battery LAND ROVER DEFENDER 1996 Workshop Manual

01INTRODUCTION
2
INFORMATION FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate inquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic and when
diluted with air becomes a readily ignitable mixture.
The vapour is heavier than air and will always fall to
the lowest level. It can readily be distributed
throughout a workshop by air current, consequently,
even a small spillage of fuel is very dangerous.
Always have a fire extinguisher containingFOAM CO
2
GAS,orPOWDERclose at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any lead lamps used must be flame
proof and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1.Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2.Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer's instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
AFUEL VAPOURwarning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.

01INTRODUCTION
8
INFORMATION JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1.Position vehicles so that jump leads will reach,
ensuring that vehiclesDO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2.Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected, connect the
jump leads as follows;
A.Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B.Connect other end of first jumper cable to positive
(+) terminal of discharged battery.
C.Connect one end of second jumper cable to
negative terminal of booster battery.
D.Connect other end of second jumper cable to a
good earth point on the disabled vehicle (eg. engine
front lifting eye, as shown in J6086),NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
3.If booster battery is installed in another vehicle,
start engine and allow to idle.
4.Start engine of vehicle with discharged battery,
following starting procedure in Owners' Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalyst, if fitted.
5.Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6.Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.

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 SPECIFICATION DATA
7
INFORMATION AIR CONDITIONING
System CFC free expansion valve system.............................................................................
Compressor Sanden TRS105N.....................................................................
Refrigerant R134a CFC free.......................................................................
Charge quantity 1.1 Kg................................................................
WIPER MOTORS
Tailgate wiper motor
Make/type IMOS (non-serviceable)........................................................................
Running current, wet screen at 20°C ambient 1.0 to 2.8 amps.................
Wiper speed, wet screen at 20°C ambient 37 to 43 cycles per minute.......................
Windscreen wiper motor
Make/type Lucas 14W uprated two speed........................................................................
Armature end float 0,1 to 0,2 mm............................................................
Brush length, minimum 4,8 mm....................................................
Brush spring tension 140 to 200 g........................................................
Resistance of armature winding
at 16ÊC (69ÊF) measured between adjacent
commutatator segments 0.23 to 0.35 ohms...................................................
Light running, rack disconnected: current at 13.5 V 2.0 amps.........
Wiper speed, wet screen, 60 seconds from cold Low speed - 45±3 rev/min, High speed - 65±5 ..............
rev/min
ELECTRICAL
System 12 volt, negative ground.............................................................................
Battery
Make/type - standard Land Rover Parts and Equipment/Lucas maintenance.......................................................
free 9-plate 072
Make/type - heavy duty Land Rover Parts and Equipment/Lucas maintenance....................................................
free 14-plate 663
Generator
Manufacturer Magnetti Marelli....................................................................
Type A127 - 100amp.................................................................................
Polarity Negative ground.............................................................................
Brush length:
New 17 mm.........................................................................
Worn, minimum free protrusion from moulding 5 mm........
Brush spring pressure flush with moulding 1.3N to 2.7N......................
Regulator voltage 13.6 to 14.4 volts.............................................................
Nominal output
Generator speed 6000 rev/min.....................................................
Control voltage 14 volt........................................................
Amp 65 amp.........................................................................

GENERAL FITTING REMINDERS
1
INFORMATION GENERAL FITTING REMINDERS
WORKSHOP SAFETY IS YOUR RESPONSIBILITY!
The suggestions, cautions and warnings in the
section are intended to serve as reminders for
trained and experienced mechanics. This manual
is not a definitive guide to automotive mechanics
or workshop safety.
Shop equipment, shop environment, and the use
and disposal of solvents, fluids, and chemicals
are subject to government regulations which are
intended to provide a level of safety. It is your
responsibility to know and comply with such
regulations.
PRECAUTIONS AGAINST DAMAGE
1.Always fit covers to protect fenders before
commencing work in engine compartment.
2.Cover seats and carpets, wear clean overalls
and wash hands or wear gloves before working
inside vehicle.
3.Avoid spilling hydraulic fluid or battery acid on
paint work. Wash off with water immediately if
this occurs. Use Polythene sheets to protect
carpets and seats.
4.Always use a recommended Service Tool where
specified.
5.Protect temporarily exposed screw threads by
replacing nuts or fitting plastic caps.SAFETY PRECAUTIONS
1.Whenever possible, use a lift when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
WARNING: Do not use a pit when
removing fuel system components.
2.Never rely on a jack alone to support vehicle.
Use axle stands carefully placed at jacking
points to provide rigid support.
3.Ensure that a suitable form of fire extinguisher is
conveniently located.
4.Check that any lifting equipment used has
adequate capacity and is fully serviceable.
5.Disconnect battery.
WARNING: Do not disconnect any pipes in
air conditioning system, unless trained
and instructed to do so. A refrigerant is
used which can cause blindness if allowed to
contact eyes.
6.Ensure that adequate ventilation is provided
when volatile degreasing agents are being used.
7.Do not apply heat in an attempt to free stiff
fixings; as well as causing damage to protective
coatings, there is a risk of damage to electronic
equipment and brake linings from stray heat.

