fuel LAND ROVER DEFENDER 1996 Owner's Guide

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
20
REPAIR OIL FILTER HEAD GASKET
Service repair no - 12.60.03
Remove
1.Clean filter head adaptor.
2.Disconnect oil cooler pipes and plug to prevent
ingress of dirt.
3.Disconnect oil pressure switch lead.
4.Remove 4 bolts and withdraw filter head,
complete with gasket.
5.Clean mating faces of filter head and cylinder
block.
6.Fit head with new gasket.
7.Tighten bolts to
45 Nm (33 lbf/ft).
8.Reconnect oil pressure switch lead.
9.Reconnect oil cooler pipes.CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery
2.Remove bonnet.
3.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
4.Remove air cleaner.See FUEL SYSTEM,
Repair, Air cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove fuel injectors and pipes.
See FUEL
SYSTEM, Repair, Fuel injectors
7.Remove heater plugs.See FUEL SYSTEM,
Repair, Heater plugs
8.Disconnect radiator top hose from thermostat.
9.Disconnect bleed hose at thermostat.
10.Disconnect water pump hose at thermostat.
11.Disconnect water temperature sensor lead.

ENGINE
23
REPAIR
43.Check and adjust valve clearances.
See Adjustment, Valve clearances - check
and adjust
44.Fit rocker cover, ensuring oil seal is satisfactory
for continued use, and renew if necessary.
45.Secure rocker cover with special seal washers
and nuts. Tighten to
10 Nm (7 lbf/ft).
46.Fit rear engine lifting bracket, securing breather
pipe and multi-plug retaining clips. Tighten fixing
bolts to
25 Nm (18 lbf/ft).
47.Fit engine harness bracket to cylinder head.
48.Secure air cleaner mounting bracket to support
strut.
49.Connect heater hose to rear of cylinder head.
50.Position heater rail and connect hose from water
pump.
51.Fit exhaust manifold and turbocharger assembly.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust manifold
52.Fit induction manifold.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Induction
manifold
53.Connect water temperature sensor lead.
54.Connect water pump hose at thermostat.
55.Fit bleed hose at thermostat.
56.Connect radiator top hose at thermostat.
57.Fit heater plugs.
See FUEL SYSTEM, Repair,
Heater plugs
58.Fit fuel injectors.See FUEL SYSTEM, Repair,
Fuel injectors
59.Fit crankcase ventilation valve and side breather
hose.
60.Fit air cleaner.
See FUEL SYSTEM, Repair,
Air cleaner
61.Refill cooling system.See COOLING SYSTEM,
Repair, Drain and refill cooling system
62.Fit bonnet.
63.Reconnect battery.OIL PUMP
Service repair no - 12.60.26
Remove
1.Remove engine front cover.
See Front cover
gasket
2.Remove 7 screws and release oil pump retaining
plate from engine front cover.
3.Mark oil pump inner gear rotor, outer gear rotor
and front cover housing for reassembly.
4.Check for rotor clearances:
Outer rotor to housing, 0,025 - 0,075 mm (0.010
- 0.030 in).
Inner rotor to outer rotor, 0,025 - 0,075 mm
(0.010 - 0.030 in).
Rotor end float, 0,026 - 0,135 mm (0.010 - 0.054
in).
5.Remove inner and outer rotors.
6.Check condition of oil pump components.
NOTE: If the oil pump seating in the front
cover or retaining plate is badly worn,
pitted or scored, a new front cover must
be fitted.
See Front cover gasket
Always renew oil pump rotors as a pair.
7.Clean sealant from pump retaining plate and
front cover.

