oil pressure LAND ROVER DEFENDER 1996 Workshop Manual

04GENERAL SPECIFICATION DATA
2
INFORMATION Camshaft
Drive 30 mm wide dry toothed belt.................................................................................
Location Right hand side (thrust side)...........................................................................
End float 0,1 - 0,2 mm...........................................................................
Number of bearings 4..........................................................
Material Steel shell, white metal lined............................................................................
Valves
Tappet clearance:
- Inlet and exhaust 0,20 mm...................................................
Seat angle:
- Inlet 30° .......................................................................
- Exhaust 45° .................................................................
Head diameter:
- Inlet 38,75 - 39,05 mm.......................................................................
- Exhaust 36,35 - 36,65 mm.................................................................
Stem diameter:
- Inlet 7,960 - 7,975 mm.......................................................................
- Exhaust 7,940 - 7,960 mm.................................................................
Valve lift:
- Inlet 9,67 mm.......................................................................
- Exhaust 9,97 mm.................................................................
Cam lift:
- Inlet 6,81 mm.......................................................................
- Exhaust 7,06 mm.................................................................
Valve head stand down:
- Inlet 0,81 - 1,09 mm.......................................................................
- Exhaust 0,86 - 1,14 mm.................................................................
Valve springs
Type Single coil.................................................................................
Length, free 46,28 mm......................................................................
Length, under 21 kg load 40,30 mm.................................................
Lubrication
System Wet sump, pressure fed.............................................................................
Pressure, engine warm at normal operating speeds 1,76 - 3,87Kgf/cm
2(25 - 55 Ibf/in2) ........
Oil pump:
- Type G-rotor integral with front cover.......................................................................
- Drive off crankshaft nose.....................................................................
Oil pressure relief valve Non-adjustable....................................................
Relief valve spring:
- Full length 51,6mm......................................................................
- Compressed length at 7.71Kg load 31mm................................
Oil filter Screw-on disposable canister.............................................................................
Engine oil cooler Combined with coolant radiator and intercooler...............................................................

GENERAL SPECIFICATION DATA
3
INFORMATION FUEL SYSTEM
Fuel lift pump type Mechanical with hand primer............................................................
Fuel lift pump pressure 42 - 55 Kgf/cm
2(3 - 4 lbf/in2) at 1800 rpm .....................................................
Fuel filter Paper element in disposable canister..........................................................................
Air cleaner Paper element type........................................................................
COOLING SYSTEM
System type Pressurised, spill return, thermostatically controlled.....................................................................
water and anti freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler and
turbo intercooler.
Cooling fan 11 blade axial flow 433 mm diameter, 1.29:1 drive.......................................................................
ratio, with viscous coupling.
Pump type Centrifugal, impellor, belt driven........................................................................
Thermostat opening 88°C .........................................................
Expansion tank cap pressure 1,06 Kgf/cm
2(15 Ibf/in2) (system pressure) ...........................................
CLUTCH
Type Valeo diaphragm spring.................................................................................
Centre plate diameter 235 mm.......................................................
Facing material Verto F202 grooved.................................................................
Release bearing Ball journal...............................................................
TRANSMISSION
Main gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward, 1 reverse, all synchromesh.............................................................................
Transfer box
Type LT230 Two speed reduction on main gearbox output. Front......................................................................
and rear drive permanently engaged via a lockable
differential
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................

GENERAL FITTING REMINDERS
5
INFORMATION JOINTS AND JOINT FACES
1.Always use correct gaskets where they are
specified.
2.Use jointing compound only when
recommended. Otherwise fit joints dry.
3.When jointing compound is used, apply in a thin
uniform film to metal surfaces; take great care to
prevent it from entering oilways, pipes or blind
tapped holes.
4.Remove all traces of old jointing materials prior
to reassembly. Do not use a tool which could
damage joint faces.
5.Inspect joint faces for scratches or burrs and
remove with a fine file or oil stone; do not allow
removed material or dirt to enter tapped holes or
enclosed parts.
6.Blow out any pipes, channels or crevices with
compressed air, fit new 'O' rings or seals
displaced by air blast.FLEXIBLE HYDRAULIC PIPES, HOSES
1.Before removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
2.Obtain appropriate plugs or caps before
detaching hose end fittings, so that ports can be
immediately covered to exclude dirt.
3.Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any hose found faulty.
4.When refitting hose, ensure that no unnecessary
bends are introduced, and that hose is not
twisted before or during tightening of union nuts.
5.Containers for hydraulic fluid must be kept
absolutely clean.
6.Do not store brake fluid in an unsealed
container. It will absorb water, and fluid in this
condition would be dangerous to use due to a
lowering of its boiling point.
7.Do not allow brake fluid to be contaminated with
mineral oil, or use a container which has
previously contained mineral oil.
8.Do not re-use brake fluid bled from system.
9.Always use clean brake fluid to clean hydraulic
components.
10.Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of dirt.
11.Absolute cleanliness must be observed with
hydraulic components at all times.
12.After any work on hydraulic systems, inspect
carefully for leaks underneath the vehicle while a
second operator applies maximum pressure to
the brakes (engine running) and operates the
steering.

