Land Rover Defender Workshop Rover Manual

							AMENDMENTINSTRUCTION SHEET
DEFENDER WORKSHOP MANUAL
Publication NumberLRL0097ENG
Amendment Number:LD003.97 Date:09/97
To ensure thatthismanual iskept uptodate andthatarecord ofamendments tothis manual isavailable, an
Amendment InstructionSheetwillbeissued witheach setofrevised pages.
TheTitle page ofthe Manual isre-issued, andthePart No.has been raised tothe next edition. Exceptforthe
Contents pages,allrevised andnew pages havetheissue dateatthe foot ofeach page, together withan
indication ofwhether thepages arerevised ornew.
This Amendment InstructionSheetmustbeinserted atthe front ofthe manual toindicate thattheamendment
has been incorporated. Donot discard previous Amendment Instructionsheets.
Yourmanual isonly complete tothis issue providing allprior Amendments areincluded.
The filing instructions givesection andpage numbers affected.Additional pagesorcomplete newsections may
be issued, insertthepages asinstructed.
FILING INSTRUCTIONS
Section DiscardExisting
Pages Insert
NewPages ReasonforAmendment
51 -Rear Axleand
Final Drive -Repairs Pages
1to 5 Pages1to 5 Clarification ofwheel nuttorque figures.
54 -Front Axleand
Final Drive -Repairs Pages
1,and 3 Pages1,and 3 Clarification ofwheel nuttorque figures.
57 -Steering -Repairs Page5 Page5 Clarificationofwheel nuttorque figures.
60 -Front Suspension -
Repairs Pages
1,and 3 Pages1,and 3 Clarification ofwheel nuttorque figures.
64 -Rear Suspension -
Repairs Page
1 Page1 Clarificationofwheel nuttorque figures.
70 -Brakes -Repairs Pages7,11, and
13 Pages
7,11, and
13 Clarification
ofwheel nuttorque figures.
74 -Wheels andTyres
- Repairs Page
5 Pages5,and 7 Clarification ofwheel nuttorque figures.  
						

							01 04050709 10 12 17 19 26 3033 37 41 47 5154 5760 6474 70 75 76 80 82 84 8688
Workshop
manual
DEFENDER 300Tdi
This manual coversvehicles from
1996 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNINGDATA
07 GENERAL FITTINGREMINDERS
09 LUBRICANTS, FLUIDSANDCAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
19 FUEL SYSTEM Tdi
26 COOLING SYSTEMTdi
30 MANIFOLD ANDEXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLEANDFINAL DRIVE
54 FRONT AXLEANDFINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS ANDTYRES
76 CHASSIS ANDBODY
80 HEATING ANDVENTILATION
82 AIRCONDITIONING
84 WIPERS ANDWASHERS
86 ELECTRICAL
88 INSTRUMENTS
Publication PartNo.LRL 0097 ENG
Published byRover Technical Communication
Ó 1996 Rover Group Limited                 
						

