1996 LAND ROVER DEFENDER battery

10MAINTENANCE
10
MAINTENANCEREV: 05/99 RENEW GEARBOX OIL
1.Ensure vehicle is level.
2.Place suitable tray under gearbox.
3.Disconnect battery.
4.Clean area around filler/level plugs.
5.Remove both plugs and allow oil to drain
completely.
WARNING: When draining gearbox, care
should be taken to ensure that oil is not
hot as personal scalding could result.
6.Refit drain plug and tighten to
30 Nm (22 lbf/ft).
7.Inject new oil into gearbox until it runs out of filler
hole. Allow excess oil to drain and wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
8.Refit filler/level plug and tighten to30 Nm (22
lbf/ft).
9.Reconnect battery.
RENEW TRANSFER GEARBOX OIL
1.Ensure vehicle is level.
2.Disconnect battery.
3.Clean area around filler/level and drain plugs.
WARNING: When draining gearbox care
should be taken to ensure that oil is not
hot as personal scalding could result.
4.Place suitable tray under transfer gearbox.
5.Remove filler/level plug to vent gearbox and
assist draining.
6.Remove drain plug and allow oil to drain.
7.Thoroughly clean drain plug threads and apply
fresh 'Hylomar' sealant.
8.Refit drain plug and tighten to
30 Nm (22lbf/ft).
9.Inject new oil of correct quantity and grade into
gearbox until oil runs out from filler/level hole.
Allow excess oil to drain and wipe clean.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
10.Thoroughly clean filler/level plug and apply fresh
'Hylomar' sealant.
11.Refit plug and tighten to
30 Nm (22 lbf/ft).
12.Reconnect battery.
CHECK/TOP UP TRANSFER GEARBOX OIL
1.Ensure vehicle is level.
2.Disconnect battery.
3.Clean area around filler/level plug.
4.Remove plug, check oil level and top up if
necessary with correct grade of oil,
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
until oil runs out from filler/level hole.
Allow excess oil to drain and wipe clean.
5.Thoroughly clean filler/level plug threads and
apply fresh 'Hylomar' sealant.
6.Refit plug and tighten to
30 Nm (22 lbf/ft).
7.Reconnect battery.

ENGINE
1
REPAIR CYLINDER COMPRESSION TEST
Service repair no - 12.25.01
1.Start and run engine to normal operating
temperature.
2.Switch off engine.
3.Disconnect spill return hose and fuel pipe from
No.1 injector.
4.Remove retaining nut, release clamp and
withdraw injector from cylinder head.
See FUEL
SYSTEM, Repair, injectors
5.Disconnect electrical lead from fuel cut-off
solenoid at injection pump to prevent delivery of
fuel to injectors. On vehicles fitted with a digital
diesel shut-off valve (DDS) immobilisation
system, disconnect DDS multi-plug.
6.Ensure injector port is clean, If necessary, crank
the engine a few revolutions to remove any
loose carbon.
7.Fit dummy injector, from diesel compression
tester kitLRT-19-007, into the cylinder head and
clamp securely in position.
8.Connect flexible hose and gauge to dummy
injector as shown above.
9.Crank engine for 10-20 seconds and note
reading on gauge. The gauge will indicate the
compression of the cylinder and maintain the
reading until the pressure release valve on the
gauge is depressed.
Expected readings of a crank test, with vehicle
battery fully charged, compression ratio 19.5:1
should be 24 bar (348 lbf/in
2).10.Repeat test procedure for remaining clinders in
turn.
NOTE: A variation in compression
readings between cylinders is often a
better indication of an engine problem
than the absolute values of compression.
11.If compression is appreciably less than correct
reading, or varies by more than 10%, piston
rings or valves may be worn or damaged.
Low pressures in adjoining cylinders may
indicate a faulty cylinder head gasket.