10MAINTENANCE
2
MAINTENANCE BATTERY CONNECTIONS
NOTE: The vehicle may be fitted with an
alarm and immobilisation system using a
battery backed-up alarm sounder.
See
ELECTRICAL, Repair, Battery
Disconnect battery leads, clean and grease with
petroleum jelly, including battery terminals.
CHECK OPERATION OF DOOR SWITCHES
When a Vehicle Immobilisation and Alarm System is
fitted it is important that all door and bonnet switches
operate correctly, otherwise perimeter and interior
protection may not function if a door or the bonnet is
opened.VEHICLE EXTERIOR
CHECK/ADJUST HEADLAMP ALIGNMENT
Check/adjust headlamp alignment.
CHECK ROAD WHEELS AND TYRES
Check road wheels for damage.
Check tyres, including spare, for compliance with
manufacture's specificaton.
Check visually for cuts, lumps, bulges, uneven tread
wear and tread depth.
See INTRODUCTION,
Information, wheels and tyres
Check/adjust tyre pressures.See WHEELS AND
TYRES, Repair, Tyres pressures
INSPECT BRAKE PADS FOR WEAR, CALIPERS
FOR LEAKS AND CONDITION OF DISCS
Check thickness of brake pads, and renew if thickness
is less than 3,00 mm (0.12 in). Check brake pads for
oil contamination and fit a new set, if necessary,
See
BRAKES, Repair, front brake pads
orSee
BRAKES, Repair, rear brake pads
WARNING: When renewing brake pads, it
is essential that only genuine components
with correct grade of lining are used.
Always fit new pads as complete axle sets, NEVER
individually or as a single wheel set. Serious
consequences could result from out of balance
braking due to mixing of linings.
CHECK FRONT WHEEL ALIGNMENT
Use recognised wheel alignment equipment to carry
out this operation.
See STEERING, Adjustment,
front wheel alignment
CHECK OPERATION OF ALL DOORS/TAILGATE,
BONNET AND LOCKS
LUBRICATE ALL DOOR/TAILGATE HINGES, AND
DOOR CHECK/LOCK MECHANISMS

10MAINTENANCE
14
MAINTENANCEREV: 05/99 ADDITIONAL MAINTENANCE SCHEDULES
Camshaft drive belt
The engine timing gears are driven by a toothed
rubber belt which must be renewed at intervals
determined by the severity of operating conditions. In
reasonable, temperate climate operation, the belt
should be renewed every 120,000 km (72,000 miles)
or every six years whichever occurs earlier.
In adverse operating conditions, such as work in dusty
atmospheres, high ambient temperatures, desert and
tropical zones, renew the belt every 60,000 km
(36,000 miles) or every three years, whichever occurs
earlier.
CAUTION: If the drive belt is not renewed
at the correct interval, it could fail,
resulting in serious engine damage.
Oil change diesel engines
If the vehicle is operated on fuel with a high sulphur
content (over 1%) the oil change intervals must not
exceed 5000 km (3000 miles).
Anti-freeze
At two yearly intervals or at the onset of the second
winter, the cooling system should be drained, flushed
and refilled with the required water and anti-freeze
solution.
Hydraulic brake fluid.
It is recommended that at 40,000 km (24,000 miles)
intervals or every two years, whichever is the earlier,
the hydraulic brake fluid should be completely
renewed.
At 80,000 km (48,000 miles) intervals or every four
years, whichever is the earlier, all hydraulic brake fluid
seals and flexible hoses should be renewed. All
working surfaces of the master cylinder and caliper
cylinders should be examined and renewed where
necessary.Air cleaner
When the vehicle is used in dusty or field conditions or
deep wading, frequent attention to the air cleaner may
be required.
Dampers
At 60,000 km (36,000 miles) intervals remove all
suspension dampers, test for correct operation, refit or
renew as necessary.
SPECIAL OPERATING CONDITIONS
When the vehicle is operated in extremely arduous
conditions or on dusty, wet or muddy terrain, more
frequent attention should be paid to all servicing
requirements.
Additional daily or weekly attention depending on
operating conditions:
Check/top-up transfer box oil.
Check steering rubber boots for security and
condition. Renew if damaged.
Check brake fluid level: Investigate cause if any fluid
loss is suspected.
Clean brake discs and calipers.
Lubricate front and rear propeller shaft
universal/sliding joints. Under tropical or severe
conditions, particularly where sand is encountered,
the sliding joints must be lubricated very frequently to
prevent ingress of abrasive material.
Every week and every maintenance inspection check
tyre pressures and inspect tyre treads and side walls.
Under arduous cross-country conditions the tyre
pressures should be checked much more frequently,
even to the extent of a daily check.
Monthly
Renew gearbox oil.
Renew transfer box oil.
Check air cleaner element and renew every 6 months
or as necessary.

