1996 LAND ROVER DEFENDER belt

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.

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.

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
11
REPAIR CRANKSHAFT OIL SEAL
Service repair no - 12.21.14
Remove
1.Remove crankshaft gear.
See Crankshaft gear
2.Prise out oil seal from front cover.
Refit
3.Lubricate a new crankshaft oil seal with clean
engine oil.
4.With lip side leading, drive in seal squarely using
special toolLRT-12-079.
5.Fit crankshaft gear.
See Crankshaft gear
CAMSHAFT GEAR
Service repair no - 12.65.24
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.Remove centre bolt and withdraw camshaft
gear, complete with hub and retaining plate.
Refit
3.Fit camshaft gear. Tighten bolt to
80 Nm (59
lbf/ft).
4.Fit camshaft drive belt.See Camshaft drive
belt

12ENGINE
12
REPAIR CAMSHAFT OIL SEAL
Service repair no - 12.13.05
Remove
1.Remove camshaft gear.
See Camshaft gear
2.Remove camshaft oil seal from front cover using
special toolLRT-12-083.
Refit
3.Lubricate a new camshaft oil seal with clean
engine oil.
4.With lip side leading, drive in seal squarely using
special toolLRT-12-082.
5.Fit camshaft gear.
See Camshaft gear
INJECTION PUMP GEAR
Service repair no - 19.30.06
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.Slacken 3 bolts on front of injector pump gear.
3.Remove special tool pin from gear.
4.Remove 3 bolts and withdraw gear and retaining
plate.
Refit
CAUTION: It is important to ensure that
when the injection pump is locked no
attempt must be made to rotate it. Take
care not to allow the crankshaft to be turned.
5.Fit gear and retaining plate. Tighten bolts to
25
Nm (18 lbf/ft).
6.Insert pin from special toolLRT-12-045in
injection pump gear and through into pump
flange.
7.Fit camshaft drive belt.
See Camshaft drive
belt