1996 LAND ROVER DEFENDER warning

10MAINTENANCE
10
MAINTENANCEREV: 05/99 RENEW GEARBOX OIL
1.Ensure vehicle is level.
2.Place suitable tray under gearbox.
3.Disconnect battery.
4.Clean area around filler/level plugs.
5.Remove both plugs and allow oil to drain
completely.
WARNING: When draining gearbox, care
should be taken to ensure that oil is not
hot as personal scalding could result.
6.Refit drain plug and tighten to
30 Nm (22 lbf/ft).
7.Inject new oil into gearbox until it runs out of filler
hole. Allow excess oil to drain and wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
8.Refit filler/level plug and tighten to30 Nm (22
lbf/ft).
9.Reconnect battery.
RENEW TRANSFER GEARBOX OIL
1.Ensure vehicle is level.
2.Disconnect battery.
3.Clean area around filler/level and drain plugs.
WARNING: When draining gearbox care
should be taken to ensure that oil is not
hot as personal scalding could result.
4.Place suitable tray under transfer gearbox.
5.Remove filler/level plug to vent gearbox and
assist draining.
6.Remove drain plug and allow oil to drain.
7.Thoroughly clean drain plug threads and apply
fresh 'Hylomar' sealant.
8.Refit drain plug and tighten to
30 Nm (22lbf/ft).
9.Inject new oil of correct quantity and grade into
gearbox until oil runs out from filler/level hole.
Allow excess oil to drain and wipe clean.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
10.Thoroughly clean filler/level plug and apply fresh
'Hylomar' sealant.
11.Refit plug and tighten to
30 Nm (22 lbf/ft).
12.Reconnect battery.
CHECK/TOP UP TRANSFER GEARBOX OIL
1.Ensure vehicle is level.
2.Disconnect battery.
3.Clean area around filler/level plug.
4.Remove plug, check oil level and top up if
necessary with correct grade of oil,
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
until oil runs out from filler/level hole.
Allow excess oil to drain and wipe clean.
5.Thoroughly clean filler/level plug threads and
apply fresh 'Hylomar' sealant.
6.Refit plug and tighten to
30 Nm (22 lbf/ft).
7.Reconnect battery.

MAINTENANCE
13
MAINTENANCE REV: 05/992.When pure diesel is emitted, retighten drain
plug.
3.Disconnect fuel inlet pipe at sedimenter. Raise
and support pipe above level of fuel tank to
prevent fuel draining from tank.
4.Support sedimenter bowl, unscrew bolt and
remove bowl.
5.Remove sedimenter element.
6.Clean all components in kerosene.
7.Fit new seals.
8.Fit element into sedimenter bowl.
9.Secure bowl to sedimenter head.
10.Fit fuel inlet pipe to sedimenter.
11.Slacken drain plug and when pure diesel is
emitted, retighten plug.
12.If necessary, prime the system.
See FUEL SYSTEM, Adjustment, Priming
the fuel system
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK SECURITY OF TOWING BRACKET
FITTINGSCARRY OUT ROAD OR ROLLER TEST
WARNING: Two wheel roller tests MUST
NOT be carried out.
For details of dynamometer testing.
See
INTRODUCTION, Information, Dynamometer
testing
Check the following components:
1.Engine for excessive noise.
2.Clutch for slip, judder or spin/drag.
3.Gear selection/noise - high/low range.
4.Steering for abnormal noise/effort.
5.Steering for free play.
6.All instruments, gauges and warning indicators.
7.Heater and air conditioning systems.
8.Heated rear screen.
9.Shock absorbers - ride irregularities.
10.Foot brake, on emergency stop, pulling to one
side, binding and pedal effort.
11.Handbrake operation.
12.Seat reclining and latching.
13.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
14.Road wheel balance.
15.Transmissions for vibrations.
16.Body noises, squeaks and rattles.
17.Excessive exhaust smoke.
18.Engine idle speed.
19.Endorse service record.
20.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD

12ENGINE
2
REPAIR ENGINE OIL PRESSURE TEST
Service repair no - 12.90.09/01
WARNING: Use suitable exhaust
extraction equipment if an engine test is
being carried out in a workshop.
WARNING: If vehicle has been running,
engine wil be hot; care must be taken
when fitting test equipment to prevent
personal injury.
1.Check that engine lubricant is to correct level.
2.Remove oil pressure switch .
3.Connect pressure test gaugeLRT-12-052A,as
shown.
4.Start and run engine to normal operating
temperature.
5.With engine running at idle check oil pressure,
which should read 1.76 bar (25.87 lbf/in
2).6.If pressure is low it can be caused by the
following:-
Thin or diluted oil.
Low oil in sump.
Choked oil strainer.
Faulty oil pressure relief valve.
Excessively worn or damaged oil pump
displacement gears.
Excessive crankshaft bearing clearance.
7.If excessive pressure is indicated it can be
caused by :-
Overfilling engine with lubricant.
Sticking oil pressure relief valve.
Blockage in breather system.