ENGINE
3
REPAIR ENGINE
Service repair no - 12.41.01
Remove
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
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
orSee CHASSIS AND BODY, Repair,
Rear undertray
CAUTION: Seal all exposed pipe ends
against ingress of dirt after disconnection.
1.Ensure vehicle is level and apply park brake.
2.Disconnect battery.
NOTE: The vehicle may be fitted with an
alarm and immobilisation system using a
battery backed-up alarm sounder.
See ELECTRICAL, Repair, battery
3.Remove bonnet.
4.Remove cable ties securing gearbox harness to
breather pipes.
5.Disconnect harness from diff lock and reverse
light switches.
6.Manouvre harness into engine bay.
7.Remove air cleaner.
See FUEL SYSTEM,
Repair, Air cleaner
8.Remove radiator assembly.See COOLING
SYSTEM, Repair, Radiator
If air conditioning is fitted the condenser will
have to be removed, compressor pipes and
heater matrix hoses disconnected.
See AIR CONDITIONING, Repair, Condenser
9.Remove rocker cover insulation.
10.Remove feed pipe/hose from turbo-charger and
intercooler.
11.Disconnect heater hoses from cylinder head and
heater rails.
12.Disconnect electrical feed plug at rear of cylinder
head.
13.Disconnect heater plug feed wire.

12ENGINE
4
REPAIR
14.Disconnect engine harness multi-plug.
15.Remove single bolt securing transmission
breather pipe clip to cylinder head and move
breather pipes aside.
16.Disconnect multi-plug and vacuum pipe from
EGR valve, if fitted.
17.Remove starter motor cover and disconnect
battery and fuse box leads.
18.Remove 3 retaining nuts and disconnect exhaust
down pipe.
19.Disconnect inlet and outlet hoses from power
steering pump.
20.Disconnect bleed hose from thermostat housing.
21.Release bleed hose from retaining clips on front
timing cover plate.
22.Remove split pin securing inner throttle cable to
injector pump lever.
23.Depress tags on outer cable adjusting nut,
remove cable from mounting bracket and move
aside.
24.If fitted, release hand throttle cable from
mounting bracket and injector pump lever and
move aside.
25.Disconnect feed pipe and spill return pipe from
injector pump.

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.

ENGINE
7
REPAIR Refit
12.Lightly grease pulley spigot and locate pulley
onto cranshaft.
13.Fit pulley retaining bolt.
14.Fit pulley retainerLRT-12-080and secure with 4
bolts.
15.Tighten pulley nut to
80 Nm (59 lbf/ft)+90°.
16.Remove pulley retainer.
17.Fit drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt; Refit
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 radiator top hose.
22.Refill cooling system.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
23.Reconnect battery.FRONT COVER PLATE AND SEAL
Service repair no - 12.65.01
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.Remove crankshaft pulley.See Crankshaft
pulley
9.Remove 14 bolts securing front cover plate. Note
that top 2 bolts also retain thermostat hose clips.
10.Remove cover plate complete with gasket.
11.Remove small gasket from centre bolt boss.
Seal replacement
12.Remove worn seal from cover and clean recess.
13.Support cover and fit new seal, open side fitted
into recess, using special toolLRT-12-077.

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.

12ENGINE
14
REPAIR ENGINE OIL SUMP
Service repair no - 12.60.44
Remove
1.Disconnect battery.
2.Drain engine oil.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
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
orSee CHASSIS AND BODY, Repair,
Rear undertray
3.Slacken sump securing bolts.
4.Break sealant around sump flange, using a
sharp knife.
5.Remove 22 bolts and withdraw sump.
Refit
6.Clean mating faces of sump, timing gear housing
and cylinder block.
7.Apply a 2,0 mm bead of 'Hylosil RTV102' to the
sump flange, ensuring bead is applied inboard of
the bolt holes.
8.Secure sump to block with 22bolts. Tighten to
25
Nm (18 lbf/ft).
9.Refill engine oil.See LUBRICANTS, FLUIDS
AND CAPACITIES, Information, Capacities
10.Reconnect battery.OIL PICK-UP STRAINER
Service repair no - 12.60.20
Remove
1.Disconnect battery.
2.Drain engine oil.
3.Remove engine oil sump.
See Engine oil
sump
4.Remove 2 bolts securing pipe support bracket to
main bearing cap fixings.
5.Remove bolts from pipe flanges.
6.Withdraw pick-up strainer assembly.
Refit
7.Postion pick-up strainer assembly, fitting a new
'O' ring seal at oil pump connection.
8.Apply Loctite 242E to threads of bolts at main
bearing cap. Fit bolts, tighten to
9 Nm (7 lbf/ft).
9.Fit bolts to pipe flanges. Tighten to25 Nm (18
lbf/ft).
10.Fit sump.See Engine oil sump
11.Reconnect battery.