fuel cap LAND ROVER DEFENDER 1996 User Guide

09LUBRICANTS, FLUIDS AND CAPACITIES
4
INFORMATIONREV: 05/99 RECOMMENDED FUEL
300 Tdi Vehicles
Diesel fuel oil, distillate, diesel fuel, automotive gas or Derv to British standard 2869, Class A1 or A2. Using diesel
fuel with a lower class rating could seriously impair vehicle performance.
Td5 Vehicles
Refer to Defender Workshop Manual VDR 100350.
V8i Vehicles
Refer to Defender Workshop Manual LRL 0185.
FUEL TANK CAPACITY
Side tank:
90 models 54,6 litres (12 gallons)........................................................................
110 models * 68,2 litres (15 gallons)....................................................................
110 Station wagon 45,5 litres (10 gallons)...........................................................
* Except Station wagon
Rear tank:
110 and 130 models 79,5 litres (17,5 gallons).........................................................

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
5
MAINTENANCE REV: 05/99 CHECK COOLING, INTERCOOLING AND HEATING
SYSTEMS
Check cooling, and heater systems for leaks and
pipes/hoses for security and condition. Refill or top up
as necessary.
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.
WARNING: Do not remove caps and plugs
when engine is hot because cooling
system is pressurised and personal
scalding could result.
1.Remove plastic plugs from thermostat housing
and radiator.
2.Fill cooling system with correct concentration
and specification of anti-freeze.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
3.Fill from expansion tank until radiator is full, with
level in expansion tank the same as in radiator.
NOTE: Care should be taken to avoid
excess coolant spillage from radiator.
4.Fit plastic plug in radiator.
5.Add a further 1 litre (1.76 pints) of coolant to
expansion tank and allow to settle.
6.Refit expansion tank cap and thermostat
housing plug.
7.Run engine at idle speed for five minutes.
8.Switch off engine, check that expansion tank
coolant is level with top of indicator post and top
up as necessary.Check intercooler and turbo-charger system for air
leaks and pipes/hoses for security and condition.
All system hoses should be renewed at first signs of
deterioration.
VALVE CLEARANCES - CHECK/ADJUST
Check/adjust valve clearances.
See ENGINE ,
Adjustment, Valve clearances - check and adjust
RENEW FUEL FILTER ELEMENT
Remove
1.Clean area around filter head and position a
container beneath.
2.Unscrew and remove filter, catch fuel released.
Refit
3.Wet seal of new filter with fuel.
4.Screw new filter into position.
5.Ensure drain tap is fully closed.

10MAINTENANCE
8
MAINTENANCE CHECK/TOP UP BRAKE FLUID RESERVOIR
WARNING: DO NOT drive the vehicle with
the fluid level below 'MIN' mark.
Brake fluid will damage painted surfaces; clean up
any spillage immediately and rinse with plenty of
water.
If brake fluid should come into contact with skin
or eyes, rinse immediately with plenty of water.
1.Check the fluid level visually through transparent
side of reservoir without removing cap.
2.If level is below 'MAX' mark clean and remove
reservoir cap.
3.Top up to 'MAX' mark with recommended brake
fluid
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
CHECK/TOP UP WASHER RESERVOIR
Top up washer reservoir to within 25 mm (1.0 in) of
filler neck. Use a screen washer solvent/anti-freeze
solution to assist removing mud, flies, and road film
and protect against freezing.
LUBRICATE ACCELERATOR LINKAGES
Lubricate accelerator cable at adjustment ferrule and
linkage with injector pump and at pedal clevis pin.CHECK/ADJUST ENGINE IDLE SPEED
Check/adjust low and high engine idle speed with
engine at normal running temperature.
See FUEL
SYSTEM, Adjustment, low and high idle speed
adjustment
CHECK/ADJUST STEERING BOX
Check steering box and pipes/hoses for fluid leaks.
Check that there is no backlash in steering box when
in straight ahead position. Adjust steering box if
necessary.
See STEERING, Adjustment, Power
steering box
VISUALLY CHECK INTERCOOLER/RADIATOR
FOR EXTERNAL OBSTRUCTIONS
Check intercooler/radiator for external obstructions. If
necessary, apply air pressure to engine side of matrix
to clear obstruction. If mud or dirt is evident, carefully
use a hose to wash away obstruction.
FLUSH DIESEL INTERCOOLER
Remove
1.Remove intercooler matrix.
See FUEL
SYSTEM, Repair, Intercooler
2.Flush matrix with ICI 'GENKLENE' proprietary
cleaner, following manufacturers instructions.
3.Dry intercooler completely ensuring that no liquid
remains in matrix.
Refit
4.Refit intercooler matrix.
See FUEL SYSTEM,
Repair, Intercooler

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.