FUEL SYSTEM
9
DESCRIPTION AND OPERATION OPERATION
Diesel engines operate by compression ignition. The
rapid compression of air in the cylinder during the
compression cycle heats the air and when fuel is
injected into the heated air, it ignites instantaneously.
During cold tarting, automatically controlled heater
plugs assist in raising the temperature of the
compressed air to ignition point.
A cold start advance unit advances the injection timing
to further assist starting. Idle quality is improved by
the high idle setting.
The engine is supplied with pre-compressed air by a
single stage turbocharger.
Exhaust gases passing over a turbine cause it to
rotate, driving a compressor mounted on the turbine
shaft. Air drawn from the cold air intake passes, via
the air cleaner, to the turbocharger where it is
compressed. Compression in the turbocharger warms
up the air considerably, so that it expands. As a result
the air mass per cylinder is reduced, having a
negative effect on power output. By fitting a charge-air
intercooler, located on the LH side of the radiator, the
air is cooled before reaching the cylinders. This
increases power output through increased mass of
oxygen in the combustion process, as well as
maximising engine durability, through maintaining
lower piston and head temperatures.
Fuel is drawn from the tank by a mechanical lift pump
and passes to the injection pump via a filter. In
addition to removing particle contamination from the
fuel, the filter incorporates a water separator, which
removes and stores water.
The sedimentor/s, when fitted, is located adjacent to
the fuel tank/s and separates contamination and water
particles in the fuel before reaching the fuel lift pump.
The injection pump meters a precisely timed, exact
quantity of fuel to the injectors in response to throttle
variations, injection timing varying with engine speed.
Any excess fuel delivered to the injection pump is
passed back to the tank via the spill return line.
Fuel is injected in a finely atomised form into the main
combustion chamber, the burning fuel expands
rapidly, creating extreme turbulence which mixes the
burning fuel thoroughly with the compressed air,
providing complete combustion.Cold Starting is assisted by heater plugs, a cold start
advance unit and a high idle setting.
Heater plugs
Heater plug operation is controlled by a timer unit,
start relay and resistor. When the ignition is turned on
the timer unit is energised, the heater plugs start to
operate and a warning light on the dashboard
illuminates, remaining on until the heater plugs are
automatically switched off.
The length of time the heater plugs will operate is
dependent on under bonnet temperature, which is
monitored by a sensor located in the timer unit.
Starting the engine results in the power supply to the
heater plugs passing through the resistor, which
reduces their operating temperature. The heater plugs
are cut out either by the temperature sensor in the
timer, or by a microswitch on the injection pump which
operates when the throttle is depressed.
Cold start advance
The cold start advance unit is connected to the engine
cooling system via hoses. It contains a temperature
sensitive element which is retracted when cold and
pulls the advance lever, via cable, towards the rear of
the pump against spring pressure. As coolant
temperature rises, the cold start element expands
releasing tension on the cable and allowing spring
pressure to move the advance lever forwards.
Exhaust gas recirculation (EGR), when fitted
Operation of the EGR system is dependent on the
following:
·Engine temperature - must be between 20°C and
100°C approx.
·Engine speed - must be between 630 and 2850
rev/min.
·Engine load - calculated by throttle position
sensor.
·EGR valve lift position.
·Duration of engine idling.

19FUEL SYSTEM
6
REPAIR SIDE MOUNTED FUEL TANK
Service repair no - 19.55.05
NOTE: This fuel tank is standard on 90
models and an option on 110/130 2 door
vehicles fitted with twin tanks.
Remove
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS are
carefully studied and implemented in the interests
of safety.
See INTRODUCTION, Information, Fuel
Handling Precautions
1.Disconnect battery.
2.Remove fuel filler cap.3.Remove fuel tank drain plug, allow fuel to drain
into a clean container and refit plug.
4.Remove RH seat cushion.
5.Release retaining catch and remove seat base
cover to gain access to fuel tank.
6.Disconnect electrical plug from fuel gauge unit.
7.Disconnect fuel supply pipe from tank.
8.Disconnect spill return pipe from fuel tank.
9.Disconnect breather pipe from fuel filler tube.
10.Slacken hose clip and remove filler hose from
filler tube.
11.From rear of tank, remove 2 nuts and washers
securing tank mounting to captive-headed bolts.
12.Support rear of fuel tank and remove captive
bolts.

