clock LAND ROVER DEFENDER 1996 Workshop Manual

07GENERAL FITTING REMINDERS
6
INFORMATION FUEL SYSTEM HOSES
CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber outer
sleeve and an inner viton core. If any of
the fuel system hoses have been disconnected, it
is imperative that the internal bore is inspected to
ensure that the viton lining has not become
separated from the amoured outer sleeve. A new
hose must be fitted if separation is evident.
METRIC BOLT IDENTIFICATION
1.An ISO metric bolt or screw, made of steel and
larger than 6 mm in diameter can be identified by
either of the symbols ISO M or M embossed or
indented on top of the head.
2.In addition to marks to identify the manufacture,
the head is also marked with symbols to indicate
the strength grade, e.g. 8.8, 12.9 or 14.9, where
the first figure gives the minimum tensile
strength of the bolt material in tens of kgf/mm
2.
3.Zinc plated ISO metric bolts and nuts are
chromate passivated, a gold-bronze colour.METRIC NUT IDENTIFICATION
1.A nut with an ISO metric thread is marked on
one face or on one of the flats of the hexagon
with the strength grade symbol 8, 12 or 14.
Some nuts with a strength 4, 5 or 6 are also
marked and some have the metric symbol M on
the flat opposite the strength grade marking.
2.A clock face system is used as an alternative
method of indicating the strength grade. The
external chamfers or a face of the nut is marked
in a position relative to the appropriate hour
mark on a clock face to indicate the strength
grade.
3.A dot is used to locate the 12 O'clock position
and a dash to indicate the strength grade. If the
grade is above 12, two dots identify the 12
O'clock position.
KEYS AND KEYWAYS
1.Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to
refit key.
2.Clean and inspect key closely; keys are suitable
for refitting only if indistinguishable from new, as
any indentation may indicate the onset of wear.
TAB WASHERS
1.Fit new washers in all places where they are
used. Always fit a new tab washer.
2.Ensure that the new tab washer is of the same
design as that replaced.

MAINTENANCE
1
MAINTENANCE SERVICE SCHEDULE
The following section describes the items detailed in
the vehicle Service Schedule. Where required
instructions are given for carrying out the service
procedure, or a cross reference is given to the section
in the manual where the procedure may be found.
Service Maintenance Schedules are published
separately to reflect the needs and intervals for each
vehicle variant. Procedures in the Workshop Manual
must be used in conjunction with the Service
Schedule sheets.
Service Maintenance Schedules are available from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle,
Merseyside, L70 1JL
VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seat belts, seat belt
mountings, seat belt buckles and operation of inertia
seat belts.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear wipers and washers and
condition of wiper blades.CHECK OPERATION OF HANDBRAKE
Handbrake check/adjust
1.Chock road wheels.
2.Raise one rear wheel clear of ground and
support securely with axle stand.
3.Release handbrake lever.
4.Underneath vehicle, tighten adjuster bolt
clockwise to
25 Nm (18 lbf/ft)to fully lock brake
drum.
5.Slacken adjusting bolt by 1.5 turns to give brake
shoes running clearance. Check that the drum is
free to rotate.
6.Adjust handbrake cable locknuts to give pawl
two notches free movement on the rachet before
being fully operational on third notch of rachet.
NOTE: Cable adjustment must ONLY be
used for initial setting and to compensate
for cable stretch. It MUST NOT be used to
take up brake shoe wear, which MUST be adjusted
at brake drum.
7.Operate handbrake to settle brake shoes.
Recheck handbrake is fully operational on third
notch of rachet pawl. Readjust if necessary.
8.Remove axle stand and wheel chocks.

MAINTENANCE
9
MAINTENANCE REV: 05/99 UNDER VEHICLE MAINTENANCE
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
maintenance, 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
RENEW ENGINE OIL AND FILTER
1.Ensure vehicle is level.
2.Run engine to warm oil, switch off ignition.
3.Disconnect battery.
4.Place suitable drain tray under sump drain plug.
5.Remove drain plug from sump and allow oil to
drain completely.
6.Fit new sealing washer, replace plug and tighten
to
35 Nm (26 lbf/ft).
7.Place drain tray under oil filter.
8.Unscrew filter anti-clockwise, using a strap
wrench if necessary.
9.Clean mating face of oil filter adaptor.
10.Coat rubber sealing washer of new filter with
clean engine oil.
11.Screw filter on clockwise until sealing washer
touches adaptor mating face, tighten a further
half turn by hand only. DO NOT overtighten.
12.Clean and remove filler cap from rocker cover.
13.Pour in correct quantity and grade of new oil
from a sealed container.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
14.Check that oil level is between upper and lower
marks on dipstick. DO NOT fill above upper
mark.
15.Firmly replace filler cap.
16.Reconnect battery, run engine and check oil filter
for leaks.
17.Stop engine, allow oil to run back into sump for a
few minutes and check oil level again. Top up if
necessary.

