1996 LAND ROVER DEFENDER ECO mode

BRAKES
3
DESCRIPTION AND OPERATION
90 Models
110/130 Models
Hydraulic system
A- Primary circuit
B- Secondary circuit
C- Pressure reducing valve (PRV)1.LH rear brake caliper
2.T connector
3.RH rear brake caliper
4.Brake servo
5.Master cylinder and reservoir
6.LH front brake caliper
7.RH front brake caliper

BRAKES
7
REPAIR REV: 05/99 FRONT BRAKE PADS - ALL MODELS
Service repair no - 70.40.02
Remove
1.Remove front road wheels .
2.Clean exterior of calipers.
3.Remove split pin from retaining pins.
4.Remove pad retaining pins and anti-rattle
springs.
5.Remove brake pads.
6.Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
7.Using piston clampLRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8.Fit brake pads.
9.Fit pad retaining pins and anti-rattle springs.
Secure with new split pins.
10.Apply service brake pedal several times to locate
pads.
11.Fit road wheels. Tighten wheel nuts to correct
torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
12.Check fluid reservoir. Top up if necessary, using
correct grade of fluid
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
.

70BRAKES
8
REPAIRREV: 05/99 REAR BRAKE PADS
Service repair no - 70.40.03
Service tool:
Remove
1.Remove rear road wheels.
2.Clean exterior of calipers.
3.Remove pad retaining pins and anti-rattle
springs. Note differences between 90 and
110/130 models.
4.Remove brake pads.
5.Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
6.Using piston clampLRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
7.Insert brake pads.
8.Fit anti-rattle springs and secure with retaining
pins.
9.Apply service brake pedal several times to locate
pads.
10.Fit road wheels, remove chassis stands and
jack. Tighten wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
11.Check fluid reservoir, top up if necessary, using
correct grade of fluid
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
.
90 Models
110/130 Models

BRAKES
13
REPAIR REAR BRAKE CALIPERS
Service repair no - 70.55.06
Service repair no - 70.55.17
Before starting repair refer to General brake service
practice
See General Brake Service Practice.
Remove caliper
1.Remove rear road wheels.
2.Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
90 Models
110/130 Models
3.Remove brake pipe from rear brake caliper.4.Seal pipe ends to prevent ingress of dirt.
5.Remove retaining pins and springs and withdraw
pads. If same pads are to be refitted, identify
them for assembly in original positions.
6.Remove 2 bolts and withdraw caliper from rear
axle.
Repair
WARNING: Do not separate caliper halves.
7.Clean outer surfaces of caliper with aerosol
brake cleaner.
8. WITH CAUTIONexpel pistons from their bores
by applying air pressure to fluid inlet port. It is
unlikely both pistons will expel at same time,
regulate rate with a suitable piece of wood
inserted between two pistons.
9.Finally, remove pistons keeping them identified
with their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal and pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and particularly seal
grooves using clean brake fluid only. If caliper or
pistons are corroded or their condition is not
perfect new parts must be fitted.
13.Apply brake fluid to new seal. Fit seal into
groove in bore. When seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat piston with brake fluid. Insert it squarely
into bore. Do not tilt piston during insertion and
leave 8mm projecting from bore.

70BRAKES
14
REPAIRREV: 05/99 15.Coat a new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston into bore recess.
16.Using special toolLRT-70-500- piston clamp,
press home seal retainer and piston.
Mounting inboard piston
17.Carry out same procedure as for removing and
fitting outboard piston and seals, instructions 8 to
16.
Fit calipers and pads to vehicle
18.Fit caliper to axle, tighten 2 bolts evenly to
82
Nm (60 lbf/ft).
19.Connect brake pipe to caliper. Tighten to15 Nm
(11 lbf/ft).
20.Remove clamp from flexible brake hose.
21.Insert pads and retaining springs, secure in
position with new retaining pins and spread ends
or fit new split pins, depending on vehicle model.
Note correct position of retaining springs on 90
models.
22.Bleed brake system
See Brake System Bleed.
23.Press brake pedal firmly several times to locate
pads.
24.Fit road wheels, remove axle stands. Finally
tighten road wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
25.Road test vehicle. Note new brake pads require
'bedding-in', for several hundred miles before
brakes are at maximum efficiency.REAR BRAKE DISC
Service repair no - 70.10.11.
Remove
1.Remove rear hub assembly
See REAR AXLE
AND FINAL DRIVE, Repair, Rear hub
assembly
.
2.Remove disc bolts.
3.Remove disc from rear hub.
Refit
4.Fit disc to rear hub.
5.Fit disc bolts. Tighten to
73 Nm (54 lbf/ft).
6.Check total disc run out, this must not exceed
0,15 mm (0.006 in). If necessary reposition disc.
7.Fit rear hub assembly
See REAR AXLE AND
FINAL DRIVE, Repair, Rear Hub Assembly
.
Disc reclamation
8.Check disc thickness. This dimension may be
machined to minimum thickness of 12 mm.
Machine equal amounts off each face.
NOTE: The brake disc MUST BE renewed if
the minimum running thickness stamped
on the disc is recorded.