09LUBRICANTS, FLUIDS AND CAPACITIES
2
INFORMATIONREV: 05/99 Propeller shaft Front
and RearNLGI - 2 Multi-purpose Lithium based GREASE
Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker
Brake and clutch
reservoirsBrake fluids having a minimum boiling point of 260°C (500°F) and complying with
FMVSS 116 DOT4
Engine coolant
(Pre-99MY)Use an ethylene glycol based anti-freeze (containing no methanol) with non-phosphate
corrosion inhibitors suitable for use in aluminium engines to ensure the protection of the
cooling system against frost and corrosion in all seasons. Use one part anti-freeze to
one part water for protection down to -36°C (-33°F).
IMPORTANT: Coolant solution must not fall below proportions one part
anti-freeze to three parts water, i.e. minimum 25% anti-freeze in coolant otherwise
damage to engine is liable to occur. Maximum concentration is 60%.
Engine coolant
(99MY on)Use Texaco XLC long life coolant. Use one part anti-freeze to one part water for
protection down to -36°C (-33°F).
IMPORTANT: Coolant solution must not fall below 50% anti-freeze otherwise
damage to the engine is liable to occur. Maximum concentration is 60%.
Battery lugs, Petroleum jelly.
earthing surfaces
where paint has
been removed.NOTE: Do not use Silicone Grease
Air Conditioning
System Refrigerant Use only refrigerant R134a
Compressor Oil Sanden oil
LUBRICATION PRACTICE
Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.
Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.
WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze, windscreen washer additives, lubricants and various adhesives.

10MAINTENANCE
2
MAINTENANCE BATTERY CONNECTIONS
NOTE: The vehicle may be fitted with an
alarm and immobilisation system using a
battery backed-up alarm sounder.
See
ELECTRICAL, Repair, Battery
Disconnect battery leads, clean and grease with
petroleum jelly, including battery terminals.
CHECK OPERATION OF DOOR SWITCHES
When a Vehicle Immobilisation and Alarm System is
fitted it is important that all door and bonnet switches
operate correctly, otherwise perimeter and interior
protection may not function if a door or the bonnet is
opened.VEHICLE EXTERIOR
CHECK/ADJUST HEADLAMP ALIGNMENT
Check/adjust headlamp alignment.
CHECK ROAD WHEELS AND TYRES
Check road wheels for damage.
Check tyres, including spare, for compliance with
manufacture's specificaton.
Check visually for cuts, lumps, bulges, uneven tread
wear and tread depth.
See INTRODUCTION,
Information, wheels and tyres
Check/adjust tyre pressures.See WHEELS AND
TYRES, Repair, Tyres pressures
INSPECT BRAKE PADS FOR WEAR, CALIPERS
FOR LEAKS AND CONDITION OF DISCS
Check thickness of brake pads, and renew if thickness
is less than 3,00 mm (0.12 in). Check brake pads for
oil contamination and fit a new set, if necessary,
See
BRAKES, Repair, front brake pads
orSee
BRAKES, Repair, rear brake pads
WARNING: When renewing brake pads, it
is essential that only genuine components
with correct grade of lining are used.
Always fit new pads as complete axle sets, NEVER
individually or as a single wheel set. Serious
consequences could result from out of balance
braking due to mixing of linings.
CHECK FRONT WHEEL ALIGNMENT
Use recognised wheel alignment equipment to carry
out this operation.
See STEERING, Adjustment,
front wheel alignment
CHECK OPERATION OF ALL DOORS/TAILGATE,
BONNET AND LOCKS
LUBRICATE ALL DOOR/TAILGATE HINGES, AND
DOOR CHECK/LOCK MECHANISMS

