1996 LAND ROVER DEFENDER fuel

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)..................................................................

GENERAL SPECIFICATION DATA
9
INFORMATION VEHICLE WEIGHTS AND PAYLOAD
When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the unladen
vehicle weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted
maximum values.
It is the customer's responsibility to limit the vehicle's payload in an appropriate manner such that neither
maximum axle loads nor Gross Vehicle Weight are exceeded.
Maximum EEC kerb weight and distribution - all optional equipment
VEHICLE AXLE WEIGHTS
90 models Standard High load
Front axle 1200 Kg (2645 lb)......................................................................... 1200 Kg (2645 lb)
Rear axle 1380 kg (3042 lb).......................................................................... 1500 Kg (3307 lb)
Gross vehicle weight 2400 Kg (5291 lb)........................................................ 2550 Kg (5622 lb)
110 models Levelled Unlevelled
Front axle 1200 Kg (2645 lb)......................................................................... 1200 Kg (2645 lb)
Rear axle 1750 Kg (3858 lb).......................................................................... 1850 Kg (4078 lb)
Gross vehicle weight 2950 Kg (6503 lb)........................................................ 3050 Kg (6724 lb)
130 models
Front axle 1580 Kg (3483 lb).........................................................................
Rear axle 2200 Kg (4850 lb)..........................................................................
Gross vehicle weight 3500 Kg (7716 lb)........................................................
NOTE: Axle weights are not accumulative. The individual maximum axle weights and gross vehicle
weight must not be exceeded.
EEC VEHICLE KERB WEIGHTS
90 models Standard High load
Soft top: 1695 Kg (3736 lb)............................................................................ 1699 Kg (3745 lb)
Pick-up: 1694 Kg (3734 lb)............................................................................ 1698 Kg (3743 lb)
Hard top: 1746 Kg (3849 lb).......................................................................... 1750 Kg (3858 lb)
Station wagon: 1793 Kg (3952 lb)................................................................. 1797 Kg (3961 lb)
110 models
Soft top: 1872 Kg (4127 lb)............................................................................ 1882 Kg (4149 lb)
Pick-up: 1880 Kg (4144 lb)............................................................................ 1890 Kg (4166 lb)
High capacity pick-up: 1917 Kg (4226 lb)...................................................... 1927 Kg (4248 lb)
Hard top: 1913 Kg (4217 lb).......................................................................... 1923 Kg (4239 lb)
Station wagon: 2018 Kg (4448 lb)................................................................. 2028 Kg (4470 lb)
County station wagon: 2054 Kg (4528 lb)...................................................... 2064 Kg (4550 lb)
130 models
Crew cab and High capacity pick-up: 2086 Kg (4598 lb)...............................
EEC kerb weight = Unladen weight + Full fuel tank + 75 Kg (165 lb).

ENGINE TUNING DATA
1
INFORMATION 300 Tdi ENGINE
Type2.5 Litre Turbo diesel intercooled .................................................................................
Firing order1-3-4-2 .....................................................................
Injection timing1,54 mm lift at T.D.C. ...............................................................
Injection timing with electronic EGR1,40 mm lift at T.D.C. ............................
Timing marks:
Valve timing - manual Slot for pin in flywheel and TDC mark on front pulley........................................................
Injection timing Timing pin (service tool).................................................................
Tappet clearances inlet and exhaust 0,20 mm cold...............................
Valve timing: Inlet Exhaust
- Opens 16°B.T.D.C. ............................................................................ 51°B.B.D.C.
- Closes 42°A.B.D.C. ............................................................................ 13°A.T.D.C.
- Peak 103°A.T.D.C. ............................................................................... 109°B.T.D.C.
- Lift 9,67 mm.................................................................................. 9,97 mm
Maximum governed speeds:
- No load (neutral/full throttle) 4600 + 40 - 120 rev/min...........................................
- Idle speed at running temperature 720±20 rev/min .................................
- Die-down time 4 seconds................................................................
INJECTION PUMP
Make & type - standard Bosch rotary R509 type with boost control and two....................................................
speed mechanical governor with auto advance and
solenoid electrical shut-off. Tamper proof sealing on,
no load governed speed and fuel adjustment screws.
Constant volume delivery valves
Make & type - Electronic EGR Bosch rotary R509/1 type with boost control and two.........................................
speed mechanical governor with auto advance and
solenoid electrical shut-off. Tamper proof sealing on
flight speed and fuel adjustment screws. Constant
volume delivery valves. Throttle position sensor for
EGR control.
HEATER PLUGS
Make & type Probe type, No.0100226129A Beru 12 volts.....................................................................
Time to reach operating temperature of 850°C 8 seconds...............

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.

07GENERAL FITTING REMINDERS
2
INFORMATION PREPARATION
1.Clean components and surrounding area prior to
removal.
2.Blank off any openings exposed by component
removal using greaseproof paper and masking
tape.
3.Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4.Close open ends of oilways, exposed by
component removal, with tapered hardwood
plugs or readily visible plastic plugs.
5.Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
6.Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7.Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1.Observe scrupulous cleanliness when
dismantling components, particularly when
brake, fuel or hydraulic system parts are being
worked on. A particle of dirt or a cloth fragment
could cause a dangerous malfunction if trapped
in these systems.
2.Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed.
3.Use marking ink to identify mating parts, to
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
4.Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
5.Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
6.Do not discard a part due for renewal until it has
been compared with the new part, to ensure that
its correct replacement has been obtained.INSPECTION-GENERAL
1.Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an incipient
failure.
2.When a component is to be checked
dimensionally against figures quoted for it, use
correct equipment (surface plates, micrometers,
dial gauges, etc.) in serviceable condition.
Makeshift checking equipment can be
dangerous.
3.Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension
is exactly limit size, and is otherwise satisfactory.
4.Use 'Plastigauge' 12 Type PG-1 for checking
bearing surface clearances. Directions for its
use, and a scale giving bearing clearances in
0,0025 mm steps are provided with it.

