Owner's Manual Classic Land Rover Defender 90, 110 and 130 · Td5

Introduction

SummaryThis manual covers the operation and routine care of the classic Land Rover Defender with the Td5 engine. Figures marked factory are the original Land Rover reference values. Where a vehicle's build book gives a different figure, follow the build book.

How this manual is arranged

Sections follow the order of use: controls, starting and driving, the transmission, brakes, off-road use, owner checks, fluids, tires, care, storage, identification and support. Specifications and an index are at the end. Use the search bar to find any word in the manual.

The build book

Each vehicle is supplied with a build book recording its specification, including engine, transmission, wheels, tires and pressures, ride height, wading depth, paint, interior materials and service schedule. Keep it with the vehicle's documents, not in the vehicle.

Warnings, cautions and notes

Controls and instruments

SummaryThe starter switch has four positions: 0, I, II and III. Warning lights should go out once the engine is running. Red lights mean stop safely and investigate. Amber lights indicate a system that needs attention or is engaged.

Starter switch

In position 0, side lights, headlights, hazard warning lights and rear fog lights remain available. Electrical items on position I are interrupted while the starter is operating.

Warning and indicator lights

Starting and driving

SummaryTurn the key to II and wait for the glow plug light to go out. Start without pressing the accelerator and release the key as soon as the engine runs. Keep to idle until the oil pressure light goes out. Before switching off, idle for at least 10 seconds.

Starting

1. Apply the handbrake. Select neutral.
2. Switch off electrical equipment that is not needed.
3. Turn the key to II. Wait for the glow plug light to go out. A warm engine does not need to wait.
4. Turn the key to III. Do not press the accelerator. Release the key as soon as the engine runs.
5. If the engine does not start within 10 seconds, release the key, wait 10 seconds and try again.
6. In cold weather or with a weak battery, hold the clutch pedal down while cranking.

Warming up

Drive away once the oil pressure light is out. Use moderate throttle and avoid laboring the engine until the temperature gauge reaches its normal position. Prolonged idling does not warm a diesel efficiently.

Parking and switching off

1. Stop the vehicle and apply the handbrake.
2. Select neutral, then release the foot brake.
3. Idle for at least 10 seconds. After towing, a long climb or sustained high speed, idle for about one minute.
4. Turn the key to I, then to 0, and remove it.

Gearbox, transfer box and diff lock

SummaryThe classic Defender has permanent four wheel drive through a two-speed transfer box with a lockable center differential. Use High range for road driving. Use Low range for slow maneuvering, towing starts and difficult ground. Engage the diff lock only on loose or slippery surfaces.

The manual main gearbox has five forward gears and reverse. The transfer box provides High and Low ranges, giving ten forward and two reverse gears. The center differential allows the front and rear axles to turn at different speeds. Vehicles built with an automatic transmission use the selector described in the build book. Transfer box and diff lock operation are the same.

Ranges

• High (H). All road driving, and off-road on dry, level ground.
• Low (L). Moving off with a heavy trailer, reversing a trailer, slow maneuvering over rocks or rough ground, steep climbs and descents, and any condition where progress cannot be kept in High.
• Neutral (N). No drive reaches the wheels regardless of the main gearbox position. Use when the vehicle is being towed, and for winching or power take-off.

Changing range when stationary

1. Stop the vehicle with the engine running. Depress the clutch.
2. Move the transfer lever in two distinct movements: High to neutral, then neutral to Low, or the reverse.
3. If the lever resists, do not force it. Select a gear with the main lever, release the clutch briefly, depress it again and retry.

Changing from Low to High while moving

1. Apply light pressure to the transfer lever toward High.
2. In one movement, depress the clutch, release the accelerator and move the lever to neutral.
3. Release the clutch for about three seconds.
4. Depress the clutch and move the lever firmly into High.
5. Select a suitable gear, release the clutch and continue.

Do not select reverse unless the vehicle is stationary.

Center differential lock

With the diff lock engaged, the front and rear propeller shafts turn at the same speed. This improves traction when grip is uneven between axles.

1. To engage: briefly ease the throttle and move the transfer lever to the left from H or L. The amber diff lock light comes on when the lock engages. Engagement can be made stationary or moving, provided the vehicle is traveling in a straight line on firm ground without wheel slip.
2. To release: move the transfer lever to the right, into H or L. The light goes out when the lock releases.