MAINTENANCE
15
MAINTENANCE ADDITIONAL MAINTENANCE SCHEDULES
Camshaft drive belt
The engine timing gears are driven by a toothed
rubber belt which must be renewed at intervals
determined by the severity of operating conditions. In
reasonable, temperate climate operation, the belt
should be renewed every 120,000 km (72,000 miles)
or every six years whichever occurs earlier.
In adverse operating conditions, such as work in dusty
atmospheres, high ambient temperatures, desert and
tropical zones, renew the belt every 60,000 km
(36,000 miles) or every three years, whichever occurs
earlier.
CAUTION: If the drive belt is not renewed
at the correct interval, it could fail,
resulting in serious engine damage.
Oil change diesel engines
If the vehicle is operated on fuel with a high sulpher
content (over 1%) the oil change intervals must not
exceed 5000 km (3000 miles).
Anti-freeze
At two yearly intervals or at the onset of the second
winter, the cooling system should be drained, flushed
and refilled with the required water and anti-freeze
solution.
Hydraulic brake fluid.
It is recommended that at 40,000 km (24,000 miles)
intervals or every two years, whichever is the earlier,
the hydraulic brake fluid should be completely
renewed.
At 80,000 km (48,000 miles) intervals or every four
years, whichever is the earlier, all hydraulic brake fluid
seals and flexible hoses should be renewed. All
working surfaces of the master cylinder and caliper
cylinders should be examined and renewed where
necessary.Air cleaner
When the vehicle is used in dusty or field conditions or
deep wading, frequent attention to the air cleaner may
be required.
Dampers
At 60,000 km (36,000 miles) intervals remove all
suspension dampers, test for correct operation, refit or
renew as necessary.
SPECIAL OPERATING CONDITIONS
When the vehicle is operated in extremely arduous
conditions or on dusty, wet or muddy terrain, more
frequent attention should be paid to all servicing
requirements.
Additional daily or weekly attention depending on
operating conditions:
Check/top-up transfer box oil.
Check steering rubber boots for security and
condition. Renew if damaged.
Check brake fluid level: Investigate cause if any fluid
loss is suspected.
Clean brake discs and calipers.
Lubricate front and rear propeller shaft
universal/sliding joints. Under tropical or severe
conditions, particularly where sand is encountered,
the sliding joints must be lubricated very frequently to
prevent ingress of abrasive material.
Every week and every maintenance inspection check
tyre pressures and inspect tyre treads and side walls.
Under arduous cross-country conditions the tyre
pressures should be checked much more frequently,
even to the extent of a daily check.
Monthly
Renew gearbox oil.
Renew transfer box oil.
Check air cleaner element and renew every 6 months
or as necessary.

12ENGINE
2
REPAIR ENGINE OIL PRESSURE TEST
Service repair no - 12.90.09/01
WARNING: Use suitable exhaust
extraction equipment if an engine test is
being carried out in a workshop.
WARNING: If vehicle has been running,
engine wil be hot; care must be taken
when fitting test equipment to prevent
personal injury.
1.Check that engine lubricant is to correct level.
2.Remove oil pressure switch .
3.Connect pressure test gaugeLRT-12-052A,as
shown.
4.Start and run engine to normal operating
temperature.
5.With engine running at idle check oil pressure,
which should read 1.76 bar (25.87 lbf/in
2).6.If pressure is low it can be caused by the
following:-
Thin or diluted oil.
Low oil in sump.
Choked oil strainer.
Faulty oil pressure relief valve.
Excessively worn or damaged oil pump
displacement gears.
Excessive crankshaft bearing clearance.
7.If excessive pressure is indicated it can be
caused by :-
Overfilling engine with lubricant.
Sticking oil pressure relief valve.
Blockage in breather system.

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.

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