FUEL SYSTEM
7
REPAIR REV: 05/99
13.Remove single bolt fixing assembly securing
front of tank to chassis mounted bracket.
14.Remove 3 bolts securing tank mounting bracket
to chassis and release bracket.
15.Lower front of tank while turning anti-clockwise
and remove from vehicle.
16.If required, remove tank gauge unit.
See
INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank
orSee INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130
Refit
17.Fit filler hose and clip to tank but do not fully
tighten. Position clip screw so that it is
accessible when tank is fitted.
18.Fit breather hose and secure with clip.
19.Position fuel tank in vehicle and loosely secure
front mounting bracket to tank with special bolt
and rubber bushes.
20.Secure mounting bracket to chassis with 3 bolts
and fully tighten to
20 Nm (15 lbf/ft).
21.Secure rear of tank to chassis mounting and
tighten captive bolt plate fixings to
20 Nm (15
lbf/ft).
22.Fully tighten front fixing bolt assembly to20 Nm
(15 lbf/ft).
23.Fit spill return and fuel supply pipes and secure
union connections.
24.Fit fuel level unit electrical plug.
25.Fit hose to filler tube and tighten upper and lower
clips.
26.Check that drain plug is secure and fill fuel tank.
27.Reconnect battery.
28.Prime fuel system
See Adjustment, Priming
the fuel system
and start engine.
29.Check system for leaks and operation of fuel
gauge.
30.Fit seat base cover and seat cushion.SIDE MOUNTED FUEL TANK - 5 DOOR VEHICLES
Service repair no - 19.55.01
NOTE: This fuel tank is used on 110/130 5
door vehicles fitted with a twin tank
option.
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS,
See
INTRODUCTION, Information, Fuel handling
precautions
are carefully studied and
implemented in the interests of safety.
Remove
1.Disconnect battery.
2.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
3.Remove RH seat cushion.
4.Remove retaining catch and remove seat base
cover to gain access to fuel tank.
5.Disconnect electrical plug from fuel gauge unit.
6.Disconnect fuel supply pipe from tank.
7.Disconnect spill return pipe from tank.
8.Remove 3 bolts securing tank to front mounting
bracket.
9.Support front of tank and remove single fixing
assembly securing tank to rear mounting
bracket.
10.Remove tank from vehicle.
11.If required, remove fuel gauge unit.
See
INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank
orSee INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130
Refit
12.Position fuel tank in vehicle and loosely secure
to rear mounting bracket with special bolt and
rubber bushes.
13.Secure tank to front mounting bracket and
tighten fixings to
20 Nm (15 lbf/ft).
14.Fully tighten rear fixing bolt assembly to20 Nm
(15 lbf/ft).
15.Fit spill return and fuel supply pipes to fuel tank
and securely tighten union connectios.
16.Fit electrical plug to fuel gauge unit.
17.Check that drain plug is secure and fill fuel tank.
18.Reconnect battery.
19.Prime fuel system.
See Adjustment, Priming
the fuel system
and start engine.
20.Check system for leaks and operation of fuel
gauge.
21.Fit seat base cover and seat cushion.

19FUEL SYSTEM
8
REPAIR REAR MOUNTED FUEL TANK - 110/130
Service repair no - 19.55.26
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS
See
INTRODUCTION, Information, FUEL HANDLING
PRECAUTIONS
are carefully studied and
implemented in the interests of safety.
Remove
1.Disconnect battery.
2.Remove fuel filler cap.
3.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
4.Slacken retaining clips and disconnect fuel filler
hose from rear tank.5.Disconnect breather hose from filler tube.
6.Disconnect electrical plug and fuel supply pipe
from outlet pipe union on fuel gauge unit.
7.If the vehicle is fitted with a tow ball drop-plate
with support bars, the bars must be removed.
8.Remove anti-roll bar chassis mountings.
See
REAR SUSPENSION, Repair, Anti-roll bar
and push roll bar down to provide access to the
tank.
9.Remove LH lashing eye to assist access to tank.
10.Position a support under the tank, preferably one
that can be progressively lowered.

COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL COOLING SYSTEM
Service repair no - 26.10.01
Draining
WARNING: DO NOT remove caps or plugs
when the engine is hot. The cooling
system is pressurised and personal
scalding could result.
1.Remove expansion tank filler cap.
2.Position a clean container under radiator if
coolant is to be reused.
3.Disconnect radiator bottom hose and allow
coolant to drain.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray and/or
integral access panels.
See CHASSIS AND BODY,
Repair, Front undertray
orSee CHASSIS AND
BODY, Repair, Rear undertray
4.When expansion tank has emptied remove
thermostat housing plug to assist drainage.
5.Similarly when coolant is below top of radiator,
remove radiator plug.
6.Fit radiator bottom hose and fully tighten hose
clip.Refill
CAUTION: It is important that the correct
procedure is followed when refilling or
topping up the cooling system to avoid
trapping air in the system.
7.Fill cooling system with 50% - 50% of
water/anti-freeze mixture
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
8.Fill through expansion tank until radiator is full,
with level in expansion tank the same as
radiator.
NOTE: Care should be taken to avoid
excess coolant spillage.
9.Fit plastic plug in radiator.
10.Add a further 1 litre (1.76 pints) of coolant into
expansion tank and allow to settle.
11.Refit expansion tank cap and thermostat
housing plug.
12.Run engine at idle speed for 5 minutes.
13.Switch off engine and allow to cool.
14.Check that coolant in expansion tank is level
with top of indicator post. Top up if necessary.