Driveline wind-up

If the diff lock light is slow to go out after release, the driveline may be wound up. Reverse a short distance, then drive forward. If the light remains on after two or three attempts, contact owner support.

Brakes and steering

SummaryThe hydraulic brakes operate on two independent circuits. If one fails, the other still stops the vehicle, with longer pedal travel and greater effort. Do not rest a foot on the brake pedal. Dry the brakes after water or mud by applying them gently at low speed.

• Resting a foot on the brake pedal overheats the brakes and reduces their efficiency.
• After wading, heavy rain or washing, apply the brakes gently several times at low speed until they are fully effective.
• If the pedal travels further than normal, feels soft, or the brake warning light stays on, stop in a safe place and contact owner support.
• On the factory vehicle, the handbrake is a drum brake on the transfer box output. Do not use it to slow a moving vehicle. The build book notes any change to the handbrake.

Steering

The steering lock engages when the key is removed and the wheel is turned. To release it, insert the key fully and turn it to I while moving the wheel slightly. Power steering assistance is reduced if the engine stops.

Off-road driving and wading

SummarySelect the gear before the obstacle and do not change gear or depress the clutch while crossing it. On slippery ground, use the highest practical gear. Descend steep slopes in first gear, Low range. The factory wading depth is 500 mm (20 in) at walking pace.

Before leaving the road

• Be familiar with the transfer box and diff lock (Section 4).
• Keep the fuel tank above one quarter. Steep angles can starve the engine on a low tank.
• All occupants wear seat belts.
• Walk any uncertain section before driving it.

Technique

• Gear selection. Choose the gear before the obstacle. Do not change gear or depress the clutch on difficult ground; the vehicle may stop and be hard to restart.
• Slippery ground. Mud, wet grass, snow and ice: use a higher gear and gentle throttle to limit wheelspin. Engage the diff lock.
• Soft sand. Keep momentum. Avoid sharp turns.
• Climbing. Approach straight up the slope. If the climb fails, reverse straight down in Low reverse. Do not attempt to turn on the slope.
• Descending. First gear, Low range, straight down the slope. Let engine braking control speed. Do not depress the clutch.
• Traversing. Avoid driving across a steep slope. If unavoidable, keep the uphill side free of load and drive slowly.
• Ridges, ditches and gullies. Cross ditches and ridges at an angle so one wheel at a time crosses. In a V-shaped gully, keep the vehicle level by straddling the lowest point where possible.

Wading

1. Check the depth, current and bottom on foot before entering.
2. Engage Low range and second or third gear. Engage the diff lock.
3. Enter slowly, then hold a steady speed of about walking pace so a small bow wave forms ahead.
4. Do not stop or change gear in the water.
5. After leaving the water, apply the brakes gently several times to dry them. Do not rely on the handbrake until it has dried.

Owner checks

SummaryDaily: lights, horn, indicators, wipers, warning lights, seat belts, brakes, and signs of leaks. Weekly or every 250 miles: engine oil, coolant, brake and clutch fluid, power steering fluid, washer fluid, and tire pressures and condition. Report any sudden drop in a fluid level or uneven tire wear.

Daily

• Lights, horn, direction indicators, wipers and washers operate.
• Warning lights go out after the engine starts.
• Seat belts latch and retract. Brakes operate normally.
• No fluid deposits on the ground beneath the vehicle.

Weekly or every 250 miles

• Engine oil level.
• Coolant level, engine cold.
• Brake fluid level.
• Clutch fluid level.
• Power steering fluid level.
• Washer reservoir level.
• Tire pressures, cold, and tire condition.

Checking the engine oil

1. Park on level ground. Switch off and wait a few minutes for the oil to drain to the sump.
2. Withdraw the dipstick, wipe it clean, reinsert it fully and withdraw it again.
3. The level must be between the lower and upper marks.
4. If needed, add oil of the correct specification (Section 8) through the filler cap, a little at a time, and recheck. Do not fill above the upper mark.

Checking fluid reservoirs

The coolant expansion tank, brake and clutch reservoirs, power steering reservoir and washer reservoir are marked with minimum and maximum levels. Check them on level ground. Check coolant with the engine cold.

