service LAND ROVER DEFENDER 1996 Owner's Manual

12ENGINE
6
REPAIR 42.Raise engine, and locate front engine mountings
to chassis.
43.Remove gearbox support and lower engine.
44.Tighten front engine mounting to chassis fixings
to
45 Nm (33 lbf/ft).
45.Release chains from engine lifting brackets and
remove hoist.
46.Connect oil cooler pipes to oil filter adaptor.
47.Fit vacuum hose to brake servo adaptor.
48.Secure fuel feed pipe in retaining clip on air
cleaner bracket.
49.Fit fuel lift pump pipes.
50.Connect feed and spill return pipes to injector
pump.
51.If fitted, reconnect hand throttle cable to
mounting bracket and injector pump.
52.Fit outer cable adjusting nut into injector pump
mounting bracket.
53.Fit inner throttle cable to injector pump and
secure with clevis and split pin.
54.Secure bleed hose in retaining clips on front
timing cover.
55.Fit bleed hose to thermostat housing.
56.Connect inlet and outlet hoses to power steering
pump.
57.Fit down pipe to exhaust manifold and secure
with 3 nuts.
58.Connect starter motor battery and fuse box
leads.
59.If fitted, connect EGR valve multi-plug and
vacuum pipe.
60.Secure breather pipe clip to cylinder head.
61.Connect engine harness multi-plug.
62.Fit heater plug feed wire.
63.Connect electrical feed plug at rear of cylinder
head.
64.Fit heater hoses to cylinder head and heater
rails.
65.Fit feed pipe/hose to turbo-charger and
intercooler.
66.Fit rocker cover insulation.
67.Fit radiator assembly.
See COOLING SYSTEM,
Repair, Radiator
If applicable, fit air
conditioning condenser, compressor pipes and
heater matrix hoses.
See AIR CONDITIONING,
Repair, Condenser
68.Fit bonnet.
69.Reconnect battery.CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1.Disconnect battery.
2.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
coupling and fan
6.Remove fan cowl.See COOLING SYSTEM,
Repair, Fan cowl
7.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
8.Fit crankshaft pulley retainerLRT-12-080and
secure with 4 bolts.
9.Remove crankshaft pulley retaining bolt
anti-clockwise using socket and suitable long
bar.
10.Remove pulley retainer.
11.Remove pulley, if necessary using extractor
LRT-12-049with thrust pad fromLRT-12-031.

ENGINE
7
REPAIR Refit
12.Lightly grease pulley spigot and locate pulley
onto cranshaft.
13.Fit pulley retaining bolt.
14.Fit pulley retainerLRT-12-080and secure with 4
bolts.
15.Tighten pulley nut to
80 Nm (59 lbf/ft)+90°.
16.Remove pulley retainer.
17.Fit drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt; Refit
18.Fit fan cowl.See COOLING SYSTEM, Repair,
Fan cowl
19.Fit viscous coupling and fan.See COOLING
SYSTEM, Repair, Viscous coupling and fan
20.Fit intercooler to induction manifold hose.
21.Fit radiator top hose.
22.Refill cooling system.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
23.Reconnect battery.FRONT COVER PLATE AND SEAL
Service repair no - 12.65.01
Remove
1.Disconnect battery.
2.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
coupling and fan
6.Remove fan cowl.See COOLING SYSTEM,
Repair, Fan cowl
7.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
8.Remove crankshaft pulley.See Crankshaft
pulley
9.Remove 14 bolts securing front cover plate. Note
that top 2 bolts also retain thermostat hose clips.
10.Remove cover plate complete with gasket.
11.Remove small gasket from centre bolt boss.
Seal replacement
12.Remove worn seal from cover and clean recess.
13.Support cover and fit new seal, open side fitted
into recess, using special toolLRT-12-077.

12ENGINE
8
REPAIR Refit
14.Fit gasket to centre bolt boss.
15.Locate new gasket and fit front cover plate using
fixing bolts as shown. Tighten bolts to
25 Nm (18
lbf/ft).
1- 25 mm,2- 35 mm,3- 50 mm,4- 100 mm,5- 110
mm
16.Fit crankshaft pulley.
See Crankshaft pulley
17.Fit drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
18.Fit fan cowl.See COOLING SYSTEM, Repair,
Fan cowl
19.Fit viscous coupling and fan.See COOLING
SYSTEM, Repair, Viscous coupling and fan
20.Fit intercooler to induction manifold hose.
21.Fit top hose to radiator.
22.Refill cooling system.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
23.Reconnect battery.CAMSHAFT DRIVE BELT
Service repair no - 12.65.18
Remove
1.Remove front cover plate.
See Front cover
plate
2.Position engine at TDC on No. 1 cylinder.
3.Remove blanking plug from flywheel housing
and insert timing toolLRT-12-044.
4.Engage timing tool pin with slot in flywheel.
5.Check correct alignment of timing mark on
camshaft gear and that crankshaft key aligns
with cast arrow on housing.
6.Insert pin from special toolLRT-12-045in
injection pump gear and through into pump
flange.