							INTRODUCTION1
INFORMATION
INTRODUCTION This
workshop manualcoversvehicles from1996
model yearonwards. Amendments andadditional
pages willbeissued toensure thatthemanual covers
latest models. Amendments andadditions willbe
identified bythe addition ofadated footer atthe
bottom ofthe page.
This Workshop Manualisdesigned toassist skilled
technicians inthe efficient repairandmaintenance of
Land Rover Defender 300Tdivehicles.
Individuals whoundertake theirownrepairs should
have some skilland training, andlimit repairs to
components whichcouldnotaffect thesafety ofthe
vehicle orits passengers. Anyrepairs required to
safety critical itemssuchassteering, brakes,
suspension orsupplementary restraintsystemshould
be carried outbyaLand Rover Dealer. Repairs to
such items should NEVER beattempted byuntrained
individuals.WARNINGS, CAUTIONSandNOTES aregiven
throughout thisManual inthe following form:
WARNING: Procedures whichmustbe
followed precisely toavoid thepossibility
of personal injury.
CAUTION: Thiscalls attention to
procedures whichmustbefollowed to
avoid damage tocomponents.
NOTE: Thiscalls attention tomethods
which makeajob easier orgives helpful
information.
DIMENSIONS The dimensions quotedaretodesign engineering
specification. Alternativeunitequivalents, shownin
brackets following thedimensions, havebeen
converted fromtheoriginal specification. REFERENCESReferences
tothe leftorright hand sideinthe manual
are made whenviewing thevehicle fromtherear.
With theengine andgearbox assembly removed,the
crankshaft endofthe engine isreferred toas the front.
To reduce repetition, someoperations coveredinthis
Manual donot include reference totesting thevehicle
after repair.
It is essential thatwork isinspected andtested after
completion andifnecessary aroad testofthe vehicle
is carried out,particularly wheresafetyrelated items
are concerned.
REPAIRS ANDREPLACEMENTS
When replacement partsarerequired itis essential
that Land Rover partsareused.
Attention isparticularly drawntothe following points
concerning repairsandthefitting ofreplacement parts
and accessories: Safetyfeatures embodied inthe
vehicle maybeimpaired ifother thanLand Rover
parts arefitted. Incertain territories, legislation
prohibits thefitting ofparts nottothe vehicle
manufacturers specification.Torquespanner values
given inthe Workshop Manualmustbestrictly
adhered to.Locking devices, wherespecified, mustbe
fitted. Ifthe efficiency ofalocking deviceisimpaired
during removal itmust bereplaced withanew one.
Certain fasteners mustnotbere-used. These
fasteners arespecified inthe Workshop Manual.
POISONOUS SUBSTANCES
Many liquids andother substances usedare
poisonous andtherefore mustnotbeconsumed. Itis
also advisable tokeep allsubstances awayfromopen
wounds. Thesesubstances amongothersinclude
anti-freeze, brakefluid,fuel,windscreen washer
additives, airconditioning refrigerant,lubricantsand
various adhesives.  
						

							01INTRODUCTION
2 INFORMATION
FUEL
HANDLING PRECAUTIONS
The following information providesbasicprecautions
which mustbeobserved iffuel isto be handled safely.
It also outlines theother areas ofrisk which mustnot
be ignored.
This information isissued forbasic guidance only,and
in any case ofdoubt, appropriate enquiriesshouldbe
made ofyour local FireOfficer orFire Department.
Fuel vapour ishighly flammable andinconfined
spaces isalso very explosive andtoxic andwhen
diluted withairbecomes areadily ignitable mixture.
The vapour isheavier thanairand willalways fallto
the lowest level.Itcan readily bedistributed
throughout aworkshop byair current, consequently,
even asmall spillage offuel isvery dangerous.
Always haveafire extinguisher containingFOAMCO2
GAS, orPOWDER closeathand when handling fuel,
or when dismantling fuelsystems andinareas where
fuel containers arestored.
WARNING: ltis imperative thatthebattery
is not disconnected duringfuelsystem
repairs asarcing atthe battery terminal
could ignitefuelvapour inthe atmosphere.
Always disconnect thevehicle batteryBEFORE
carrying outwork onthe fuel system.
Whenever fuelisbeing handled, transferred or
stored, orwhen fuelsystems arebeing dismantled
all forms ofignition mustbeextinguished or
removed, anyleadlamps usedmust beflame proof
and kept clear ofspillage.
No one should bepermitted torepair components
associated withfuelwithout firsthaving hadfuel
system training. Hot
fuel handling precautions
WARNING: Beforecommencing any
operation requiringfueltobe drained from
the fuel tank, thefollowing procedure must
be adhered to:
1. Allow sufficient timeforthe fuel tocool, thus
avoiding contactwithhotfuels.
2. Vent thesystem byremoving thefuel filler capin
a well ventilated area.Refitthefiller capuntil the
commencement offuel drainage.
Fuel transfer
WARNING: Fuelmust notbeextracted or
drained fromanyvehicle whileitis
standing overapit.
The transfer offuel from thevehicle fueltank must be
carried outinawell ventilated area.Anapproved
transfer tankmust beused according tothe transfer
tank manufacturers instructionsandlocal regulations,
including attentiontogrounding oftanks.
Fuel tankremoval
A FUEL VAPOUR warninglabelmust beattached to
the fuel tank upon removal fromthevehicle.
Fuel tankrepair
Under nocircumstances shouldarepair toany tank
be attempted. 
						