Fluids and capacities

SummaryFactory Td5 engine oil is SAE 5W-30 or 5W-40 meeting ACEA A1/B1, about 7.2 liters plus 1.0 liter with a new filter. Brake and clutch fluid is DOT 4. Coolant is OAT ethylene glycol antifreeze mixed 50/50 with water. Capacities are approximate; always set levels with the dipstick or level plug.

Fuel

• Use clean diesel. Usable tank capacity: 90, 60 L (15.9 gal). 110 and 130, 75 L (19.8 gal).
• The fuel cap vents during the first half turn. Do not remove it fully until pressure has released.
• Water in diesel damages the injection system. The fuel filter water trap is drained at service, and sooner if the water in fuel light comes on.

Service schedule

The service schedule for each vehicle is set at delivery and recorded in its build book, with space to record each service.

Dynamometer testing

The vehicle has permanent four wheel drive. It must not be tested on a two-wheel dynamometer or roller brake tester except by a technician familiar with four wheel drive procedures.

Tires and wheels

SummaryCheck tire pressures cold. Pressure rises about 3 psi when warm; do not reduce a warm tire to the cold figure. Factory pressures for a Defender 110 on 7.50 R16 are 28 psi front and 48 psi rear. The pressures for a specific vehicle are recorded in its build book.

• Fit radial tires of the same make and type on all four wheels. Do not fit cross-ply tires.
• If the vehicle has stood in the sun, move it to shade and allow the tires to cool before checking.
• Wheels marked TUBED require an inner tube, even with a tubeless tire.
• Pressures reduced for sand or rock must be restored before driving on the road.
• Report uneven tread wear. It usually indicates incorrect pressure or alignment.

Changing a wheel

1. Park on firm, level ground away from traffic. Hazard lights on, handbrake applied, Low range and first gear selected, engine off.
2. Passengers out, on the side away from traffic. Chock the wheel diagonally opposite.
3. Loosen the wheel nuts half a turn before raising the vehicle.
4. Position the jack at the jacking point for that wheel under the axle and raise until the tire clears the ground.
5. Remove the nuts and wheel. Fit the spare, tighten the nuts lightly in a diagonal sequence, lower the vehicle, then tighten fully.
6. Have the nut torque checked at the earliest opportunity.

Care of paint and materials

SummaryWash the paint by hand with a pH-neutral shampoo; do not use automatic brush car washes. Clean leather with a barely damp cloth and condition it two to four times a year. Brush Alcantara; never condition it. Wipe engraved metal with a dry cloth only. Consult owner support before polishing or coating the paint.

Paint

The paint is a multi-stage finish applied to each panel separately.

1. Rinse loose dirt from the vehicle.
2. Wash from top to bottom with a pH-neutral shampoo and a soft mitt, using a second bucket of clean water to rinse the mitt.
3. Rinse and dry with clean microfiber towels.

• Do not use automatic brush car washes.
• Keep pressure washers at least 12 in (30 cm) from the paint and away from panel edges, seams and seals.
• Remove bird droppings, tree sap and tar promptly.
• Do not machine polish, apply ceramic coatings or fit protection film without consulting owner support.

Leather

The leather is full-grain. Natural marks in the hide are part of the material. In areas of frequent contact, such as bolsters, armrests and the steering wheel, the color softens and lightens over time as the surface wears. This is expected.

• Wipe with a soft cloth barely damp with clean water.
• Clean with a mild leather cleaner two to four times a year, then apply a thin coat of leather conditioner. Test new products on a hidden area.
• Blot spills. Do not rub.
• Do not use solvents, household wipes or silicone products.
• Prolonged direct sun dries leather. Park in shade where possible.

Wool carpet

Vacuum regularly. Spot-clean with a barely damp cloth and a wool-safe cleaner. Do not saturate.

Alcantara

Brush lightly with a soft brush. Wipe with a damp microfiber cloth to lift the pile. Do not use leather cleaner or conditioner.

Engraved metal

Wipe with a soft dry cloth. Do not use metal polish, which removes engraved detail and tone.

Glass, gauges and wiper blades

Clean glass and gauge faces with an ammonia-free cleaner applied to a cloth, not sprayed onto the surface. Wipe wiper blades with washer fluid. Replace blades that smear.

