ventilation LAND ROVER DEFENDER 1996 Workshop Manual

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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
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.

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.

12ENGINE
20
REPAIR OIL FILTER HEAD GASKET
Service repair no - 12.60.03
Remove
1.Clean filter head adaptor.
2.Disconnect oil cooler pipes and plug to prevent
ingress of dirt.
3.Disconnect oil pressure switch lead.
4.Remove 4 bolts and withdraw filter head,
complete with gasket.
5.Clean mating faces of filter head and cylinder
block.
6.Fit head with new gasket.
7.Tighten bolts to
45 Nm (33 lbf/ft).
8.Reconnect oil pressure switch lead.
9.Reconnect oil cooler pipes.CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery
2.Remove bonnet.
3.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
4.Remove air cleaner.See FUEL SYSTEM,
Repair, Air cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove fuel injectors and pipes.
See FUEL
SYSTEM, Repair, Fuel injectors
7.Remove heater plugs.See FUEL SYSTEM,
Repair, Heater plugs
8.Disconnect radiator top hose from thermostat.
9.Disconnect bleed hose at thermostat.
10.Disconnect water pump hose at thermostat.
11.Disconnect water temperature sensor lead.

ENGINE
23
REPAIR
43.Check and adjust valve clearances.
See Adjustment, Valve clearances - check
and adjust
44.Fit rocker cover, ensuring oil seal is satisfactory
for continued use, and renew if necessary.
45.Secure rocker cover with special seal washers
and nuts. Tighten to
10 Nm (7 lbf/ft).
46.Fit rear engine lifting bracket, securing breather
pipe and multi-plug retaining clips. Tighten fixing
bolts to
25 Nm (18 lbf/ft).
47.Fit engine harness bracket to cylinder head.
48.Secure air cleaner mounting bracket to support
strut.
49.Connect heater hose to rear of cylinder head.
50.Position heater rail and connect hose from water
pump.
51.Fit exhaust manifold and turbocharger assembly.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust manifold
52.Fit induction manifold.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Induction
manifold
53.Connect water temperature sensor lead.
54.Connect water pump hose at thermostat.
55.Fit bleed hose at thermostat.
56.Connect radiator top hose at thermostat.
57.Fit heater plugs.
See FUEL SYSTEM, Repair,
Heater plugs
58.Fit fuel injectors.See FUEL SYSTEM, Repair,
Fuel injectors
59.Fit crankcase ventilation valve and side breather
hose.
60.Fit air cleaner.
See FUEL SYSTEM, Repair,
Air cleaner
61.Refill cooling system.See COOLING SYSTEM,
Repair, Drain and refill cooling system
62.Fit bonnet.
63.Reconnect battery.OIL PUMP
Service repair no - 12.60.26
Remove
1.Remove engine front cover.
See Front cover
gasket
2.Remove 7 screws and release oil pump retaining
plate from engine front cover.
3.Mark oil pump inner gear rotor, outer gear rotor
and front cover housing for reassembly.
4.Check for rotor clearances:
Outer rotor to housing, 0,025 - 0,075 mm (0.010
- 0.030 in).
Inner rotor to outer rotor, 0,025 - 0,075 mm
(0.010 - 0.030 in).
Rotor end float, 0,026 - 0,135 mm (0.010 - 0.054
in).
5.Remove inner and outer rotors.
6.Check condition of oil pump components.
NOTE: If the oil pump seating in the front
cover or retaining plate is badly worn,
pitted or scored, a new front cover must
be fitted.
See Front cover gasket
Always renew oil pump rotors as a pair.
7.Clean sealant from pump retaining plate and
front cover.

MANUAL GEARBOX
1
DESCRIPTION AND OPERATION R380 GEARBOX
Description
The all synchromesh five speed manual gearbox unit,
is married to a two speed transfer gearbox.
All the gears, including reverse, run on needle roller
bearings and the main, layshaft and primary shafts
are supported by tapered roller bearings.The whole of the geartrain is lubricated through
drillings in the shafts, supplied by a low pressure
pump driven from the rear of the layshaft. The gear
change has a single rail selector and spool type
interlock. The main and transfer gearboxes ventilate
through nylon pipes, which terminate high up in the
engine compartment to prevent water entry when the
vehicle is operating in adverse conditions.
R380 Gearbox Components
1.Mainshaft 1st gear
2.Mainshaft 2nd gear
3.Mainshaft 3rd gear
4.Primary input shaft/4th gear
5.Mainshaft 5th gear
6.Layshaft
7.Mainshaft
8.Lubrication pump
9.Oil filter10.Ventilation pipe
11.Single rail gear shift
12.1st/2nd synchromesh
13.Oil seals
14.3rd/4th synchromesh
15.5th/reverse gear synchromesh
16.Selective spacers (mainshaft/layshaft end float)
17.Selective spacer (5th gear/reverse hub)

REAR AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel rear axle casing houses a separate
spiral bevel type differential unit, which is off set to the
right of the vehicle centre line. The differential unit
drives the rear wheels via the axle shafts and fully
floating hubs which are mounted on tapered roller
bearings.
Lubrication
The differential is lubricated with oil and the hub
bearings with grease.The hub bearings are fitted with inner and outer seals.
The outer seals prevent the differential oil mixing with
the hub grease and the inner seals prevent dirt
ingress into the hub.
Ventilation
Ventilation of the hub bearings is through the outer oil
seals and the differential ventilation pipe, which
terminates at a high level.
Rear axle hub - 90
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Wheel bearing stub axle6.Wheel bearings
7.Inner hub seal
8.Outer hub/axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc

51REAR AXLE AND FINAL DRIVE
2
DESCRIPTION AND OPERATION
Rear axle hub - 110/130
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Wheel bearing stub axle
6.Wheel bearings
7.Inner hub seal8.Outer hub/axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc
11.Drive flange
12.Drive shaft circlip
13.Dust cap

REAR AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication from the hub seals can
be caused by a faulty internal seal. For example, if the
seals which separate the differential from the hubs are
faulty and the vehicle is operating or parked on an
embankment, oil from the differential may flood one
hub resulting in a lack of lubrication in the differential.
When a seal is found to be leaking check the axle
ventilation system, as a blockage can cause internal
pressure to force oil past the seals.
See 'Description and Operation' for illustrations of oil
seal locations.
When investigating hub seal leaks check the grease
for dilution with oil. Also check the differential oil level,
for signs of metal particles in the oil and the condition
of internal seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and raise
the differential oil level, giving a false impression that
the housing has been overfilled.
Do not assume that a high oil level in the
differential is due to over filling or, that a low level
is because of an external leak.

FRONT AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel front axle casing houses a separate
spiral bevel type differential unit, which is off-set to the
right of the vehicle centre line. The differential unit
drives the front wheels via the axle shafts and
constant velocity joints which are totally enclosed in
the spherical and swivel housings.The front wheels are pivoted on tape roller bearings at
the top and bottom of the swivel housing. The wheel
hubs on all axles are supported by two taper bearings
and driven by drive flanges which are splined to the
one piece, stub shaft/constant velocity joint.
Front axle hub and swivel housing
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Stub axle
6.Wheel bearings
7.Inner and outer hub seals
8.Axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc
11.Drive flange
12.Shim washer and circlip13.Dust cap
14.Constant velocity joint/shaft
15.Thrust collar for CV joint
16.Roller bearing
17.Spacer
18.Circlip
19.Top and bottom swivel taper bearing
20.Top and bottom swivel pins
21.Spherical housing, seal and retainer
22.Swivel housing
23.Constant velocity shaft seal