MAINTENANCE
9
MAINTENANCE REV: 05/99 UNDER VEHICLE MAINTENANCE
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
maintenance, or remove and refit procedures are
required, it may be necessary to remove the
undertray and/or integral access panels
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
RENEW ENGINE OIL AND FILTER
1.Ensure vehicle is level.
2.Run engine to warm oil, switch off ignition.
3.Disconnect battery.
4.Place suitable drain tray under sump drain plug.
5.Remove drain plug from sump and allow oil to
drain completely.
6.Fit new sealing washer, replace plug and tighten
to
35 Nm (26 lbf/ft).
7.Place drain tray under oil filter.
8.Unscrew filter anti-clockwise, using a strap
wrench if necessary.
9.Clean mating face of oil filter adaptor.
10.Coat rubber sealing washer of new filter with
clean engine oil.
11.Screw filter on clockwise until sealing washer
touches adaptor mating face, tighten a further
half turn by hand only. DO NOT overtighten.
12.Clean and remove filler cap from rocker cover.
13.Pour in correct quantity and grade of new oil
from a sealed container.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
14.Check that oil level is between upper and lower
marks on dipstick. DO NOT fill above upper
mark.
15.Firmly replace filler cap.
16.Reconnect battery, run engine and check oil filter
for leaks.
17.Stop engine, allow oil to run back into sump for a
few minutes and check oil level again. Top up if
necessary.

10MAINTENANCE
10
MAINTENANCEREV: 05/99 RENEW GEARBOX OIL
1.Ensure vehicle is level.
2.Place suitable tray under gearbox.
3.Disconnect battery.
4.Clean area around filler/level plugs.
5.Remove both plugs and allow oil to drain
completely.
WARNING: When draining gearbox, care
should be taken to ensure that oil is not
hot as personal scalding could result.
6.Refit drain plug and tighten to
30 Nm (22 lbf/ft).
7.Inject new oil into gearbox until it runs out of filler
hole. Allow excess oil to drain and wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
8.Refit filler/level plug and tighten to30 Nm (22
lbf/ft).
9.Reconnect battery.
RENEW TRANSFER GEARBOX OIL
1.Ensure vehicle is level.
2.Disconnect battery.
3.Clean area around filler/level and drain plugs.
WARNING: When draining gearbox care
should be taken to ensure that oil is not
hot as personal scalding could result.
4.Place suitable tray under transfer gearbox.
5.Remove filler/level plug to vent gearbox and
assist draining.
6.Remove drain plug and allow oil to drain.
7.Thoroughly clean drain plug threads and apply
fresh 'Hylomar' sealant.
8.Refit drain plug and tighten to
30 Nm (22lbf/ft).
9.Inject new oil of correct quantity and grade into
gearbox 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
10.Thoroughly clean filler/level plug and apply fresh
'Hylomar' sealant.
11.Refit plug and tighten to
30 Nm (22 lbf/ft).
12.Reconnect battery.
CHECK/TOP UP TRANSFER GEARBOX OIL
1.Ensure vehicle is level.
2.Disconnect battery.
3.Clean area around filler/level plug.
4.Remove plug, check oil level and top up if
necessary with correct grade of oil,
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
until oil runs out from filler/level hole.
Allow excess oil to drain and wipe clean.
5.Thoroughly clean filler/level plug threads and
apply fresh 'Hylomar' sealant.
6.Refit plug and tighten to
30 Nm (22 lbf/ft).
7.Reconnect battery.

ENGINE
1
REPAIR CYLINDER COMPRESSION TEST
Service repair no - 12.25.01
1.Start and run engine to normal operating
temperature.
2.Switch off engine.
3.Disconnect spill return hose and fuel pipe from
No.1 injector.
4.Remove retaining nut, release clamp and
withdraw injector from cylinder head.
See FUEL
SYSTEM, Repair, injectors
5.Disconnect electrical lead from fuel cut-off
solenoid at injection pump to prevent delivery of
fuel to injectors. On vehicles fitted with a digital
diesel shut-off valve (DDS) immobilisation
system, disconnect DDS multi-plug.
6.Ensure injector port is clean, If necessary, crank
the engine a few revolutions to remove any
loose carbon.
7.Fit dummy injector, from diesel compression
tester kitLRT-19-007, into the cylinder head and
clamp securely in position.
8.Connect flexible hose and gauge to dummy
injector as shown above.
9.Crank engine for 10-20 seconds and note
reading on gauge. The gauge will indicate the
compression of the cylinder and maintain the
reading until the pressure release valve on the
gauge is depressed.
Expected readings of a crank test, with vehicle
battery fully charged, compression ratio 19.5:1
should be 24 bar (348 lbf/in
2).10.Repeat test procedure for remaining clinders in
turn.
NOTE: A variation in compression
readings between cylinders is often a
better indication of an engine problem
than the absolute values of compression.
11.If compression is appreciably less than correct
reading, or varies by more than 10%, piston
rings or valves may be worn or damaged.
Low pressures in adjoining cylinders may
indicate a faulty cylinder head gasket.