1996 LAND ROVER DEFENDER roof

01INTRODUCTION
2
INFORMATION FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate inquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic and when
diluted with air becomes a readily ignitable mixture.
The vapour is heavier than air and will always fall to
the lowest level. It can readily be distributed
throughout a workshop by air current, consequently,
even a small spillage of fuel is very dangerous.
Always have a fire extinguisher containingFOAM CO
2
GAS,orPOWDERclose at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any lead lamps used must be flame
proof and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1.Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2.Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer's instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
AFUEL VAPOURwarning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.

04GENERAL SPECIFICATION DATA
8
INFORMATION Fuses
Type Autofuse (blade type) blow ratings to suit individual.................................................................................
circuits
Horns
Make/type Mixo TR99........................................................................
Starter motor
Make and type Bosch 12v.................................................................
BULBS
REPLACEMENT BULBS TYPE
Headlamps 12V 60/55W Halogen
Front side lamps 12V 5W bayonet
Side repeater lamps 12V 5W capless
Tail lamps 12V 5/21W bayonet
Direction indicator lamps 12V 21W bayonet
Number plate lamp 12V 5W capless
Reverse lamp 12V 21W bayonet
Rear fog guard lamp 12V 21W bayonet
Interior roof lamps 12V 10W festoon
Instrument illumination 12V 1.2W capless
Warning light panel 12V 1.2W bulb/holder unit
Hazard warning switch 12V 1.2W capless
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.

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...............

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.

MANIFOLD AND EXHAUST SYSTEM
1
DESCRIPTION AND OPERATION MANIFOLDS AND EXHAUST SYSTEM
Description
The exhaust systems fitted on all models with the
300Tdi engine comprise three sections; front pipe
assembly, intermediate silencer assembly, and tail
pipe and silencer assembly. All sections, including
silencers, are manufactured from luminised steel to
give the system a durable working life under all
conditions. Special clamps are provided to ensureleak proof jointing between the various sections,
which are supported by flexible rubber mountings.
Catalytic convertor
When fitted, the catalytic converter is integral with the
front pipe assembly, which also incorporates a flexible
joint. The catalyst forms part of the engine emission
control that can also include an EGR valve system
See FUEL SYSTEM, Repair, EGR valve
Exhaust system - 90
1.Gasket
2.Front pipe
3.Front pipe with catalytic converter
4.Front mounting bracket
5.Intermediate silencer6.Intermediate mounting brackets
7.Tail pipe silencer*
8.Tail pipe silencer mounting
9.Tail pipe mounting
* Deleted on later models

33CLUTCH
4
REPAIR RELEASE BEARING ASSEMBLY
Service repair no - 33.10.07
Remove
1.Remove gearbox
See MANUAL GEARBOX,
Repair, R380 Gearbox
.
2.Remove clutch slave cylinder
See Slave
cylinder
.
3.Remove release bearing sleeve retainer staple.
4.Withdraw bearing and sleeve.
5.Remove clutch release lever from bearing guide,
complete with sliper pads.
6.If necessary, unscrew 2 bolts and remove
bearing guide from bell housing.
Refit
7.If removed, fit bearing guide to bell housing.
Tighten bolts to
25 Nm (18 lbf/ft).
8.Prior to reassembly, grease pivot post, socket,
slipper pads, pins, and ball end of slave cylinder
push-rod.
9.Fit slipper pads onto release lever pins and
locate lever on pivot post.
10.Smear release bearing sleeve inner diameter
with molybdenum disulphide grease and fit to
bearing guide, locating slipper pads to sleeve
flats.
11.Fit new bearing sleeve retainer staple.
12.Fit clutch slave cylinder
See Slave cylinder.
13.Fit gearbox
See MANUAL GEARBOX, Repair,
R380 Gearbox
.SLAVE CYLINDER
Service repair no - 33.35.01
NOTE: All hose and pipe connections and
joints should be tightened to
15 Nm (11
lbf/ft).
Remove
1.Drain hydraulic fluid from system at slave
cylinder bleed valve.
2.Disconnect fluid pipe.
3.Remove 2 bolts and withdraw slave cylinder and
backing plate.
4.If dust cover is not withdrawn with slave cylinder,
withdraw it from bell housing.
CAUTION: If removing slave cylinder with
gearbox in situ, DO NOT detach push-rod
and clip from clutch release lever in bell
housing.
Refit
5.Coat both sides of backing plate with Hylomar
P232M waterproof jointing compound.
6.Locate backing plate and dust cover in position
on slave cylinder.
7.Fit slave cylinder, engaging push-rod through
centre of dust cover and with bleed screw
uppermost.
8.Reconnect fluid pipe.
9.Replenish and bleed clutch hydraulic system
See Bleed hydraulic system.
10.Check for fluid leaks with pedal depressed and
also with system at rest.

