motor LAND ROVER DEFENDER 1996 Workshop Manual

INTRODUCTION
3
INFORMATION SYNTHETIC RUBBER
Many 'O' ring seals, flexible pipes and other similar
items which appear to be natural rubber are made of
synthetic materials called Fluoroelastomers. Under
normal operating conditions this material is safe, and
does not present a health hazard. However, if the
material is damaged by fire or excessive heat, it can
break down and produce highly corrosive Hydrofluoric
acid which can cause serious burns on contact with
skin. Should the material be in a burnt or overheated
condition handle only with seamless industrial gloves.
Decontaminate and dispose of the gloves immediately
after use.
If skin contact does occur, remove any contaminated
clothing immediately and obtain medical assistance
without delay. In the meantime, wash the affected
area with copious amounts of cold water or limewater
for fifteen to sixty minutes.
RECOMMENDED SEALANTS
A number of branded products are recommended in
this manual for use during maintenance and repair
work.
These items include:
HYLOMAR GASKET AND JOINTING COMPOUND
and
HYLOSIL RTV SILICONE COMPOUND.
They should be available locally from garage
equipment suppliers. If there is any problem obtaining
supplies, contact the following company for advice
and the address of the nearest supplier.
MARSTON LUBRICANTS LTD.
Hylo House,
Cale Lane,
New Springs,
Wigan WN2 1JR
Tel 01942 824242USED ENGINE OIL
WARNING: Prolonged and repeated
contact with engine or motor oil will result
in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
Used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities should be provided.
Handling precautions
1.Avoid prolonged and repeated contact with oils,
particularly used engine oils.
2.Wear protective clothing, including impervious
gloves where applicable.
3.Do not put oily rags in pockets.
4.Avoid contaminating clothes, particularly
underwear, with oil.
5.Overalls must be cleaned regularly. Discard
unwashable clothing and oil impregnated
footwear.
6.First aid treatment must be obtained immediately
for open cuts and wounds.
7.Use barrier creams, before each work period, to
help the removal of oil from the skin.
8.Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.
9.Do not use gasoline, kerosene, diesel fuel,
petrol, thinners or solvents for washing the skin.
10.If skin disorders develop, obtain medical advice.
11.Where practicable, degrease components prior
to handling.
12.Where there is a risk of eye contact, eye
protection should be worn, for example, goggles
or face shields; in addition an eye wash facility
should be provided.
Disposing of used oils
Environmental protection precaution
It is illegal to pour used oil onto the ground, down
sewers or drains, or into waterways.
Dispose of used oil through authorised waste disposal
contractors. If in doubt contact your Local Authority for
advice on disposal facilities.

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.........................................................................

04GENERAL SPECIFICATION DATA
8
INFORMATION Fuses
Type Autofuse (blade type) blow ratings to suit individual.................................................................................
circuits
Horns
Make/type Mixo TR99........................................................................
Starter motor
Make and type Bosch 12v.................................................................
BULBS
REPLACEMENT BULBS TYPE
Headlamps 12V 60/55W Halogen
Front side lamps 12V 5W bayonet
Side repeater lamps 12V 5W capless
Tail lamps 12V 5/21W bayonet
Direction indicator lamps 12V 21W bayonet
Number plate lamp 12V 5W capless
Reverse lamp 12V 21W bayonet
Rear fog guard lamp 12V 21W bayonet
Interior roof lamps 12V 10W festoon
Instrument illumination 12V 1.2W capless
Warning light panel 12V 1.2W bulb/holder unit
Hazard warning switch 12V 1.2W capless
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.

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.

12ENGINE
4
REPAIR
14.Disconnect engine harness multi-plug.
15.Remove single bolt securing transmission
breather pipe clip to cylinder head and move
breather pipes aside.
16.Disconnect multi-plug and vacuum pipe from
EGR valve, if fitted.
17.Remove starter motor cover and disconnect
battery and fuse box leads.
18.Remove 3 retaining nuts and disconnect exhaust
down pipe.
19.Disconnect inlet and outlet hoses from power
steering pump.
20.Disconnect bleed hose from thermostat housing.
21.Release bleed hose from retaining clips on front
timing cover plate.
22.Remove split pin securing inner throttle cable to
injector pump lever.
23.Depress tags on outer cable adjusting nut,
remove cable from mounting bracket and move
aside.
24.If fitted, release hand throttle cable from
mounting bracket and injector pump lever and
move aside.
25.Disconnect feed pipe and spill return pipe from
injector pump.

