steering wheel 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
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05
07
09
10
12
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19
26
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41
47
51
54
57
60
64
74
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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

01INTRODUCTION
4
INFORMATIONREV: 05/99 ACCESSORIES AND CONVERSIONS
DO NOT FITunapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitting of non-approved conversions
to the vehicle.
WHEELS AND TYRES
WARNING: DO NOT replace the road
wheels with any type other than genuine
Land Rover wheels which are designed for
multi-purpose on and off road use and have very
important relationships with the proper operation
of the suspension system and vehicle handling.
Replacement tyres must be of the make and sizes
recommended for the vehicle, and all tyres must
be the same make, ply rating and tread pattern.
STEAM CLEANING
To prevent consequential rusting, any steam cleaning
within the engine bayMUSTbe followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine coolant pipes and hose clips.
SPECIFICATION
The specification details and instructions set out in
this Manual apply only to a range of vehicles and not
to any one. For the specification of a particular vehicle
purchasers should consult their Dealer.
The Manufacturer reserves the right to vary
specifications with or without notice, and at such times
and in such manner as it thinks fit. Major as well as
minor changes may be involved in accordance with
the Manufacturer's policy of constant product
improvement.
Whilst every effort is made to ensure the accuracy of
the particulars contained in this Manual, neither the
Manufacturer or Dealer, by whom this Manual is
supplied, shall in any circumstances be held liable for
any inaccuracy or the consequences thereof.SPECIAL SERVICE TOOLS
The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified,only these tools should be used
to avoid the possibility of personal injury or
damage to the components.Also, the amount of
time which they save can be considerable.
Special tools bulletins will be issued periodically giving
details of new tools as they are introduced.
All orders and enquiries from the United Kingdom
should be sent direct to Cartool (UK) Ltd. Overseas
orders should be placed with the local Cartool
distributor, where one exists. Countries where there is
no distributor may order direct from:
Cartool (UK) Ltd.
Unit 3,
Sterling Business Park,
Brackmills,
Northampton,
England, NN4 7EX.
The tools recommended in this Workshop Manual are
listed in an illustrated catalogue, obtainable from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle,
Merseyside, L70 1JL
COPYRIGHT
Ó1999 Rover Group Limited
All rights reserved. No part of this publication may be
produced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, recording or other
means without prior written permission of Rover
Group.

INTRODUCTION
5
INFORMATION JACKING
The following instructions must be carried out before
raising the vehicle off the ground.
1.Use a solid level ground surface.
2.Apply parking brake.
3.Select 1st gear in main gearbox.
4.Select Low range in transfer gearbox.
CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be
adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS.
Body structure
Bumpers
Fuel lines
Brake lines
Front radius arms
Panhard rod
Steering linkage
Rear Trailing links
Fuel tank
Engine sump
Gearbox bell housing
Jack or support vehicle by axles only.
Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOTuse the jack for any other purpose. Refer to
Owner's Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used, see J6083.
CAUTION: Do not commence work on the
underside of the vehicle until suitable axle
stands have been positioned under the
axle, see J6084.
Raise the front of the vehicle
1.Position cup of hydraulic arm under differential
casing.
NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the
ground as the rear axle has less sway stiffness.
2.Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.

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
11
INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number and the
recommended maximum vehicle weights are stamped
on a plate riveted to the brake pedal box in the engine
compartment. The VIN is also stamped on a plate
visible through the LH side of the windscreen, see
J6088.
A.Type approval
B.Identification
C.Maximum permitted laden weight for vehicle
D.Maximum vehicle and trailer weight
E.Maximum road weight-front axle
F.Maximum road weight-rear axle
The number is also stamped on the RH side of the
chassis to the rear of the front lashing eye, see J6089.
The Vehicle Identification Number identifies the
manufacturer, model range, wheel base, body type,
engine, steering, transmission, model year and place
of manufacture. The following example shows the
coding process.
SALLDHMF7TA
SAL= World manufacturer identifier
LD= Land Rover Defender
H= 110 inch,V= 90inch,K= 130 inch
M= 4 door Station Wagon,A= 90 Soft Top, Hard Top,
Pick-up,B= 2 door Station Wagon,E= 2 door 130
Crew cab,F= 4 door 130 Crew cab,H= 130 High
Capacity Pick-up
F= 2.5L (300Tdi)
7= RH drive, 5 speed manaul,8= LH drive, 5 speed
manual
T= 1996 MY, volume build,N= 1996 MY, non-volume
build
A= Solihull build,F= CKD, assembled locally from kit

04GENERAL SPECIFICATION DATA
4
INFORMATIONREV: 05/99 Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts, 32°angularity of universal joint on full
lock
Ratio 3.54:1.................................................................................
Propeller shafts
Type, front and rear Tubular 51 mm dia...........................................................
Universal joints Open type Hookes O3EHD.................................................................
STEERING
Power steering box
Make/type Adwest Varamatic - worm and roller box........................................................................
Ratio Variable: straight ahead 19.3:1 on lock 14.3:1.................................................................................
Steering wheel turns, lock-to-lock 3.375....................................
Steering pump
Make/type Hobourn-Eaton series 500........................................................................
Steering geometry
Steering wheel diameter 412 mm (16.22 in)..................................................
Toe-out measurement 0 to 2 mm toe out......................................................
Toe-out included angle 0°to 0°20' .....................................................
Camber angle 0°* ..................................................................
Castor angle 3°* .....................................................................
Swivel pin inclination static 7°* ...............................................
* Check with vehicle on level ground, in unladen
condition and five gallons of fuel. Rock the front of the
vehicle up and down to allow it to take up a normal
static position.
Turning circle between kerbs
90 models:
265/75 x 16 tyres 12,65 m (41.5 ft)..............................................................
All other tyres 11,70 m (38.4 ft)...................................................................
110 models:
750 x 16 tyres 13,41 m (44 ft)..................................................................
130 models:
750 x 16 tyres 15,24 m (50 ft)..................................................................

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
7
MAINTENANCE RENEW AUXILIARY DRIVE BELT
Renew drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
RENEW COMPRESSOR DRIVE BELT
Renew compressor drive belt.
See AIR
CONDITIONING, Repair, Compressor drive belt
CHECK/TOP UP POWER STEERING RESERVOIR
WARNING: DO NOT start engine if fluid
level in reservoir has dropped below
dipstick - severe damage to the power
steering system could result.
NOTE: Check fluid level with engine
switched off and system cold. Ensure that
steering wheel is not turned after stopping
engine.
1.Clean and remove reservoir cap.
2.Wipe distick clean and fully refit cap.
3.Remove cap and check fluid level. Ensure fluid
level is between UPPER mark and end of
dipstick.
4.Top up, if necessary, with recommended fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
DO NOT fill above
UPPER mark on dipstick.CHECK/TOP UP CLUTCH FLUID RESERVOIR
WARNING: Clutch fluid will damage
painted surfaces; clean up any spillage
immediately and rinse with plenty of water.
If clutch fluid should come into contact with the
skin or eyes, rinse immediately with plenty of
water.
1.Clean and remove reservoir cap.
2.Check fluid level and top up if necessary,
maintaining the level approximately 10 mm (0.39
in) below top of reservoir, using recommended
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids

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.