37MANUAL GEARBOX
6
REPAIRREV: 05/99 78.Position crossmember and locate over fixing
studs of LH and RH gearbox mounting rubbers.
79.Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
80.Fit intermediate silencer.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 90
orSee MANIFOLD AND EXHAUST
SYSTEM, Repair, Intermediate pipe - 110/130
.
81.Fit front pipe to exhaust manifold
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe
.
82.Fit rear propeller shaft to transmission brake
drum. Tighten nuts to
47 Nm (33 lbf/ft).
83.Remove 3 bolts securing support cradle to
transmission and remove hoist.
84.Reconnect battery earth strap to transfer box
fixing.
85.Connect speedometer cable to transfer box and
secure with retaining clip.
86.Coat both sides of clutch slave clinder backing
plate with Hylomar P232M waterproof sealant.
87.Locate backing plate on slave cylinder.
88.Fit slave cylinder to bell housing, engaging
push-rod through centre of dust cover, and with
bleed screw uppermost. Tighten bolts to
25 Nm
(18 lbf/ft).
89.Fit front propeller shaft to transfer box. Tighten
nuts to
47 Nm (33 lbf/ft).
90.Refill main gearbox and transfer boxSee
MAINTENANCE , Under vehicle maintenance
.
91.Feed transmission brake cable through heel
board and ensure grommet is correctly located.
NOTE: Apply a soap solution to aid fitment
of cable.
92.Lower vehicle on ramp.
93.Fit ties to secure gearbox harness to
transmission breather pipes.
94.Fit breather pipe retaining clip to rear of engine.
95.Reconnect charge air hose at turbocharger.
96.Reconnect intake hose at induction manifold. If
EGR system is fitted, reconnect intake hose at
intercooler.
97.Reconnect radiator top hose at thermostat
housing.
98.Fit viscous fan unit
See COOLING SYSTEM,
Repair, Viscous coupling and fan
.
99.Reconnect battery.100.Refill cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system
.
101.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
102.Locate insulation pad over gear levers and fit to
tunnel cover.
103.Fit gear lever with gaiter to lower lever spline
and secure with retaining nut.
104.Fit gear lever cover.
105.Fit gear lever and transfer box lever knobs.
106.Fit gearbox cover carpet.
107.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Under
vehicle maintenance
.

STEERING
3
REPAIR REV: 05/99
NOTE: The steering column is a non
serviceable component and can only be
serviced as a complete assembly.
25.Fit main support bracket and padding to steering
column and manoeuvre column into position in
vehicle.
26.Loosely secure main support bracket and
harness bracket to bulkhead.
27.Loosely fit clamp and rubber packing strip to
column.
28.Loosely secure lower end of column to lower
support bracket.
29.Loosely secure clamp bracket to main support
bracket.
30.Working inside vehicle cab, fit tie-bar to column
bracket and secure with single bolt to
22 Nm (16
lbf/ft).
31.Finally, tighten main support bracket, clamp
bracket, upper clamp, and lower support bracket
nuts and bolts. (M6 bolts
9 Nm (6 lbf/ft),M8
bolts
22 Nm (16 lbf/ft).
32.Fit brake pedal boxSee BRAKES, Repair,
Brake pedal
.
33.Fit steering lock/switch in position and rotate
steering column inner shaft to line up slot with
switch plunger.
34.Secure lock to column with clamp and shear
bolts. Evenly tighten bolts but do not shear them.
35.Temporarily fit steering wheel and operate
switch and lock mechanism several times to
ensure it functions correctly.
36.Fully tighten switch retaining bolts until heads
shear.
37.Connect electrical leads to rear of switch. Fit
alarm system passive coil, if applicable.
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.
38.Fit switch assembly on steering column and
tighten clamping screw.
39.Connect switch assembly multi-plugs and
electrical leads to main harness.
40.Offer up instrument panel, connect speedometer
cable, multi-plugs and electrical leads to main
harness. If applicable, fit vehicle alarm system
connections.
See ELECTRICAL, Repair,
Vehicle immobilisation and alarm system
.
41.Secure panel with 4 screws.
42.Locate top half of nacelle in position and fit to
switch gaiters/grommets.43.Fit lower half of nacelle and loosely tighten fixing
screws.
44.Ensure switch gaiters/grommets are correctly
located and fully tighten fixings.
45.Turn indicator cancelling ring so that slots are
vertical and lug with arrow points to the left, in
direction of indicator switch.
46.Fit steering wheel with finisher attachment lug at
bottom, ensuring that indicator cancelling forks
locate in cancelling ring slots.
47.Secure wheel with nut and new shake-proof
washer. Tighten to
43 Nm (32 lbf/ft).
48.Fit steering wheel decal.
49.If necessary, fit new universal joints to support.
Note that long joint is fitted to short length of
shaft and short joint to long end. Joints can only
be fitted one way to shaft.
50.With steering lock engaged and road wheels in
straight ahead position, align reassembly marks,
and fit collapsible shaft assembly with long leg of
shaft to steering box. Fit pinch bolts and tighten
to
25 Nm (18 lbf/ft).