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

12ENGINE
2
SPECIFICATIONS, TORQUE REV: 05/99Nm
Cylinder head
Cylinder head to cylinder block
M10 x 117 40 Nm + 60° ..........................................................................................
M12 x 100 40 Nm + 60° ..........................................................................................
M12 x 140 40 Nm + 60°+20° ......................................................................................
Stub pipe heater feed 22.................................................................................
Water temperature sensor 14.........................................................................
Blanking plug cylinder head 14.......................................................................
Engine lifting brackets 25................................................................................
Electrical harness clip bracket 25...................................................................
Exhaust manifold stud 10................................................................................
Exhaust manifold nut 45.................................................................................
Inlet manifold stud 8.......................................................................................
Inlet manifold nut and bolt 25..........................................................................
Air temperature sensor, inlet manifold 14.......................................................
Blanking plug, inlet manifold 14......................................................................
Heatshield to inlet manifold 6.........................................................................
Glow plug 20...................................................................................................
Glow plug terminal nut 2................................................................................
Injector clamp (stud) 8...................................................................................
Injector clamp (nut) 25....................................................................................
Thermostat housing 25...................................................................................
Water outlet elbow to thermostat housing 25..................................................
Water temperature switch, thermostat housing 11..........................................
Plug thermostat housing 6.............................................................................
Rocker shaft pedestal bolt 5 Nm + 50° ..................................................................
Rocker cover (stud) 8.....................................................................................
Rocker cover (fixing nut) 10............................................................................
Breather cyclone to rocker cover 9................................................................
Tappet adjusting nut 16..................................................................................
Front cover to cylinder block 25......................................................................
Front cover plate to front cover 25..................................................................
Static idler - timing belt (stud) 10.....................................................................
Static idler - timing belt (nut) 45......................................................................
Tensioner (timing belt) 45...............................................................................
Camshaft hub bolt 80......................................................................................
Timing pulley to camshaft hub 25...................................................................
Fuel injection pump (stud) 8...........................................................................
Fuel injection pump (nut) 25...........................................................................
Abutment bracket to injection pump 25...........................................................
Support bracket injection pump to cylinder block 25.......................................
Fuel injection pump access plate to front cover plate 25................................
Timing pulley to injection pump hub 25...........................................................
TV Damper pulley bolt to crankshaft 80 Nm + 90° ..................................................
Fan pulley to hub 25.......................................................................................
Fan and viscous coupling to hub 45...............................................................
Auto tensioner, auxiliary drive (stud) 14..........................................................
Auto tensioner, auxiliary drive (nut) 45...........................................................
Auxiliary mounting bracket to cylinder block (stud) 8.....................................
Auxiliary mounting bracket to cylinder block (bolt and nut) 25........................
Water pump to block and mounting plate 25..................................................
Water pump pulley to hub 25..........................................................................

ENGINE
3
SPECIFICATIONS, TORQUENm
Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Starter motor (bolt and nut) 45........................................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................
Generator to auxiliaries mounting bracket 25.................................................
Tachometer electrical connection 4...............................................................

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
2
DESCRIPTION AND OPERATION A mechanical lift pump, with a hand priming facility, is
driven by the camshaft, and is mounted on the RH
side of the engine.
A fuel filter, with a replaceable element and
incorporating a water separator, is mounted on the
front RH side of the engine compartment.
A fuel sedimentor may be fitted when the vehicle is
operating in more arduous conditions, and is used to
minimise water deposits in the fuel system before
reaching the fuel pump and filter.
Fuel injection is carried out by a Bosch direct injection
pump, incorporating a cold start advance unit and a
high idle setting. The pump is mounted on the RH side
of the engine and is driven directly by gears in the
front cover from the crankshaft. The pump meters and
distributes fuel to 4 pintle type injectors located in
pre-combustion chambers in the cylinder head. Four
heater plugs, located in the cylinder head directly
below each injector, are fitted to improve cold starting.
An optional hand throttle, for use with a centre power
take off, is located on the fascia to the LH side of the
fuse box, and is linked independently to the fuel
injection pump throttle lever.
Air intake
The air cleaner is mounted on the RH side of the
engine and is connected by hoses to the cold air
intake duct and turbocharger inlet. Fitted between the
air cleaner and turbocharger is the crankcase breather
hose which connects to a breather filter on the rocker
cover.
A single stage turbocharger, fitted between the
exhaust manifold and exhaust down pipe, is
connected by hoses to the air cleaner and an
intercooler which is mounted on the LH side of the
radiator. The intercooler is connected by a hose to the
inlet manifold. When an EGR valve is fitted to the
turbocharger, additional pipes/hoses are used to
connect the components.Exhaust gas recirculation (EGR), when fitted.
Exhaust gas recirculation is controlled by an ECU
mounted under the front centre seat or cubby box and
receives the following inputs:
·Engine temperature from coolant temperature
sender unit on LH side of cylinder head.
·Throttle position from potentiometer on injection
pump.
·Engine speed from speedometer.
When all correct signals are received, the EGR
solenoid allows vacuum to open EGR valve and
recirculate a portion of the exhaust gas. See J6196 for
the EGR system component location and 'Operation'
for full system function.

FUEL SYSTEM
3
DESCRIPTION AND OPERATION
90 FUEL SYSTEM
110 FUEL SYSTEM
1.Fuel filter
2.Supply pipe, lift pump to filter
3.Supply pipe, fuel filter to injection pump
4.Fuel injection pump
5.Fuel lift pump
6.Spill return pipe, injection pump to tank7.Supply pipe, sedimentor to fuel pump
8.Fuel tank
9.Supply pipe, fuel tank to sedimentor
10.Fuel filler pipe
11.Breather pipe
12.Sedimentor, if fitted
NOTE: If a sedimentor is not fitted, the fuel
supply pipe from the tank will connect
directly to the fuel lift pump.

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.