76CHASSIS AND BODY
36
REPAIRREV: 05/99 26.Release demist hose and lift parcel shelf from
lower fascia panel (heater duct). Feed main
harness leads and plugs through aperture in
parcel shelf.
27.Remove parcel shelf.
28.Remove 7 screws securing bottom edge of lower
fascia panel to fascia bulkhead, noting position
of both footwell cover retaining plates.
29.Remove both retaining plates and lower footwell
covers.
30.Unscrew 2 retaining bolts securing top edge of
lower fascia panel to bulkhead.
31.With assistance, lower fascia panel and, if
applicable, disconnect RH radio speaker leads.
32.Remove fascia panel from vehicle.Refit
33.Position lower fascia panel to bulkhead,
reconnect RH speaker leads, if applicable, and
secure top edge with 2 bolts.
34.Locate RH footwell cover retaining plate under
bottom edge of fascia panel and secure with 3
screws.
35.Repeat operation for LH footwell cover retaining
plate.
36.Fit remaining lower fascia panel fixing screws.
37.Locate parcel shelf. Ensure all radio and
auxiliary switch panel harness leads and plugs
are fed through aperture in parcel shelf.
38.Fit demist hoses into heater duct of lower fascia
panel. Ensure flanges of hose grommets are
correctly seated.
39.Fit trim panel and secure with cap fasteners.
40.Reconnect LH speaker leads, if applicable,
locate wiper motor cover pins in lower fascia
panel and secure wth 3 screws. Ensure wiper
rack cover is correctly seated. On LH drive
vehicles, reconnect multi-plugs to rear of switch
panel.
41.Secure finisher to wiper motor cover.
42.Fit door check strap covers on both sides.
43.Fit footwell vents to lower fascia panel.
44. Models fitted with hand throttle:
Fit hand throttle cover.
Secure LH side of fuse box.
45.Fit fuse box cover.
46.Fit auxiliary switch cover to parcel tray, if
applicable.

84WIPERS AND WASHERS
4
REPAIR
9.Remove door check strap cover and 3 screws
and withdraw wiper motor cover. If applicable,
disconnect switch multi-plugs and/or radio
speaker leads.
10.Disconnect wiper motor multi-plug.
11.Disconnect earth lead. (Not applicable on later
models)
12.Lift rubber sleeve from wiper motor and slacken
wiper motor to drive tube nut.
13.Remove 2 screws and release wiper motor
retaining strap, complete with mounting pad and
earth tag.
14.Pull wiper motor and drive rack clear of drive
tubes.Refit
15.Feed drive rack into drive tube until fully located
in wheel boxes.
16.Finger tighten drive tube nut.
17.Position motor mounting pad, fit retaining strap,
including earth tag and secure wiper motor
assembly.
18.Fully tighten drive tube nut and fit rubber sleeve.
19.Fit wiper motor multi-plug and earth lead to tag
on motor retaining strap.
20.Before fitting fascia panels, fit wiper blades,
reconnect battery and test wiper operation.
21.Refit fascia panels, noting that air conditioning
panel must be located and secured, on LH side,
with single screw, before instrument panel is
fitted.
22.Fit steering wheel
See STEERING, Repair,
Steering wheel.

86ELECTRICAL
12
DESCRIPTION AND OPERATION VEHICLE ALARM SYSTEM BUILT-IN TEST
NOTE: The handset should be detached
from the key to allow perimetric testing of
the alarm system. The system will
automatically switch to volumetric testing if the
handset is in close proximity to the starter switch.
The built-in test procedure can be accessed providing
the following conditions exist:
Alarm disarmed.
Ignition 'off'.
Doors unlocked.
Bonnet closed.
With assistance, the test mode can be entered by
completing the following instructions within 5 seconds:
1.Open bonnet.
2.Turn starter switch 'on'.
3.Open driver's door (far enough to activate door
switch).
4.Turn starter switch 'off'.
5.Turn starter switch 'on'.
If the test mode has been correctly accessed, the
alarm sounder/horn will operate briefly and the
anti-theft alarm indicator and direction indicator lamps
will flash.
Perimetric tests
The anti-theft alarm indicator light and direction
indicator lamps will flash when:
1.Door switches are activated.
2.The bonnet is opened.
3.Key switches are activated.Volumetric tests
Press the LH (unlock) button or move the handset
close to the starter switch to disable perimetric testing
and enable volumetric testing. If movement is
detected within the vehicle by the ultrasonic sensor
the anti-theft alarm indicator and direction indicator
lamps will illuminate.
NOTE: Exit the anti-theft alarm built-in test
by turning the starter switch to the 'off'
position.
If the previously described conditions are not achieved
during the built-in test procedure, this would indicate a
fault in the alarm system. Before undertaking detailed
fault diagnosis procedures, first make visual checks of
components such as a faulty door switch or blown
alarm system fuse.