07GENERAL FITTING REMINDERS
6
INFORMATION FUEL SYSTEM HOSES
CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber outer
sleeve and an inner viton core. If any of
the fuel system hoses have been disconnected, it
is imperative that the internal bore is inspected to
ensure that the viton lining has not become
separated from the amoured outer sleeve. A new
hose must be fitted if separation is evident.
METRIC BOLT IDENTIFICATION
1.An ISO metric bolt or screw, made of steel and
larger than 6 mm in diameter can be identified by
either of the symbols ISO M or M embossed or
indented on top of the head.
2.In addition to marks to identify the manufacture,
the head is also marked with symbols to indicate
the strength grade, e.g. 8.8, 12.9 or 14.9, where
the first figure gives the minimum tensile
strength of the bolt material in tens of kgf/mm
2.
3.Zinc plated ISO metric bolts and nuts are
chromate passivated, a gold-bronze colour.METRIC NUT IDENTIFICATION
1.A nut with an ISO metric thread is marked on
one face or on one of the flats of the hexagon
with the strength grade symbol 8, 12 or 14.
Some nuts with a strength 4, 5 or 6 are also
marked and some have the metric symbol M on
the flat opposite the strength grade marking.
2.A clock face system is used as an alternative
method of indicating the strength grade. The
external chamfers or a face of the nut is marked
in a position relative to the appropriate hour
mark on a clock face to indicate the strength
grade.
3.A dot is used to locate the 12 O'clock position
and a dash to indicate the strength grade. If the
grade is above 12, two dots identify the 12
O'clock position.
KEYS AND KEYWAYS
1.Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to
refit key.
2.Clean and inspect key closely; keys are suitable
for refitting only if indistinguishable from new, as
any indentation may indicate the onset of wear.
TAB WASHERS
1.Fit new washers in all places where they are
used. Always fit a new tab washer.
2.Ensure that the new tab washer is of the same
design as that replaced.

09LUBRICANTS, FLUIDS AND CAPACITIES
2
INFORMATIONREV: 05/99 Propeller shaft Front
and RearNLGI - 2 Multi-purpose Lithium based GREASE
Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker
Brake and clutch
reservoirsBrake fluids having a minimum boiling point of 260°C (500°F) and complying with
FMVSS 116 DOT4
Engine coolant
(Pre-99MY)Use an ethylene glycol based anti-freeze (containing no methanol) with non-phosphate
corrosion inhibitors suitable for use in aluminium engines to ensure the protection of the
cooling system against frost and corrosion in all seasons. Use one part anti-freeze to
one part water for protection down to -36°C (-33°F).
IMPORTANT: Coolant solution must not fall below proportions one part
anti-freeze to three parts water, i.e. minimum 25% anti-freeze in coolant otherwise
damage to engine is liable to occur. Maximum concentration is 60%.
Engine coolant
(99MY on)Use Texaco XLC long life coolant. Use one part anti-freeze to one part water for
protection down to -36°C (-33°F).
IMPORTANT: Coolant solution must not fall below 50% anti-freeze otherwise
damage to the engine is liable to occur. Maximum concentration is 60%.
Battery lugs, Petroleum jelly.
earthing surfaces
where paint has
been removed.NOTE: Do not use Silicone Grease
Air Conditioning
System Refrigerant Use only refrigerant R134a
Compressor Oil Sanden oil
LUBRICATION PRACTICE
Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.
Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.
WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze, windscreen washer additives, lubricants and various adhesives.

LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION REV: 05/99 CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Pints
Engine sump oil 5,8................................................................ 10.20
Extra when refilling after fitting new filter 0,85.......................... 1.50
Manual gearbox 2,67............................................................... 4.70
Transfer gearbox oil 2,30......................................................... 4.00
Front differential 1,70............................................................... 3.00
Rear differential 1,70................................................................ 3.00
Power steering box and reservoir LHD 2,90............................ 5.00
Power steering box and reservoir RHD 3,40............................ 6.00
Swivel pin housing oil/grease (each) 0,35................................ 0.60
Fuel tank usable fuel 79,5........................................................ 17.5 gall
Cooling system 11,50................................................................ 20.20
Washer bottle 3,0................................................................... 5.28
NOTE: * All levels must be checked by dipstick or level plugs as applicable.
ANTI-FREEZE
PERCENTAGE CONCENTRATION - 50%
PROTECTION - LOWER TEMPERATURE LIMIT
Complete protection
Vehicle may be driven away immediately from cold,
-33°C (-36°F).
Safe limit protection
Coolant in semi-frozen state. Engine may be started
and driven away after warm-up period, -41°C (-42°
F).Lower protection
Prevents frost damage to cylinder head, block and
radiator. Thaw out before starting engine, -47°C (-53°
F).
CAUTION: Anti-freeze content must never
be allowed to fall below 25% (pre 99MY) or
50% (99MY on) otherwise damage to the
engine is liable to occur. Anti-freeze content
should not exceed 60% (all models) as this will
greatly reduce cooling efficiency.