ENGINE
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine block
Bearing cap 133...............................................................................................
Blanking plug, oil gallery, rear 37....................................................................
Oil squirt jet assembly 17................................................................................
Drain plug, cylinder block 25...........................................................................
Oil squirt jet, vacuum pump cam 7.................................................................
Connecting rod to cap 59................................................................................
Oil pick up assembly to bearing cap 9...........................................................
Oil pick up assembly to front cover 25............................................................
Camshaft thrust plate 9..................................................................................
Oil drain pipe to block (internal) 25.................................................................
Oil drain pipe to block (external) 25................................................................
Sump to cylinder block and front cover 25......................................................
Drain plug, oil sump 35...................................................................................
Tappet guide 14..............................................................................................
Breather side cover assembly 25....................................................................
Baffle plate to breather side cover 4..............................................................
Vacuum pump 25............................................................................................
Fuel lift pump 25.............................................................................................
Flywheel housing 45.......................................................................................
Flywheel housing clutch cover stud 10...........................................................
Plug, flywheel housing 12...............................................................................
Rear oil seal assembly 25...............................................................................
Oil filter adaptor 45..........................................................................................
Waxstat adaptor to oil filter adaptor 9............................................................
Oil pressure switch 17.....................................................................................
Oil filter, spin on 13.........................................................................................
Oil cooler unions to filter adaptor 45...............................................................
Oil level tube 25..............................................................................................
Engine mounting foot to cylinder block 85......................................................
Engine mounting foot to flywheel housing 45.................................................
Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................
Flywheel to crankshaft 146..............................................................................
Clutch cover plate to flywheel 34....................................................................
Flex drive plate to crankshaft (auto) 146..........................................................
Flex drive plate to ring gear (auto) 25.............................................................
Flex drive plate to torque converter (auto) 45.................................................

FUEL SYSTEM
1
DESCRIPTION AND OPERATION DESCRIPTION
Fuel system
The fuel system incorporates a supply and spill return
line on all models as illustrated below.
On 90 models, see J6191, the fuel tank is mounted at
the RH side of the vehicle chassis under the front
seat.On standard 110 and 130 models the fuel tank is
located at the rear of the vehicle between the chassis
longitudenal sections, as shown in J6192.
As an option, a twin tank system fitted with a
combined change-over tap and 3 way fuel supply and
return system, can be installed on both 110 and 130
models, see J6193.
The tank/s on all vehicles is vented by a 2 way valve
in the filler cap.
FUEL SYSTEM LAYOUT
1.Fuel tank
2.Fuel sedimentor, if fitted
3.Fuel lift pump
4.Fuel filter5.Fuel injection pump
6.Spill return line
7.Fuel injectors

19FUEL SYSTEM
4
DESCRIPTION AND OPERATION
110/130 TWIN TANK FUEL SYSTEM - 5 DOOR
VEHICLES
1.Fuel filter
2.Supply pipe, lift pump to filter
3.Supply pipe, filter to injection pump
4.Fuel injection pump
5.Fuel lift pump
6.Spill return pipe, injection pump to change-over
tap
7.Supply pipe, fuel tank change-over tap to lift
pump
8.Spill return pipe, change-over tap to side tank
9.Change-over tap, spill return
10.Fuel filler cap
11.Side fuel tank12.Supply pipe, side tank to sedimentor
13.Sedimentor, if fitted, side tank
14.Supply pipe, sedimentor to fuel tank
change-over tap
15.Change-over tap, side and rear tanks
16.Supply pipe, rear sedimentor to fuel tank
change-over tap
17.Spill return pipe, change-over tap to rear tank
18.Rear fuel tank
19.Fuel filler pipe
20.Breather pipe
21.Supply pipe, rear tank to sedimentor
22.Sedimentor, if fitted, rear tank
NOTE: If sedimentors are not fitted, the
fuel supply pipe from the side and rear
tanks connects directly to the fuel tank
change-over tap.

FUEL SYSTEM
1
REPAIR FUEL INJECTION PUMP
Service repair no - 19.30.07
Remove
1.Disconnect battery.
2.Disconnect and remove high pressure fuel
injection pipes, pump to injectors.
3.Viewing valve mechanism through oil filler cap
aperture, turn crankshaft clockwise until No. 1
cylinder is just before TDC.
4.Remove blanking plug from flywheel housing
and fit timing toolLRT-12-044, locating centre
pin on flywheel.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
adjustments or 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
or
See CHASSIS AND BODY, Repair, Rear undertray
5.Carefully rotate crankshaft clockwise until centre
pin engages with timing slot in flywheel.
6.Remove injection pump access plate, complete
with gasket, from front cover plate.
7.Fit pin fromLRT-12-045to injection pump gear.
8.Restrain pulley nut to prevent straining timing
belt and remove drive gear to pump hub fixing
bolts and retaining plate.
9.Remove pin from pump gear.
10.Fit gear retaining toolLRT-12-045with an 8 mm
washer, 1,5 - 2 mm thick, under each bolt head
in addition to the existing washer.
11.Remove throttle cable and hand throttle cable, if
fitted.
12.Disconnect lead from fuel cut-off solenoid, and
EGR throttle position sensor multi-plug, if fitted.