engine LAND ROVER DEFENDER 1996 Repair Manual

12ENGINE
18
REPAIR FLYWHEEL HOUSING
Service repair no - 12.53.01
Remove
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 3 fixings and withdraw starter motor.
6.Remove 2 bolts from top of flywheel housing.
7.Remove 4 bolts securing bottom of flywheel
housing to engine mounting brackets.
8.Remove inner bolts and lift off flywheel housing.Refit
9.Clean rear face of housing and mating face on
block, ensuring all old sealant is removed.
10.Apply sealant to flywheel housing mating face on
cylinder block.
11.Fit housing to cylinder block. Tighten retaining
bolts to
45 Nm (33 lbf/ft).
12.Remove surplus sealant from block.
13.Fit starter motor.
14.Fit flywheel.
See Flywheel
15.Fit clutch.See CLUTCH, Repair, Clutch
assembly
16.Fit gearbox.See MANUAL GEARBOX, Repair,
R380 gearbox
17.Reconnect battery.

ENGINE
19
REPAIR OIL FILTER
Service repair no - 12.60.01
Remove
1.Place drain tray under oil filter.
2.Unscrew filter anti-clockwise, using a strap
wrench, if necessary.
Refit
3.Clean mating face of oil filter adaptor.
4.Coat rubber sealing ring of new filter with clean
engine oil.
5.Screw on filter until sealing ring touches
machined face, then tighten a further half turn by
hand only. DO NOT over tighten.OIL TEMPERATURE CONTROL VALVE
Service repair no - 12.60.69
Remove
1.Clean adaptor housing.
2.Disconnect oil cooler feed pipe from thermostat
extension housing and plug to prevent ingress of
dirt.
3.Remove 2 bolts and carefully withdraw
thermostat extension housing (1) complete with
'O' ring seal (2), thermostat (3), 2 washers (4)
and spring (5).
4.Inspect all parts and renew as necessary.
Refit
5.Fit thermostat to extension housing ensuring pin
locates in hole.
6.Fit two washers and spring to thermostat.
7.Fit a new 'O' ring to extension housing.
8.Insert spring into adaptor and secure extension
housing to adaptor. Tighten bolts to
9Nm(7
lbf/ft).

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
21
REPAIR 12.Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Induction
manifold
13.Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust manifold
14.Disconnect heater hose from water pump and
move heater rail aside.
15.Disconnect heater hose from rear of cylinder
head.
16.Remove bolt securing air cleaner mounting
bracket to support strut.
17.Remove bolt securing harness bracket to
cylinder head.
18.Remove rear engine lifting bracket. This will also
release clips securing transmission and engine
breather pipes and multi-plug. Note loose spacer
beneath inner clip.
19.Unscrew 3 bolts, with sealing washers and
remove rocker cover.
20.Remove 3 nuts and 2 bolts and lift rocker shaft
assembly from cylinder head.
21.Remove push rods and store as an identified set
to allow refitment to same location.
22.Remove valve stem caps.
23.Evenly slacken and then remove cylinder head
to block retaining bolts in the sequence shown in
J6157. Two of the bolts also secure the air
cleaner mounting bracket.
24.Lift off cylinder head and remove gasket.
Refit
25.Thoroughly clean mating faces of cylinder block
and head.
26.Select new gasket of correct thickness.
CAUTION: Three gaskets, of different
thicknesses, are available and can be
identified by the number of small holes
punched in the RH side of the gasket. One hole
identifies the thinnest gasket, two holes the
middle thickness and three holes the thickest.
When renewing a gasket it must be of the same
thickness as the one removed.
27.Position gasket on cylinder block with
identification holes on RH side and TOP
identification mark uppermost.

12ENGINE
22
REPAIR
28.Lower cylinder head onto block ensuring correct
location with dowels.
NOTE: Cylinder head retaining bolts can
be used up to a maximum of five times.
29.Lubricate threads of bolts with light oil and fit to
positions shown below. (Fit air cleaner mounting
bracket at positions 6 and 14).
Bolt sizes:
M10 x 117mm locations 3, 5, 12, and 13.
M12 x 140mm locations 1, 2, 7, 8, 9, 10, 15, 16, 17,
and 18.
M12 x 100mm locations 4, 6, 11, 14.
30.Tighten bolts so that underside of heads just
make contact with cylinder head.
31.Following the sequence indicated, tighten all
bolts to
40 Nm (30 lbf/ft).
32.Attach angle gaugeLRT-12-007.
33.Make a suitable pointer from welding rod and
attach to a bolt screwed into a rocker shaft
securing bolt hole.
34.Tighten all bolts through 60°strictly in sequence
illustrated.
35.Repeat 60°tightening procedure, again strictly in
sequence illustrated.
36.Tighten the 10 longer bolts (M12 x 140mm) a
further 20°, again following the sequence
illustrated.
NOTE: Repositioning of the pointer will be
necessary to reach all bolts, the pointer
can be fitted to the rocker shaft securing
studs using 2 nuts.
CAUTION: The double tightening
procedure MUST be carried out, on no
account should the bolt tightening be
performed in one operation, otherwise damage to
the cylinder head may occur.
37.Fit valve stem caps.
38.Fit push rods to locations from which they were
removed.
39.Position rocker shaft assembly over locating
studs and fit retaining nuts and bolts, but do not
tighten at this stage.
40.Attach angle gaugeLRT-12-007.
41.Make a suitable pointer and attach to one of the
rocker shaft locating studs.
42.Tighten all fixings in turn to
5 Nm (4 lbf/ft).Then
tighten a further 50°in same sequence.
NOTE: Repositioning of the pointer will be
necessary to reach all fixings.

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.

12ENGINE
24
REPAIR Refit
8.Fit oil pump rotors in front cover.
9.Apply a bead of RTV sealant around retaining
plate.
10.Fit oil pump retaining plate to front cover,
securely tighten screws.
11.Fit front cover to cylinder block.
See Front
cover gasket
OIL PRESSURE RELIEF VALVE
Service repair no - 12.60.56
Remove
1.Remove engine oil sump.
See Engine oil
sump
2.Unscrew relief valve retaining plug from base of
front cover.
3.Withdraw valve spring and plunger and check for
wear.
Valve spring free length, 68.00 mm (2.68 in).
NOTE: If the valve plunger sleeve is badly
worn, pitted or scored, a new front cover
must be fitted.
See Front cover gasket
Always renew valve spring and plunger as a pair.
Refit
4.Insert valve plunger and spring into sleeve in
front cover and secure with retaining plug.
5.Fit engine oil sump.
See Engine oil sump

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