							INTRODUCTION3
INFORMATION
SYNTHETIC
RUBBER
Many 0ring seals, flexible pipesandother similar
items which appear tobe natural rubberaremade of
synthetic materials calledFluoroelastomers. Under
normal operating conditions thismaterial issafe, and
does notpresent ahealth hazard. However, ifthe
material isdamaged byfire orexcessive heat,itcan
break downandproduce highlycorrosive Hydrofluoric
acid which cancause serious burnsoncontact with
skin. Should thematerial beinaburnt oroverheated
condition handleonlywithseamless industrialgloves.
Decontaminate anddispose ofthe gloves immediately
after use.
If skin contact doesoccur, remove anycontaminated
clothing immediately andobtain medical assistance
without delay.Inthe meantime, washtheaffected
area withcopious amounts ofcold water orlimewater
for fifteen tosixty minutes.
RECOMMENDED SEALANTS
A number ofbranded products arerecommended in
this manual foruse during maintenance andrepair
work. These itemsinclude:
HYLOMAR GASKETANDJOINTING COMPOUND
andHYLOSIL RTVSILICONE COMPOUND.
They should beavailable locallyfromgarage
equipment suppliers.Ifthere isany problem obtaining
supplies, contactthefollowing company foradvice
and theaddress ofthe nearest supplier.
MARSTON LUBRICANTS LTD.
Hylo House,
Cale Lane,
New Springs,
Wigan WN21JR
Tel 01942 824242 USED
ENGINE OIL
WARNING: Prolongedandrepeated
contact withengine ormotor oilwill result
in the removal ofnatural fatsfrom the
skin, leading todryness, irritationanddermatitis.
Used engine oilcontains potentially harmful
contaminants whichmaycause skincancer.
Adequate meansofskin protection andwashing
facilities shouldbeprovided.
Handling precautions
1. Avoid prolonged andrepeated contactwithoils,
particularly usedengine oils.
2. Wear protective clothing,including impervious
gloves whereapplicable.
3. Do not putoily rags inpockets.
4. Avoid contaminating clothes,particularly
underwear, withoil.
5. Overalls mustbecleaned regularly. Discard
unwashable clothingandoilimpregnated
footwear.
6. First aidtreatment mustbeobtained immediately
for open cutsandwounds.
7. Use barrier creams, beforeeachworkperiod, to
help theremoval ofoil from theskin.
8. Wash withsoap andwater toensure alloilis
removed (skincleansers andnailbrushes will
help). Preparations containinglanolinreplace the
natural skinoilswhich havebeen removed.
9. Do not use gasoline, kerosene, dieselfuel,
petrol, thinners orsolvents forwashing theskin.
10. Ifskin disorders develop,obtainmedical advice.
11. Where practicable, degreasecomponents prior
to handling.
12. Where thereisarisk ofeye contact, eye
protection shouldbeworn, forexample, goggles
or face shields; inaddition aneye wash facility
should beprovided.
Disposing ofused oils
Environmental protectionprecaution
It is illegal topour used oilonto theground, down
sewers ordrains, orinto waterways.
Dispose ofused oilthrough authorised wastedisposal
contractors. Ifin doubt contact yourLocal Authority for
advice ondisposal facilities.  
						