ENGINE
1
ADJUSTMENT REV: 05/99 VALVE CLEARANCES - CHECK AND ADJUST
Service repair no - 12.29.48
Adjust
CAUTION: If the crankshaft is rotated with
excessive valve clearace, it is possible
that the push rods could be dislodged
from the cam follower seating and fracture the
cam follower slide. To prevent damage, eliminate
all clearance from any loose rockers before
turning the crankshaft to adjust clearances.
1.Rotate crankshaft until No.8 valve (counting from
front of engine) is fully open.
2.Using a 0,20 mm (0.008 in) feeler gauge adjust
clearance of No.1 valve.
3.Slacken locknut and turn adjusting screw
clockwise to reduce clearance and
anti-clockwise to increase clearance. Tighten
locknut to
16 Nm.
4.Repeat operation for remaining tappets in the
following sequence:
No.3 tappet with No.6 valve fully open.
No.5 tappet with No.4 valve fully open.
No.2 tappet with No.7 valve fully open.
No.8 tappet with No.1 valve fully open.
No.6 tappet with No.3 valve fully open.
No.4 tappet with No.5 valve fully open.
No.7 tappet with No.2 valve fully open.
5.On completion, recheck clearances and adjust
as necessary.

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.

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
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).

19FUEL SYSTEM
2
ADJUSTMENT LOW AND HIGH IDLE SPEED ADJUSTMENT
NOTE: The high idle speed (cold start idle)
is automatically set by the setting of the
low idle speed and cannot be adjusted
individually.
1.Check and adjust throttle cable.
See Throttle
cable
2.Start engine and run it until normal operating
temperature is reached.
3.Using a suitable tachometer, check the engine
idle speed,
See ENGINE TUNING DATA,
Information, 300Tdi
4.If adjustment is necessary, first slacken the
locknut on injection pump.
5.Turn adjustment screw clockwise to increase
engine speed or anti-clockwise to decrease the
speed. Run engine at an increased speed for a
few seconds then check idle speed again.
6.When correct speed has been achieved, hold
adjuster screw steady while tightening locknut.
NOTE: The low idle speed control is the
only permitted adjustment in service. Any
additional adjustments required must be
entrusted to authorised Bosch agents.THROTTLE PEDAL ADJUSTMENT
Adjust
1.First ensure that throttle cable is correctly
adjusted
See Throttle cable
2.Depress throttle pedal, by hand, to full extent of
injection pump lever travel. Slacken locknut and
adjust throttle pedal stop screw to take up
clearance between screw and bulkhead. Ensure
no strain is placed upon throttle cable and pump
lever.
3.Retighten locknut.

FUEL SYSTEM
3
ADJUSTMENT INJECTION PUMP TIMING - CHECK AND ADJUST
Service repair no - 19.30.01
1.Viewing the valve mechanism through oil filler
aperture, turn crankshaft clockwise until inlet
valve of No.1 cylinder has just closed. No.1
cylinder is now just before TDC.
2.Remove blanking plug from flywheel housing
and insert 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
3.Cearfully rotate crankshaft clockwise until centre
pin engages timing slot in flywheel.
4.Remove injection pump access plate, complete
with gasket, from front cover plate.
5.Fit locking pinLRT-12-045/2to injection pump
gear. If difficulty is experienced in inserting pin,
adjustments will be needed to correctly set
injection pump timing as follows:
6.Support injection pump retaining nut to prevent
strain on timing belt.
7.Slacken the 3 keeper plate retaining bolts.
8.Carefully turn fixing nut and keeper plate until
locking pin can be inserted, without restriction,
into injection pump gear.
9.Tighten keeper plate bolts to
25 Nm (18 lbf/ft)
and remove locking pin.
10.Refit injection pump access plate plate and
gasket.
11.Remove flywheel timing tool and refit blanking
plug.
12.Run engine until normal operating temperature is
reached and check that idle speed adjustment,
See low and high idle speed adjustmentand
throttle cable adjustment
See Throttle cable
are correct.

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.