coolant level LAND ROVER DEFENDER 1996 Workshop Manual

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).........................

LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION REV: 05/99 CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Pints
Engine sump oil 5,8................................................................ 10.20
Extra when refilling after fitting new filter 0,85.......................... 1.50
Manual gearbox 2,67............................................................... 4.70
Transfer gearbox oil 2,30......................................................... 4.00
Front differential 1,70............................................................... 3.00
Rear differential 1,70................................................................ 3.00
Power steering box and reservoir LHD 2,90............................ 5.00
Power steering box and reservoir RHD 3,40............................ 6.00
Swivel pin housing oil/grease (each) 0,35................................ 0.60
Fuel tank usable fuel 79,5........................................................ 17.5 gall
Cooling system 11,50................................................................ 20.20
Washer bottle 3,0................................................................... 5.28
NOTE: * All levels must be checked by dipstick or level plugs as applicable.
ANTI-FREEZE
PERCENTAGE CONCENTRATION - 50%
PROTECTION - LOWER TEMPERATURE LIMIT
Complete protection
Vehicle may be driven away immediately from cold,
-33°C (-36°F).
Safe limit protection
Coolant in semi-frozen state. Engine may be started
and driven away after warm-up period, -41°C (-42°
F).Lower protection
Prevents frost damage to cylinder head, block and
radiator. Thaw out before starting engine, -47°C (-53°
F).
CAUTION: Anti-freeze content must never
be allowed to fall below 25% (pre 99MY) or
50% (99MY on) otherwise damage to the
engine is liable to occur. Anti-freeze content
should not exceed 60% (all models) as this will
greatly reduce cooling efficiency.

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.

COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL COOLING SYSTEM
Service repair no - 26.10.01
Draining
WARNING: DO NOT remove caps or plugs
when the engine is hot. The cooling
system is pressurised and personal
scalding could result.
1.Remove expansion tank filler cap.
2.Position a clean container under radiator if
coolant is to be reused.
3.Disconnect radiator bottom hose and allow
coolant to drain.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
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
orSee CHASSIS AND
BODY, Repair, Rear undertray
4.When expansion tank has emptied remove
thermostat housing plug to assist drainage.
5.Similarly when coolant is below top of radiator,
remove radiator plug.
6.Fit radiator bottom hose and fully tighten hose
clip.Refill
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.
7.Fill cooling system with 50% - 50% of
water/anti-freeze mixture
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
8.Fill through expansion tank until radiator is full,
with level in expansion tank the same as
radiator.
NOTE: Care should be taken to avoid
excess coolant spillage.
9.Fit plastic plug in radiator.
10.Add a further 1 litre (1.76 pints) of coolant into
expansion tank and allow to settle.
11.Refit expansion tank cap and thermostat
housing plug.
12.Run engine at idle speed for 5 minutes.
13.Switch off engine and allow to cool.
14.Check that coolant in expansion tank is level
with top of indicator post. Top up if necessary.

COOLING SYSTEM
5
REPAIR 28.Secure steering pump and bracket to auxiliary
mounting bracket.
29.Fit steering pump pulley.
30.Fit drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
31.Fit fan cowl
See Fan cowl.
32.Fit viscous fan unit
See Viscous coupling and
fan
.
33.Fit intercooler top hose.
34.Fit radiator top hose.
35.Refill cooling system.
See Adjustment, Drain
and refill cooling system
36.Reconnect battery.THERMOSTAT
Service repair no - 26.45.01
Remove
1.Partially drain cooling system, until coolant level
is below thermostat housing.
2.Disconnect top hose from outlet elbow.
3.Disconnect electrical connections to water
temperature switch.
4.Unscrew 2 bolts and remove outlet elbow.
5.Withdraw thermostat. Note 88°C rating of
thermostat.
6.Place thermostat in a container half full of water.
Heat water and observe temperature at which
thermostat begins to open. Thermostat is
satisfactory if it opens between 85°-89°C.
Refit
7.Fit thermostat with jiggle pin/vent hole upwards.
8.Secure outlet elbow to thermostat housing.
Tighten bolts to
25 Nm (18 lbf/ft).
9.Fit water temperature switch connections.
10.Fit top hose to outlet elbow.
11.Refill cooling system.
See Adjustment, Drain
and refill cooling system