12ENGINE
10
REPAIR 17.Slacken belt tensioner securing bolt to finger
tight.
18.Insert 13 mm square drive extension bar in
tensioner plate.
NOTE: Belt tensioning should be carried
out using a dial type torque meter having a
range not exceeding
60 Nm (44 lbf/ft).The
torque meter should be used in the almost vertical
position.
19.Apply a tension of
15 Nm (11 lbf/ft)for a new
belt or
12 Nm (9 lbf/ft)for an original belt. When
tension is correct, tighten clamp bolt.
20.Tighten injection pump gear bolts.
21.Remove pin from injection pump gear.
22.Disengage timing pin from timing slot in flywheel
or ring gear.
23.Rotate crankshaft one and three quarter turns in
a clockwise direction; then continue rotation until
timing pin in timing tool can be engaged with slot
in flywheel.
24.Disengage timing pin.
25.Insert pin from special toolLRT-12-045in
injection pump gear and through into pump
flange.
26.Slacken injection pump gear retaining bolts.
27.Slacken tensioner and retension belt.
28.Tighten injection pump gear retaining bolts.
29.Remove pin from injection pump gear.
30.Remove timing tool and refit plug.
31.Fit front cover plate using new gaskets.
See Front cover plate and seal
CRANKSHAFT GEAR
Service repair no - 12.65.25
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.If the crankshaft gear cannot be removed by
hand, use special toolLRT-12-078with main
body and thrust button from special tool
LRT-12-031, as illustrated . Withdraw gear
complete with 'O' ring seal.
Refit
3.Lubricate new 'O' ring seal with petroleum jelly
and slide onto crankshaft, taking care not to
damage seal on woodruff keys.
4.Fit crankshaft gear and tap fully home ensuring
'O' ring seal is properly seated.
5.Fit camshaft drive belt.
See Camshaft drive
belt

ENGINE
11
REPAIR CRANKSHAFT OIL SEAL
Service repair no - 12.21.14
Remove
1.Remove crankshaft gear.
See Crankshaft gear
2.Prise out oil seal from front cover.
Refit
3.Lubricate a new crankshaft oil seal with clean
engine oil.
4.With lip side leading, drive in seal squarely using
special toolLRT-12-079.
5.Fit crankshaft gear.
See Crankshaft gear
CAMSHAFT GEAR
Service repair no - 12.65.24
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.Remove centre bolt and withdraw camshaft
gear, complete with hub and retaining plate.
Refit
3.Fit camshaft gear. Tighten bolt to
80 Nm (59
lbf/ft).
4.Fit camshaft drive belt.See Camshaft drive
belt

12ENGINE
12
REPAIR CAMSHAFT OIL SEAL
Service repair no - 12.13.05
Remove
1.Remove camshaft gear.
See Camshaft gear
2.Remove camshaft oil seal from front cover using
special toolLRT-12-083.
Refit
3.Lubricate a new camshaft oil seal with clean
engine oil.
4.With lip side leading, drive in seal squarely using
special toolLRT-12-082.
5.Fit camshaft gear.
See Camshaft gear
INJECTION PUMP GEAR
Service repair no - 19.30.06
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.Slacken 3 bolts on front of injector pump gear.
3.Remove special tool pin from gear.
4.Remove 3 bolts and withdraw gear and retaining
plate.
Refit
CAUTION: It is important to ensure that
when the injection pump is locked no
attempt must be made to rotate it. Take
care not to allow the crankshaft to be turned.
5.Fit gear and retaining plate. Tighten bolts to
25
Nm (18 lbf/ft).
6.Insert pin from special toolLRT-12-045in
injection pump gear and through into pump
flange.
7.Fit camshaft drive belt.
See Camshaft drive
belt

ENGINE
13
REPAIR FRONT COVER GASKET
Service repair no - 12.65.10
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.Remove crankshaft gear.See Crankshaft gear
3.Remove camshaft gear.See Camshaft gear
4.Remove injection pump gear.See Injection
pump gear
5.Remove fuel injection pump.See FUEL
SYSTEM, Repair, Fuel injection pump
6.Remove engine oil sump.See Engine oil
sump
7.Remove oil pick up strainer.See Oil pick-up
strainer
8.Remove 10 bolts securing timing gear housing to
block.
9.Withdraw timing gear housing complete with
gasket.
10.Clean all gasket material from mating faces.
Refit
11.Fit slave guide studs to locate gasket.
12.Fit new gasket to cylinder block.
13.Align flats on oil pump with flats on crankshaft.
14.Fit front cover to block taking care not to damage
oil seal.15.Secure with bolts of correct length in locations
where slave studs are not fitted, see J6149.
16.Remove slave studs and fit correct length bolts.
17.Tighten all bolts to
25 Nm (18 lbf/ft).
1- 25 mm,2- 35 mm,3- 80 mm.
18.Fit oil pick-up strainer.
See Oil pick-up
strainer
19.Fit oil sump.See Engine oil sump
20.Fit fuel injection pump.See FUEL SYSTEM,
Repair, Fuel injection pump
21.Fit injection pump gear.See Injection pump
gear
22.Fit camshaft gear.See Camshaft gear
23.Fit crankshaft gear.See Crankshaft gear
24.Fit camshaft drive belt.See Camshaft drive
belt

