
guard is fitted and is attached to the tank
with the existing front and rear fixings.
15.If required, remove tank gauge unit.
See
INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank
orSee INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130
Refit
16.If applicable, locate stone guard under tank.
17.Raise rear tank into position and connect spill
return pipe to the elbow with the nut and olive.
18.Continue to raise tank so that front and rear
mounting bolts locate in respective tank flange
holes.
19.Fit and tighten fixings to
20 Nm (15 lbf/ft).
20.Connect fuel suppnly pipe to the tank unit.
21.Fit fuel filler hose and breather pipe to filler tube
and secure with retaining clips.
22.Fit LH lashing eye to chassis.23.Fit anti-roll bar chassis mountings.
See REAR
SUSPENSION, Repair, Anti-roll bar
24.Check that drain plug is secure and fill fuel tank.
25.Reconnect battery.
26.Prime fuel system.
See Adjustment, Priming
the fuel system
and start engine.
27.Check system for leaks and operation of fuel
gauge.

33CLUTCH
2
FAULT DIAGNOSIS FAULT/SYMPTOM CHART
Symptoms
Slip Spin/Drag Judder/Fierce Fault Item
* * * Worn or oil on clutch linings 2
* * * Mechanical damage45678
* * Distorted clutch plate 2
* Failed or air in hydraulic system 12 13
* * Primary shaft tight fit in crankshaft bush 15 17
* Clutch splines sticking 2 15
* Weak clutch plate springs or insecure/worn
engine/gearbox mountings6
* Insecure/worn propeller shafts
* Insecure/worn suspension components/rubber
bushes
The items refered to in this chart relate to the clutch components shown in J6270 and J6271.See Description
and operation, Description
CLUTCH NOISE - MECHANICAL FAULTS
Noise from clutch or gearbox in neutral, which
disappears when clutch is depressed.
Suspect gearbox input/primary shaft bearings
See MANUAL GEARBOX, Fault diagnosis,
R380 gearbox
.
Noise from clutch or gearbox in neutral, which
changes tone or becomes worse when the clutch
is depressed.
Suspect worn release bearing.
Knocking/rattling from clutch or gearbox in
neutral, which is reduced or disappears when the
clutch is depressed.
Suspect worn/weak release lever retainer or
clutch unit.
Noise from clutch or gearbox in neutral, which
disappears when clutch is depressed.
Suspect gearbox fault
See MANUAL
GEARBOX, Fault diagnosis, R380 gearbox
.HYDRAULIC FAULTS
Unable to dis-engage clutch, little or no pedal
resistance.
1.Check condition, specification and level of fluid.
2.Check pipes and cylinders for leaks.
3.Check that air vent in reservoir lid is clear.
Suspect faulty master cylinder if no fluid leaks
present
See Repair, Master cylinder.
Spongy pedal operation
1.Check condition, specification and level of fluid.
2.Check that air vent in reservoir lid is clear.
Suspect air in fluid
See Repair, Bleed
hydraulic system
.
Clutch is difficult to dis-engage and/or does not
immediately re-engage when pedal is released.
1.Check condition, specification and level of fluid.
2.Check that air vent in reservoir lid is clear.
Suspect pedal pivot, master cylinder or slave
cylinder seizure
See Repair, Master cylinder.

REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect shock absorbers.
6.Disconnect flexible brake hose at RH chassis
side member and breather hose at banjo
connection on axle casing.
7.Disconnect lower links at axle.8.Mark differential and propeller shaft flanges with
identification marks for assembly.
9.Remove 4 nuts and bolts, lower propeller shaft
and tie to one side.
10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.If applicable, remove anti-roll bar links at axle
See REAR SUSPENSION, Repair, anti-roll
bar
.
14.Remove axle assembly.