Land Rover1994–1999

Defender 2.5 TDI: Common faults & known problems

Common faults & known problems

9 known faults documented in workshop bulletins. Of these, two concern the engine and fuel system and two the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Updated Technical specifications

Engine & fuel system

2 documented faults — symptoms, causes and workshop fixes.

Poor engine performance

Affects Defender 300 Tdi: VIN 111838→/VIN 554794→.Fit new part

Symptoms

Poor priming of the fuel lift pump after fuel filter changed or drained.

Cause

Fuel lift pump overstroking causing failure.

Repair

  1. Fit new fuel lift pump and gasket.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Fuel lift pumpERR 50571
Fuel lift pump gasketERR 73391

Data: Motorwise Workshop. Bulletin 1.

Turbocharger (TC) intercooler bottom hose detached from intercooler or turbocharger (TC)

Retaining clip not securing hose sufficiently. Fix: fit a new part.

Overview

Affects
Defender: →VIN LD 939976.
Remedy
Fit new part

Repair steps

  1. Fit new retaining clips.
  2. Tighten clips to 3.5 Nm.
  3. Start engine.
  4. Allow engine to reach normal operating temperature.
  5. Switch ignition OFF.
  6. Allow vehicle to stand for 30 minutes.
  7. Retighten clips to 3.5 Nm.

Parts

Parts listed in the bulletin
PartPart numberQty
Retaining clipSTC1284

Data: Motorwise Workshop. Bulletin 3.

Electrical & ignition

1 documented fault — symptoms, causes and workshop fixes.

Unreliable starter motor operation

Affects Defender: 300 Tdi, VIN LD 941962→. Defender: 12J, VIN LD 944084→.Fit new part

Cause

Water entering starter solenoid through inadequate sealing.

Repair

  1. Fit new starter motor.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Starter motorERR 50091

Data: Motorwise Workshop. Bulletin 2.

Brakes

2 documented faults — symptoms, causes and workshop fixes.

ABS warning lamp illuminates permanently or intermittently

Poor routing of ABS wheel speed sensor wiring harness around front flexible brake hose. Fix: fit a new part.

Overview

Affects
All models with ABS, VIN XA 159810-2A 62899.
Remedy
Fit new part

Repair steps

  1. Release brake system fluid pressure.
  2. Remove brake hose and pipe from hub mounting bracket.
  3. Fit new hub mounting bracket.
  4. Fit brake pipe, brake hose and ABS wheel speed sensor wiring harness to hub mounting bracket.
  5. Bleed brake system.

Parts

Parts listed in the bulletin
PartPart numberQty
Front ABS wheel speed sensorSSW1000502
Front ABS wheel speed sensor clip bracket, rightRGY0000201
Front ABS wheel speed sensor clip bracket, leftRGY0000301
ABS harness clipDYC1014102
Clip - brake hose to ABS harnessNTC82422

Data: Motorwise Workshop. Bulletin 6.

ABS warning lamp illuminates permanently or intermittently

Poor routing of ABS wheel speed sensor wiring harness around the rear axle.

Overview

Affects
All models with ABS.

Repair steps

  1. Fit cable tie and clip around axle tube.
  2. Ensure the cable tie is outboard of the shock absorber with the clip on top of the axle tube.
  3. Fit ABS wheel speed sensor wiring harness to clip.
  4. Repeat procedure for opposite side.

Parts

Parts listed in the bulletin
PartPart numberQty
ABS wheel speed sensor assembly - rearSSW1000601
Accelerator cableRGY5000102

Data: Motorwise Workshop. Bulletin 7.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Heavy clutch pedal action

Overview

Affects
All models with manual transmission, 1999→.
Remedy
Fit modified part
Parts
4 parts

Cause

Clutch pedal return spring weak.

Repair

  1. Remove and discard clutch pedal return spring.
  2. Fit modified clutch pedal return spring and bushes.
Parts4 parts
Parts listed in the bulletin
PartPart numberQty
Clutch pedal return springEDP7510L1
BushDCP3212L2
BushCLP31801
GasketANR63321

Data: Motorwise Workshop. Bulletin 9.

Air conditioning & heating

1 documented fault — symptoms, causes and workshop fixes.

Heater unable to demist front screen

Overview

Affects
All models.

Symptoms

Sound of water moving in heater.

Cause

Heater air intake drain valve sticking or blocked.

Water trapped in heater ducting.

Repair

  1. Ensure air intake drain valve operates correctly.
  2. Ensure air intake drain tube is not blocked.

Data: Motorwise Workshop. Bulletin 4.

Wipers & visibility

1 documented fault — symptoms, causes and workshop fixes.

Erratic front wiper operation

Front wiper arm loose, allowing wiper spindle to rotate without moving wiper arm. Fix: adjust and tighten.

Overview

Affects
90/110/130/Defender, 1995-09: VIN 600000→.
Remedy
Adjust & tighten

Symptoms

Front wipers not working.

Repair steps

  1. Remove wiper arm nut protective cover and remove nut.
  2. If wiper arm has come loose from spindle inspect affected components for damage. Replace components as necessary.
  3. Ensure wiper motor is in park position.
  4. Fit front wiper arm. Tighten wiper arm nut as follows:.
  5. Freelander (97-06): 18 Nm.
  6. Freelander 2 (06-): 25 Nm.
  7. 90/110/130/Defender: 17 Nm.
  8. Discovery 3 (04-): 18 Nm.
  9. Range Rover (02-): 18 Nm.
  10. Range Rover Sport: 34 Nm.

Data: Motorwise Workshop. Bulletin 8.

Other

1 documented fault — symptoms, causes and workshop fixes.

Alloy wheels difficult to remove

Overview

Affects
All models with alloy wheels, →03/01.
Remedy
Clean & lubricate
Parts
1 part

Cause

Corrosion between hub spigot and wheel centre.

Repair

  1. Clean corrosion from wheel contact surfaces.
  2. Apply anti-seize grease to wheel contact surfaces.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Anti-seize greaseRYL105020L1

Data: Motorwise Workshop. Bulletin 5.

Glossary

Technical terms used in this guide.

VIN
Vehicle identification number — 17 characters, found at the base of the windscreen and on the V5C logbook
Nm
Newton-metres — the standard unit for how tightly a bolt is done up
ABS
Anti-lock braking system — stops the wheels locking under hard braking
Anti-Seize
Grease that stops mating parts (like a wheel on a hub) from corroding together
Hub Spigot
The raised centre of the hub that locates the wheel
Solenoid
An electrically operated valve or actuator
Wheel Speed Sensor
A sensor at each wheel used by ABS and stability control
Wiring Harness
The bundled cables that carry power and signals around the vehicle
Bushes
Rubber mountings that let a suspension or body joint move without metal-to-metal contact

Frequently asked questions

What are the common faults with the Land Rover Defender 2.5 TDI?

This guide contains nine workshop bulletins for the Land Rover Defender 2.5 TDI. Of these, two concern the engine and fuel system and two the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Land Rover Defender 2.5 TDI have these faults?

No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.

Can I check for Land Rover Defender 2.5 TDI faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.

Related guides

Glossary term

See in the glossary →