set 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.

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.

FRONT AXLE AND FINAL DRIVE
5
OVERHAUL 38.Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39.Fit swivel bearing housing to axle flange with 7
bolts. Tighten to
73 Nm (54 lbf/ft).
40.Grease and fit upper and lower swivel pin taper
roller bearings.
41.Position swivel pin housing over swivel bearing
housing.
42.Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43.Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44.Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45.Apply Loctite 270 or equivalent to lower swivel
pin bolts.
78 Nm (58 lbf/ft),bend over lock tabs.
46.Tighten top swivel pin bolts to
78 Nm (58 lbf/ft).
Check and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47.Attach a spring balance to ball joint bore and pull
balance to determine effort required to turn
swivel pin housing.
Resistance, once initial inertia has been
overcome, should be1.16 to 1.46 kg.Adjust by
removing or adding shims to top swivel pin.
48.When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit bolts and
tighten to
78 Nm (58 lbf/ft),and bend over lock
tabs.
49.Apply recommended grease between lips of
swivel oil seal.50.Fit oil seal, joint washer and retaining plate with
7 bolts and spring washers. Tighten to
11 Nm (8
lbf/ft).
51.Fit tie rod and drag link and secure with new
cotter pins. Tighten fixing to
40 Nm (30 lbf/ft).
52.Fit brake disc shield.
53.Loosely fit lock stop bolt and nut.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11 Nm (8 lbf/ft).
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.
Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 O'clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.
62.Place mud shield in position and secure stub
axle to swivel pin housing with 6 bolts and
tighten evenly to
65 Nm (48 lbf/ft).
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit complete front hub assembly
See Repair,
Front hub assembly
.
65.Check swivel pin housing oil drain plug is fitted.
66.Fill swivel assembly to correct level, with new oil
See SECTION 10, Maintenance, Under
vehicle maintenance
.
NOTE: On later vehicles fill swivel pin
housing with 0.33 Litres of Molytex EP 00
grease.
67.Set steering lock stop bolts
See STEERING,
Adjustment, Steering lock stops
.

STEERING
7
OVERHAUL Fitting sector shaft cover
73.Fit new sealing ring to cover.
74.Align cover with casing.
75.Screw cover assembly fully on to sector shaft
adjuster screw.
76.If necessary back off sector shaft adjuster screw.
Tap cover in place to allow cover to joint fully
with casing.
NOTE: Before tightening fixings, rotate
input shaft to ensure sector shaft roller is
free to move in valve worm. If initial
resistance is left, turn adjuster screw
approximately two turns in a clockwise direction.
77.Fit cover bolts. Tighten to
75 Nm (55 lbf/ft).
Fitting cylinder cover
78.Fit new square section seal to cover.
79.Remove slave bolt fitted at instruction 68. Press
cover into cylinder just to clear retainer ring
groove.
80.Fit retaining ring to groove with one end of ring
positioned 12 mm from extractor hole.
Adjusting sector shaft
NOTE: Refit drop arm and tighten nut
sufficiently to ensure that no backlash
exists between drop arm and sector shaft.
81.To set worm on centre, rotate input shaft to full
inner-lock (full right lock for a left hand drive
vehicle, full left lock for a right hand drive
vehicle). Rotate input shaft back towards centre
two full turns.
82.The box is now on centre and can be adjusted.
83.Hold input shaft and rock drop arm to establish
backlash is present. Continue rocking and slowly
turn sector shaft adjusting screw clockwise.
Continue rotating adjuster screw until backlash
has almost been eliminated.