12ENGINE
14
REPAIR ENGINE OIL SUMP
Service repair no - 12.60.44
Remove
1.Disconnect battery.
2.Drain engine oil.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
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
orSee CHASSIS AND BODY, Repair,
Rear undertray
3.Slacken sump securing bolts.
4.Break sealant around sump flange, using a
sharp knife.
5.Remove 22 bolts and withdraw sump.
Refit
6.Clean mating faces of sump, timing gear housing
and cylinder block.
7.Apply a 2,0 mm bead of 'Hylosil RTV102' to the
sump flange, ensuring bead is applied inboard of
the bolt holes.
8.Secure sump to block with 22bolts. Tighten to
25
Nm (18 lbf/ft).
9.Refill engine oil.See LUBRICANTS, FLUIDS
AND CAPACITIES, Information, Capacities
10.Reconnect battery.OIL PICK-UP STRAINER
Service repair no - 12.60.20
Remove
1.Disconnect battery.
2.Drain engine oil.
3.Remove engine oil sump.
See Engine oil
sump
4.Remove 2 bolts securing pipe support bracket to
main bearing cap fixings.
5.Remove bolts from pipe flanges.
6.Withdraw pick-up strainer assembly.
Refit
7.Postion pick-up strainer assembly, fitting a new
'O' ring seal at oil pump connection.
8.Apply Loctite 242E to threads of bolts at main
bearing cap. Fit bolts, tighten to
9 Nm (7 lbf/ft).
9.Fit bolts to pipe flanges. Tighten to25 Nm (18
lbf/ft).
10.Fit sump.See Engine oil sump
11.Reconnect battery.

ENGINE
15
REPAIR FLYWHEEL
Service repair no - 12.53.07
Remove
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Fit 2, long, 8 mm bolts into the clutch bolt holes,
as shown, to use as handles when lifting the
flywheel off the crankshaft.
5.Remove fan cowl.
See COOLING SYSTEM,
Repair, Fan cowl
6.Fit crankshaft pulley retainerLRT-12-080and
secure with 4 bolts, to restrain crankshaft while
removing flywheel retaining bolts.
7.Remove bolts and lift off flywheel.
Refit
NOTE: To prevent excessive flywheel
run-out, ensure that mating faces of
flywheel and crankshaft are clean.
8.Locate flywheel on crankshaft, remove lifting
bolts, and secure flywheel with new patched
retaining bolts, progressively tighten to
147 Nm
(108 lbf/ft).
9.Check the flywheel for possible run-out by
mounting a dial test indicator with the stylus in a
loaded condition resting on the flywheel face at a
radius of 114 mm (4.50 in) from the centre.
10.Turn flywheel and check that run-out does not
exceed 0,07 mm (0.003 in).
11.Should run-out be excessive, remove flywheel
and check again for irregularities on crankshaft
and flywheel mating faces and location dowel.
12.Remove crankshaft pulley retainer.
13.Fit fan cowl.
See COOLING SYSTEM, Repair,
Fan cowl
14.Fit clutch.See CLUTCH, Repair, Clutch
assembly
15.Fit gearbox.See MANUAL GEARBOX, Repair,
R380 gearbox
16.Reconnect battery.

12ENGINE
16
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing, the complete housing
assembly (1) must be renewed. Housing and seal
assemblies are supplied with their own
former/seal guide (2) already fitted. This former
must not be removed before fitting the assembly
to the engine. If a seal and housing assembly is
received without a former/guide fitted it must be
returned to the supplier. Used formers/guides
must be discarded immediately after use, under
no circumstances should they be reused on other
assemblies.
NOTE: A different rear oil seal housing,
with integral 'O' ring seal and gasket, was
fitted on earlier engines. They must be
replaced with the current housing and gasket (3)
shown below.
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Remove flywheel.See Flywheel
5.Remove 5 bolts and withdraw seal housing,
complete with gasket.
Refit
NOTE: The raised side of groove at the
bottom of seal housing gasket must be
fitted to cylinder block face.
6.Insert slave studs to locate seal housing gasket.
7.Position new gasket over slave studs and
crankshaft flange onto cylinder block.
8.Fit new seal housing assembly, with
former/guide in-situ, over crankshaft flange. This
action will eject former/guide.
9.Secure assembly to cylinder block, removing
slave studs individually and inserting bolts.
Tighten to
25 Nm (18 lbf/ft).
10.Refit flywheel.See Flywheel