timing belt LAND ROVER DEFENDER 1996 Workshop Manual

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
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
8
REPAIR Refit
14.Fit gasket to centre bolt boss.
15.Locate new gasket and fit front cover plate using
fixing bolts as shown. Tighten bolts to
25 Nm (18
lbf/ft).
1- 25 mm,2- 35 mm,3- 50 mm,4- 100 mm,5- 110
mm
16.Fit crankshaft pulley.
See Crankshaft pulley
17.Fit drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
18.Fit fan cowl.See COOLING SYSTEM, Repair,
Fan cowl
19.Fit viscous coupling and fan.See COOLING
SYSTEM, Repair, Viscous coupling and fan
20.Fit intercooler to induction manifold hose.
21.Fit top hose to radiator.
22.Refill cooling system.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
23.Reconnect battery.CAMSHAFT DRIVE BELT
Service repair no - 12.65.18
Remove
1.Remove front cover plate.
See Front cover
plate
2.Position engine at TDC on No. 1 cylinder.
3.Remove blanking plug from flywheel housing
and insert timing toolLRT-12-044.
4.Engage timing tool pin with slot in flywheel.
5.Check correct alignment of timing mark on
camshaft gear and that crankshaft key aligns
with cast arrow on housing.
6.Insert pin from special toolLRT-12-045in
injection pump gear and through into pump
flange.

ENGINE
9
REPAIR
NOTE: If the camshaft gear is to be
removed during these operations its
retaining bolt should be slackened before
the timing belt is removed.
7.Slacken belt tensioner bolt.
8.Remove idler pulley.
9.Remove timing belt.
NOTE: If excessive timing belt debris is
evident in the front cover, this is probably
due to the misalignment of the front timing
cover caused by incorrect assembly of the fuel
injection pump bracket.
See FUEL SYSTEM,
Repair, Fuel Injection pump
NOTE: During use, a belt develops a wear
pattern relative to its running direction, if
the original belt is to be re-used it must be
refitted so that it rotates in the original direction.
Mark belt direction of rotation, using soft chalk, to
ensure correct refitment.
CAUTION: The belt must be stored on its
edge on a clean surface and in such a
manner that bends are not less than 50
mm (2.0in.) radius. Do not bend belts at an acute
angle, otherwise premature failure could result.Belt tensioner
NOTE: The belt tensioner need only be
removed if it is being replaced or for
access purposes to remove front cover.
10.Remove securing bolt and withdraw tensioner
complete with spacer.
Refit
11.If necessary, fit belt tensioner and spacer.
Tighten fixing bolt to
45 Nm (33lbf/ft).
Timing belt fitting and tensioning
NOTE: It is important that belt tensioning
is carried out carefully and accurately. The
following procedure involves tensioning
the belt twice to ensure that it is equally tensioned
between each gear. New and original belts are
tensioned to different figures.
12.Ensure timing marks are correctly aligned, pin
from special toolLRT-12-045is correctly
inserted in injection pump gear and timing tool
LRT-12-044is fitted to flywheel housing with pin
located in flywheel slot.
13.Fit belt, observing rotational marks made during
removal. Feed belt over gears keeping it tight on
drive side.
14.Fit idler pulley.
15.Slacken injection pump gear retaining bolts.
16.Adjust belt to correctly sit in gears.

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

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.