1996 LAND ROVER DEFENDER clutch

01
04
05
07
09
10
12
17
19
26
30
33
37
41
47
51
54
57
60
64
74
70
75
76
80
82
84
86
88Workshop manual
DEFENDER 300Tdi
This manual covers vehicles from
1996 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
19 FUEL SYSTEM Tdi
26 COOLING SYSTEM Tdi
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS AND TYRES
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
88 INSTRUMENTS
Publication Part No. LRL 0097 ENG (3rd Edition)
Published by Rover Technical Communication
Ó1999 Rover Group Limited

GENERAL SPECIFICATION DATA
3
INFORMATION FUEL SYSTEM
Fuel lift pump type Mechanical with hand primer............................................................
Fuel lift pump pressure 42 - 55 Kgf/cm
2(3 - 4 lbf/in2) at 1800 rpm .....................................................
Fuel filter Paper element in disposable canister..........................................................................
Air cleaner Paper element type........................................................................
COOLING SYSTEM
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler and
turbo intercooler.
Cooling fan 11 blade axial flow 433 mm diameter, 1.29:1 drive.......................................................................
ratio, with viscous coupling.
Pump type Centrifugal, impellor, belt driven........................................................................
Thermostat opening 88°C .........................................................
Expansion tank cap pressure 1,06 Kgf/cm
2(15 Ibf/in2) (system pressure) ...........................................
CLUTCH
Type Valeo diaphragm spring.................................................................................
Centre plate diameter 235 mm.......................................................
Facing material Verto F202 grooved.................................................................
Release bearing Ball journal...............................................................
TRANSMISSION
Main gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward, 1 reverse, all synchromesh.............................................................................
Transfer box
Type LT230 Two speed reduction on main gearbox output. Front......................................................................
and rear drive permanently engaged via a lockable
differential
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................

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.

MAINTENANCE
3
MAINTENANCE UNDER BONNET MAINTENANCE
UNDER BONNET COMPONENTS
A - RH drive
1.Brake fluid reservoir
2.Clutch fluid reservoir
3.Air cleaner element
4.Engine breather filter
5.Oil filler cap
6.Oil level dipstick
7.Heater/air conditioning unit
8.Windscreen washer reservoir
9.Power steering pump reservoir10.Intercooler and hoses
11.Radiator filler plug
12.Radiator
13.Oil cooler
14.Fuel filter
15.Accelerator linkage
16.Expansion tank
17.Air cleaner dump valve

10MAINTENANCE
4
MAINTENANCE
UNDER BONNET COMPONENTS
B - LH drive
1.Brake fluid reservoir
2.Clutch fluid reservoir
3.Air cleaner element
4.Engine breather filter
5.Oil filler cap
6.Oil level dipstick
7.Heater/air conditioning unit
8.Windscreen washer reservoir
9.Power steering pump reservoir10.Intercooler and hoses
11.Radiator filler plug
12.Radiator
13.Oil cooler
14.Fuel filter
15.Accelerator linkage
16.Expansion tank
17.Air cleaner dump valve

MAINTENANCE
7
MAINTENANCE RENEW AUXILIARY DRIVE BELT
Renew drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
RENEW COMPRESSOR DRIVE BELT
Renew compressor drive belt.
See AIR
CONDITIONING, Repair, Compressor drive belt
CHECK/TOP UP POWER STEERING RESERVOIR
WARNING: DO NOT start engine if fluid
level in reservoir has dropped below
dipstick - severe damage to the power
steering system could result.
NOTE: Check fluid level with engine
switched off and system cold. Ensure that
steering wheel is not turned after stopping
engine.
1.Clean and remove reservoir cap.
2.Wipe distick clean and fully refit cap.
3.Remove cap and check fluid level. Ensure fluid
level is between UPPER mark and end of
dipstick.
4.Top up, if necessary, with recommended fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
DO NOT fill above
UPPER mark on dipstick.CHECK/TOP UP CLUTCH FLUID RESERVOIR
WARNING: Clutch fluid will damage
painted surfaces; clean up any spillage
immediately and rinse with plenty of water.
If clutch fluid should come into contact with the
skin or eyes, rinse immediately with plenty of
water.
1.Clean and remove reservoir cap.
2.Check fluid level and top up if necessary,
maintaining the level approximately 10 mm (0.39
in) below top of reservoir, using recommended
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids

10MAINTENANCE
12
MAINTENANCEREV: 05/99 LUBRICATE PROPELLER SHAFT UNIVERSAL
AND SLIDING JOINTS
1.Clean all grease nipples on front and rear
propeller shafts.
2.Using a low pressure hand grease gun, apply
recommended grease
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
to grease
nipples at front and rear propeller shaft universal
and sliding joints.
VISUALLY CHECK BRAKE, FUEL, CLUTCH
HOSES/PIPES/UNIONS FOR CHAFING, LEAKS
AND CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
RENEW CATALYTIC CONVERTERS
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
manifolds and exhaust system
CHECK FOR FLUID LEAKS FROM POWER
STEERING AND SUSPENSION SYSTEMS,
HYDRAULIC PIPES AND UNIONS FOR CHAFING
AND CORROSION
CHECK/TIGHTEN STEERING UNIT AND STEERING
ROD BALL JOINT FIXINGS, CHECK CONDITION
OF BALL JOINTS AND DUST COVERSBall joints are lubricated for life during manufacture
and require no further lubrication unless the rubber
boot has been dislodged or damaged. All joints should
be checked at specified service intervals, but more
frequently if vehicle is used under arduous conditions.
1.Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent, fit a new joint assembly.
See
STEERING, Repair, Drop arm ball See
STEERING, Repair, Track rod and See
STEERING, Repair, Drag link and drag link
ends
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN AND CLEAN FUEL SEDIMENTER, IF
FITTED
The fuel sedimenter is located on a chassis side
member on the RH side of vehicle near rear wheel. It
increases the working life of the fuel filter by removing
larger droplets of water and other matter from fuel.
NOTE: On 110/130 models with a twin tank
fuel system, two sedimenters may be
fitted, one on each side of the vehicle
chassis.
1.Slacken drain plug and allow any water to drain
off.

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