warning LAND ROVER DEFENDER 1996 Workshop Manual

AMENDMENT INSTRUCTION SHEET
DEFENDER WORKSHOP MANUAL
Publication Number LRL 0097 ENG (2nd Edition)
Amendment Number:LD002.99Date:05/99
To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an
Amendment Instruction Sheet will be issued with each set of revised pages.
·The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the
Contents pages, all revised and new pages have the issue date at the foot of each page, together with an
indication of whether the pages are revised or new.
·This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment
has been incorporated. Do not discard previous Amendment Instruction sheets.
·Your manual is only complete to this issue providing all prior Amendments are included.
·The filing instructions give section and page numbers affected. Additional pages or complete new sections may
be issued, insert the pages as instructed.
FILING INSTRUCTIONS
Section Discard Existing
PagesInsert New Pages Reason for Amendment
Title Page Title Page Title Page Part number raised to 3rd edition.
01 - Introduction Contents page Contents page Page numbers amended.
01 - Introduction -
InformationPages 1 and 4 Pages 1 and 4 Special service tools section amended.
04 - General
Specification DataPages 1, 4 and 11 Pages 1, 4, and 11 Correction of typographical errors.
09 - Lubricants, Fluids
and CapacitiesPages 1 to 3 Pages 1 to 3 New anti-freeze introduced.
10 - Maintenance Page 5, and pages
9to15Page 5, and pages
9to14Anti-freeze information updated, page layout
amended.
12 - Engine -
AdjustmentPage 1 Page 1 Warning amended to Caution.
12 - Engine -
Specifications, TorquePages 1 and 2 Pages 1 and 2 Page layout and torque figures amended.
19 - Fuel System -
RepairPages 7 and 9 Pages 7 and 9 Cross references amended.
26 - Cooling System -
RepairPage 4 Page 4 Cross reference amended.
37 - Manual Gearbox -
RepairPages 1 and 6 Pages 1 and 6 Cross references amended.
37 - Manual Gearbox -
Specifications, TorquePage 1 Page 1 Page layout amended.
41 - Transfer Gearbox -
RepairPage 5 Page 5 Correction of typographical error.

INTRODUCTION
1
INFORMATION REV: 05/99 INTRODUCTION
This workshop manual covers vehicles from 1996
model year onwards. Amendments and additional
pages will be issued to ensure that the manual covers
latest models. Amendments and additions will be
identified by the addition of a dated footer at the
bottom of the page.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover Defender 300Tdi, Td5, and V8i vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system should
be carried out by a Land Rover Dealer. Repairs to
such items should NEVER be attempted by untrained
individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft end of the engine is referred to as the front.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out, particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer's specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.

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.

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
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.

01INTRODUCTION
6
INFORMATION 3.Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1.Position cup of hydraulic arm under differential
casing.
2.Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3.Lower jack until axle sits securely on axle
stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a 'drive on' type ramp which supports vehicle
on its road wheels. If a 'wheel-free' condition is
required, use a 'drive on' ramp incorporating a
'wheel-free' system providing support beneath axle
casings. Alternatively, place vehicle on a firm, flat floor
and support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using 'Two Post' ramps
that employ four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.DYNAMOMETER TESTING
The front and rear axles cannot be driven
independently.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal workshop
safety standards are applied, there is no speed
restriction during testing except any that may apply to
the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.

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.

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.

GENERAL SPECIFICATION DATA
11
INFORMATION REV: 05/99 TYRE SIZE AND PRESSURES
90 models Front Rear
Normal - all load conditions
205 R16 radial
& 265/75 R16 (multi-terrain)1,9 bar .................................. 2,4 bar
28 Ibf/in
235 Ibf/in2
2,0 kgf/cm22,5 kgf/cm2
750 R16 radial1,9 bar ........................................................ 2,75 bar
28 Ibf/in240 Ibf/in2
2,0 kgf/cm22,8 kgf/cm2
110 models
Normal - all load conditions
750 R16 Radial1,9 bar ....................................................... 3,3 bar
28 Ibf/in
248 Ibf/in2
2,0 kgf/cm23,4 kgf/cm2
130 models
Normal - all load conditions
750 R16 Radial3,0 bar ....................................................... 4,5 bar
44 Ibf/in
265 Ibf/in2
3,1 kgf/cm24,6 kgf/cm2
WARNING: Tyre pressures must be
checked with the tyres cold, as the
pressure is about 0,21 bar (3 Ibf/in
2, 0,2
kgf/cm2) higher at running temperature. If the
vehicle has been parked in the sun or high
ambient temperatures, DO NOT reduce the tyre
pressures, move the vehicle into the shade and
wait for the tyres to cool before checking the
pressures.
WHEELS
90 models
Steel wheel size:
Heavy duty - UK and Western Europe 6.5F X 16.............................
Other markets 5.5F X 16..................................................................
Alloy wheel size 7J X 16................................................................
110 models
Steel wheel size:
Heavy duty - UK and Western Europe 6.5F X 16.............................
Other markets 5.5F X 16..................................................................
130 models
Steel wheel size:
Heavy duty - UK and Western Europe 6.5F X 16.............................
Other markets 5.5F X 16..................................................................
WARNING: Always use the same make and
type of radial-ply tyres, front and rear. DO
NOT use cross-ply tyres, or interchange
tyres from front to rear.
·If the the wheel is marked 'TUBED', an inner
tube MUST be fitted, even with a tubeless tyre.
·If the wheel is marked 'TUBELESS', an inner
tube must NOT be fitted.

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.