							01INTRODUCTION
4 INFORMATION
ACCESSORIES
ANDCONVERSIONS
DO NOT FITunapproved accessoriesorconversions,
as they could affect thesafety ofthe vehicle.
Land Rover willnot accept liability fordeath, personal
injury, ordamage toproperty whichmayoccur asa
direct resultofthe fitting ofnon-approved conversions
to the vehicle.
WHEELS ANDTYRES
WARNING: DONOT replace theroad
wheels withanytype other thangenuine
Land Rover wheels whicharedesigned for
multi-purpose onand offroad useand have very
important relationships withtheproper operation
of the suspension systemandvehicle handling.
Replacement tyresmustbeofthe make andsizes
recommended forthe vehicle, andalltyres must
be the same make, plyrating andtread pattern.
STEAM CLEANING
To prevent consequential rusting,anysteam cleaning
within theengine bayMUST befollowed bycareful
re-waxing ofthe metallic components affected.
Particular attentionmustbegiven tothe steering
column, enginecoolant pipesandhose clips.
SPECIFICATION The specification detailsandinstructions setout in
this Manual applyonlytoarange ofvehicles andnot
to any one. Forthespecification ofaparticular vehicle
purchasers shouldconsult theirDealer.
The Manufacturer reservestheright tovary
specifications withorwithout notice,andatsuch times
and insuch manner asitthinks fit.Major aswell as
minor changes maybeinvolved inaccordance with
the Manufacturers policyofconstant product
improvement.Whilst everyeffortismade toensure theaccuracy of
the particulars containedinthis Manual, neitherthe
Manufacturer orDealer, bywhom thisManual is
supplied, shallinany circumstances beheld liable for
any inaccuracy orthe consequences thereof. SPECIAL
SERVICE TOOLS
The useofapproved specialservice toolsis
important. Theyareessential ifservice operations are
to be carried outefficiently, andsafely. Where special
tools arespecified, onlythese toolsshould beused
to avoid thepossibility ofpersonal injuryor
damage tothe components. Also,theamount of
time which theysave canbeconsiderable.
Special toolsbulletins willbeissued periodically giving
details ofnew tools asthey areintroduced.
All orders andenquiries fromtheUnited Kingdom
should besent direct toV. L.Churchill. Overseas
orders should beplaced withthelocal V.L.Churchill
distributor, whereoneexists. Countries wherethereis
no distributor mayorder direct from:
V. L.Churchill Limited,
PO Box 3,
Daventry, Northants,
England, NN114NF.
The tools recommended inthis Workshop Manualare
listed inamulti-language illustratedcatalogue,
obtainable from:
Messers. V.L.Churchill atthe above address,
or from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle, Merseyside, L701JL
COPYRIGHT Ó 1996 Rover Group Limited
All rights reserved. Nopart ofthis publication maybe
produced, storedinaretrieval systemortransmitted
in any form, electronic, mechanical, recordingorother
means without priorwritten permission ofRover
Group. 
						

							INTRODUCTION5
INFORMATION
JACKING The
following instructions mustbecarried outbefore
raising thevehicle offthe ground.
1. Use asolid levelground surface.
2. Apply parking brake.
3. Select 1stgear inmain gearbox.
4. Select Lowrange intransfer gearbox.
CAUTION: Toavoid damage occurring to
the under bodycomponents ofthe vehicle
the following jackingprocedures mustbe
adhered to.
DO NOT POSITION JACKSORAXLE STANDS
UNDER THEFOLLOWING COMPONENTS.
Body structure
Bumpers Fuel lines
Brake lines
Front radius arms
Panhard rod
Steering linkage
Rear Trailing links
Fuel tank
Engine sump
Gearbox bellhousing
Jack orsupport vehiclebyaxles only.
Vehicle jack
The jack provided withthevehicle isonly intended to
be used inan emergency, forchanging atyre. Do
NOT usethejack forany other purpose. Referto
Owners Manualforvehicle jacklocation pointsand
procedure. Neverworkunder avehicle supported by
the vehicle jack.
Hydraulic jack
A hydraulic jackwithaminimum 1500kg,3,300 lbs
load capacity mustbeused, seeJ6083.
CAUTION: Donot commence workonthe
underside ofthe vehicle untilsuitable axle
stands havebeen positioned underthe
axle, seeJ6084.
Raise thefront ofthe vehicle
1. Position cupofhydraulic armunder differential
casing.
NOTE: Thedifferential casingisnot
central tothe axle. Careshould betaken
when raising thefront roadwheels offthe
ground asthe rear axle hasless sway stiffness.
2. Raise frontroad wheels toenable anaxle stand
to be installed underlefthand axletube.    
						