Cold weather, storage and battery

SummaryIn extreme cold, cranking time increases and warning lights may take several seconds to go out. At -22°F (-30°C), the starter may need to run for up to 30 seconds. For storage longer than two weeks, fill the tank, connect a battery maintainer and raise tire pressures slightly.

Cold weather

• Switch off all electrical equipment before starting. Hold the clutch pedal down while cranking.
• Maintain coolant at a 50/50 mix for protection to -33°F (-36°C).
• In very cold climates, a cylinder block heater improves starting.

Storage

1. Wash and dry the vehicle, including the interior.
2. Fill the fuel tank to reduce condensation.
3. Park in a dry, ventilated building. Use a breathable cover.
4. Connect a smart battery maintainer.
5. Raise tire pressures by a few psi. Restore them before driving.

If possible, drive the vehicle for at least 20 minutes every few weeks. Brief start-and-stop runs are not recommended.

Battery

Keep the terminals clean, tight and lightly coated with petroleum jelly.

Jump starting

1. Use a 12-volt donor battery. Keep the vehicles apart.
2. Connect red lead: flat battery positive to donor positive.
3. Connect black lead: donor negative to a clean, unpainted metal point on the flat vehicle's engine, away from the battery.
4. Run the donor engine, then start the vehicle.
5. Remove the leads in reverse order.

Keys, identification and security

SummaryThe VIN appears in three places: a plate on the top of the brake pedal box in the engine compartment, a stamping on the right side of the chassis forward of the front spring turret, and a plate visible through the base of the windshield.

The VIN plate also shows type approval, gross vehicle weight, gross train weight and maximum axle loads where required. Do not exceed these weights. Record the VIN and engine number with the build book.

Keys

• Record the key numbers in the build book.
• Keep spare keys, key numbers and vehicle documents at home, not in the vehicle.
• From outside, lock the doors with the key. Locking with the sill buttons and closing the door can lock the keys inside.

When leaving the vehicle

1. Close all windows and any roof opening.
2. Remove valuables or place them out of sight.
3. Remove the key and turn the steering wheel until the lock engages.
4. Lock all doors.

Roadside and owner support

SummaryIn a breakdown, move off the road if safe, switch on the hazard lights, place a warning triangle behind the vehicle and move passengers away from traffic. Then call owner support on +1 518.714.0772 with the VIN or vehicle name, location and a description of the fault.

Breakdown

1. Move the vehicle off the main road onto the shoulder or verge, if it is safe to do so.
2. Switch on the hazard warning lights.
3. Place a warning triangle or flashing light at a suitable distance behind the vehicle, where permitted.
4. Move passengers out through the doors away from traffic and to a safe place.
5. Call owner support.

Owner support

Helderburg Concierge provides service and repair at the owner's location. A Helderburg mechanic is sent to the vehicle. Parts for the vehicle remain available for its life.

Towing the vehicle

Place the transfer box in neutral when the vehicle is towed with all four wheels on the ground. The key must be at I or II so the steering is unlocked. Power assistance to steering and brakes is not available with the engine off. Transport on a flatbed is preferred.

Specifications

SummaryThe Td5 is a 2,498 cc five cylinder turbo diesel with electronic unit injectors, fitted to the classic Defender from 1998 to 2007. The 300Tdi is a 2,495 cc four cylinder turbo diesel with a mechanical injection pump. Factory wading depth is 500 mm (20 in) for all models.

Common questions

Index

• Alcantara10
• Approach angle14
• Battery11
• Brake fluid8
• Brakes5
• Breakdown13
• Build book1
• Car washing10
• Clutch fluid8
• Cold weather11
• Concierge13
• Coolant8
• Departure angle14
• Diff lock4
• Dipstick7
• Dynamometer8
• Engine oil8
• Engraved metal10
• Exhaust fumes3
• Fuel8
• Glow plugs3
• Ground clearance14
• Handbrake5
• High range4
• Jump starting11
• Keys12
• Leather10
• Low range4
• Owner checks7
• Paint10
• Power steering fluid8
• Service schedule8
• Specifications14
• Starter switch2
• Storage11
• Tire pressures9
• Tire size9
• Towing limits14
• Towing the vehicle13
• Turbocharger3
• VIN12
• Wading6
• Warning lights2
• Wheel changing9
• Wind-up4
• Wool carpet10