ENGINE
5
REPAIR
26.Disconnect both pipes from fuel lift pump.
27.Release fuel feed pipe from retaining clip on air
cleaner bracket.
28.Disconnect vacuum hose from brake servo.
29.Remove oil pipes from oil filter adaptor.30.Using suitable hoist, fit chains to lifting brackets
and support engine.
31.Remove nuts and plain washers securing front
engine mountings to chassis.
32.Support gearbox.
33.Remove engine to bell housing fixings, leaving
starter motor attached to engine.
34.Carefully raise engine to release from gearbox.
35.Ensure all relevant connections to engine have
been removed.
36.Remove engine.
Refit
37.Clean bell housing.
38.Apply Hylomar sealant to mating faces of bell
housing and flywheel housing.
39.Lubricate splines of gearbox primary pinion with
Rocol MV 3.
40.Carefully lower engine into position and locate
primary pinion into clutch and engage bell
housing dowels.
41.Fit engine to bell housing fixings. Tighten to
40
Nm (30 lbf/ft).

12ENGINE
6
REPAIR 42.Raise engine, and locate front engine mountings
to chassis.
43.Remove gearbox support and lower engine.
44.Tighten front engine mounting to chassis fixings
to
45 Nm (33 lbf/ft).
45.Release chains from engine lifting brackets and
remove hoist.
46.Connect oil cooler pipes to oil filter adaptor.
47.Fit vacuum hose to brake servo adaptor.
48.Secure fuel feed pipe in retaining clip on air
cleaner bracket.
49.Fit fuel lift pump pipes.
50.Connect feed and spill return pipes to injector
pump.
51.If fitted, reconnect hand throttle cable to
mounting bracket and injector pump.
52.Fit outer cable adjusting nut into injector pump
mounting bracket.
53.Fit inner throttle cable to injector pump and
secure with clevis and split pin.
54.Secure bleed hose in retaining clips on front
timing cover.
55.Fit bleed hose to thermostat housing.
56.Connect inlet and outlet hoses to power steering
pump.
57.Fit down pipe to exhaust manifold and secure
with 3 nuts.
58.Connect starter motor battery and fuse box
leads.
59.If fitted, connect EGR valve multi-plug and
vacuum pipe.
60.Secure breather pipe clip to cylinder head.
61.Connect engine harness multi-plug.
62.Fit heater plug feed wire.
63.Connect electrical feed plug at rear of cylinder
head.
64.Fit heater hoses to cylinder head and heater
rails.
65.Fit feed pipe/hose to turbo-charger and
intercooler.
66.Fit rocker cover insulation.
67.Fit radiator assembly.
See COOLING SYSTEM,
Repair, Radiator
If applicable, fit air
conditioning condenser, compressor pipes and
heater matrix hoses.
See AIR CONDITIONING,
Repair, Condenser
68.Fit bonnet.
69.Reconnect battery.CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1.Disconnect battery.
2.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
coupling and fan
6.Remove fan cowl.See COOLING SYSTEM,
Repair, Fan cowl
7.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
8.Fit crankshaft pulley retainerLRT-12-080and
secure with 4 bolts.
9.Remove crankshaft pulley retaining bolt
anti-clockwise using socket and suitable long
bar.
10.Remove pulley retainer.
11.Remove pulley, if necessary using extractor
LRT-12-049with thrust pad fromLRT-12-031.

12ENGINE
18
REPAIR FLYWHEEL HOUSING
Service repair no - 12.53.01
Remove
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Remove flywheel.See Flywheel
5.Remove 3 fixings and withdraw starter motor.
6.Remove 2 bolts from top of flywheel housing.
7.Remove 4 bolts securing bottom of flywheel
housing to engine mounting brackets.
8.Remove inner bolts and lift off flywheel housing.Refit
9.Clean rear face of housing and mating face on
block, ensuring all old sealant is removed.
10.Apply sealant to flywheel housing mating face on
cylinder block.
11.Fit housing to cylinder block. Tighten retaining
bolts to
45 Nm (33 lbf/ft).
12.Remove surplus sealant from block.
13.Fit starter motor.
14.Fit flywheel.
See Flywheel
15.Fit clutch.See CLUTCH, Repair, Clutch
assembly
16.Fit gearbox.See MANUAL GEARBOX, Repair,
R380 gearbox
17.Reconnect battery.

ENGINE
3
SPECIFICATIONS, TORQUENm
Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Starter motor (bolt and nut) 45........................................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................
Generator to auxiliaries mounting bracket 25.................................................
Tachometer electrical connection 4...............................................................