							01INTRODUCTION
6 INFORMATION
3.
Position anaxle stand under righthand axle
tube, carefully lowerjackuntil axle sitssecurely
on both axlestands, remove trolleyjack.
4. Before commencing workonunderside of
vehicle re-check securityofvehicle onstands.
5. Reverse procedure whenremoving vehiclefrom
stands.
Raise rearofvehicle
1. Position cupofhydraulic armunder differential
casing.
2. Raise vehicle toenable axlestands tobe
installed underleftand right hand axletubes.
3. Lower jackuntil axle sitssecurely onaxle
stands, remove trolleyjack.
4. Before commencing workonunderside of
vehicle re-check securityofvehicle onstands.
5. Reverse procedure whenremoving vehiclefrom
stands.
HYDRAULIC VEHICLERAMP(FOUR POST)
Use only adrive ontype ramp which supports vehicle
on itsroad wheels. Ifa wheel-free conditionis
required, useadrive onramp incorporating a
wheel-free systemproviding supportbeneath axle
casings. Alternatively, placevehicle onafirm, flatfloor
and support onaxle stands.
TWO POST VEHICLE RAMPS
The manufacturer ofLAND ROVER VEHICLES
DOES NOTrecommend usingTwoPost ramps
that employ fouradjustable supportarms.These
are NOT considered safeforLand Rover vehicles.
If vehicle isinstalled onaTwo Post ramp
responsibility forsafety ofvehicle andpersonnel
performing serviceoperations isin the hands of
the Service Provider. DYNAMOMETER
TESTING
The front andrear axles cannot bedriven
independently.
WARNING: DONOT attempt todrive
individual wheelswithvehicle supported
on floor jacks orstands.
Four wheel dynamometers
Provided thatfront andrear dynamometer rollersare
rotating atidentical speedsandthatnormal workshop
safety standards areapplied, thereisno speed
restriction duringtesting except anythat may apply to
the tyres.
Two wheel dynamometers
IMPORTANT: Useafour wheel dynamometer for
brake testing ifpossible.
If brake testing onasingle axlerigisnecessary it
must becarried outwith propeller shafttorear axle
removed, ANDneutral selected inBOTH main
gearbox andtransfer gearbox. Whenchecking brakes,
run engine atidle speed tomaintain servovacuum.
If checking engineperformance, thetransfer boxmust
be inhigh range andpropeller shafttostationary axle
must beremoved. 
						

							INTRODUCTION7
INFORMATION
TOWING
CAUTION:
Thevehicle haspermanent
four-wheel drive.Thefollowing towing
instructions mustbeadhered to:
Towing thevehicle onallfour wheels withdriver
operating steeringandbrakes.
1. Turn ignition keytoposition 1torelease
steering lock.
2. Select neutral inmain gearbox andtransfer
gearbox.
3. Secure towrope, chain orcable tofront towing
eyes (alternative typesshown).
4. Release theparking brake.
CAUTION: Thebrake servoandpower
assisted steeringsystemwillnotbe
functional withouttheengine running.
Greater pedalpressure willberequired toapply
the brakes, thesteering systemwillrequire
greater efforttoturn thefront roadwheels.
The vehicle towconnection shouldbeused only
in normal roadconditions, snatchrecovery
should beavoided. Rear
suspended towbybreakdown vehicle
1. Ifthe front axleisto be trailed turnignition keyto
position 1torelease steering lock.
2. Select neutral inmain gearbox andtransfer box.
CAUTION: Thesteering wheeland/or
linkage mustbesecured inastraight
ahead position. DONOT usethesteering
lock mechanism forthis purpose.
TRANSPORTING THEVEHICLE BYTRAILER
Lashing/towing eyesareprovided onfront andrear of
the chassis sidemembers, seeJ6085, tofacilitate the
securing ofthe vehicle toatrailer orother means of
transportation.
CAUTION: Underbody components must
not beused aslashing points.
Install vehicle ontrailer andapply parkbrake. Select
neutral inmain gearbox.