1996 LAND ROVER DEFENDER exhaust

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
21
REPAIR 12.Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Induction
manifold
13.Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust manifold
14.Disconnect heater hose from water pump and
move heater rail aside.
15.Disconnect heater hose from rear of cylinder
head.
16.Remove bolt securing air cleaner mounting
bracket to support strut.
17.Remove bolt securing harness bracket to
cylinder head.
18.Remove rear engine lifting bracket. This will also
release clips securing transmission and engine
breather pipes and multi-plug. Note loose spacer
beneath inner clip.
19.Unscrew 3 bolts, with sealing washers and
remove rocker cover.
20.Remove 3 nuts and 2 bolts and lift rocker shaft
assembly from cylinder head.
21.Remove push rods and store as an identified set
to allow refitment to same location.
22.Remove valve stem caps.
23.Evenly slacken and then remove cylinder head
to block retaining bolts in the sequence shown in
J6157. Two of the bolts also secure the air
cleaner mounting bracket.
24.Lift off cylinder head and remove gasket.
Refit
25.Thoroughly clean mating faces of cylinder block
and head.
26.Select new gasket of correct thickness.
CAUTION: Three gaskets, of different
thicknesses, are available and can be
identified by the number of small holes
punched in the RH side of the gasket. One hole
identifies the thinnest gasket, two holes the
middle thickness and three holes the thickest.
When renewing a gasket it must be of the same
thickness as the one removed.
27.Position gasket on cylinder block with
identification holes on RH side and TOP
identification mark uppermost.

ENGINE
23
REPAIR
43.Check and adjust valve clearances.
See Adjustment, Valve clearances - check
and adjust
44.Fit rocker cover, ensuring oil seal is satisfactory
for continued use, and renew if necessary.
45.Secure rocker cover with special seal washers
and nuts. Tighten to
10 Nm (7 lbf/ft).
46.Fit rear engine lifting bracket, securing breather
pipe and multi-plug retaining clips. Tighten fixing
bolts to
25 Nm (18 lbf/ft).
47.Fit engine harness bracket to cylinder head.
48.Secure air cleaner mounting bracket to support
strut.
49.Connect heater hose to rear of cylinder head.
50.Position heater rail and connect hose from water
pump.
51.Fit exhaust manifold and turbocharger assembly.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust manifold
52.Fit induction manifold.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Induction
manifold
53.Connect water temperature sensor lead.
54.Connect water pump hose at thermostat.
55.Fit bleed hose at thermostat.
56.Connect radiator top hose at thermostat.
57.Fit heater plugs.
See FUEL SYSTEM, Repair,
Heater plugs
58.Fit fuel injectors.See FUEL SYSTEM, Repair,
Fuel injectors
59.Fit crankcase ventilation valve and side breather
hose.
60.Fit air cleaner.
See FUEL SYSTEM, Repair,
Air cleaner
61.Refill cooling system.See COOLING SYSTEM,
Repair, Drain and refill cooling system
62.Fit bonnet.
63.Reconnect battery.OIL PUMP
Service repair no - 12.60.26
Remove
1.Remove engine front cover.
See Front cover
gasket
2.Remove 7 screws and release oil pump retaining
plate from engine front cover.
3.Mark oil pump inner gear rotor, outer gear rotor
and front cover housing for reassembly.
4.Check for rotor clearances:
Outer rotor to housing, 0,025 - 0,075 mm (0.010
- 0.030 in).
Inner rotor to outer rotor, 0,025 - 0,075 mm
(0.010 - 0.030 in).
Rotor end float, 0,026 - 0,135 mm (0.010 - 0.054
in).
5.Remove inner and outer rotors.
6.Check condition of oil pump components.
NOTE: If the oil pump seating in the front
cover or retaining plate is badly worn,
pitted or scored, a new front cover must
be fitted.
See Front cover gasket
Always renew oil pump rotors as a pair.
7.Clean sealant from pump retaining plate and
front cover.

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

19FUEL SYSTEM
2
DESCRIPTION AND OPERATION A mechanical lift pump, with a hand priming facility, is
driven by the camshaft, and is mounted on the RH
side of the engine.
A fuel filter, with a replaceable element and
incorporating a water separator, is mounted on the
front RH side of the engine compartment.
A fuel sedimentor may be fitted when the vehicle is
operating in more arduous conditions, and is used to
minimise water deposits in the fuel system before
reaching the fuel pump and filter.
Fuel injection is carried out by a Bosch direct injection
pump, incorporating a cold start advance unit and a
high idle setting. The pump is mounted on the RH side
of the engine and is driven directly by gears in the
front cover from the crankshaft. The pump meters and
distributes fuel to 4 pintle type injectors located in
pre-combustion chambers in the cylinder head. Four
heater plugs, located in the cylinder head directly
below each injector, are fitted to improve cold starting.
An optional hand throttle, for use with a centre power
take off, is located on the fascia to the LH side of the
fuse box, and is linked independently to the fuel
injection pump throttle lever.
Air intake
The air cleaner is mounted on the RH side of the
engine and is connected by hoses to the cold air
intake duct and turbocharger inlet. Fitted between the
air cleaner and turbocharger is the crankcase breather
hose which connects to a breather filter on the rocker
cover.
A single stage turbocharger, fitted between the
exhaust manifold and exhaust down pipe, is
connected by hoses to the air cleaner and an
intercooler which is mounted on the LH side of the
radiator. The intercooler is connected by a hose to the
inlet manifold. When an EGR valve is fitted to the
turbocharger, additional pipes/hoses are used to
connect the components.Exhaust gas recirculation (EGR), when fitted.
Exhaust gas recirculation is controlled by an ECU
mounted under the front centre seat or cubby box and
receives the following inputs:
·Engine temperature from coolant temperature
sender unit on LH side of cylinder head.
·Throttle position from potentiometer on injection
pump.
·Engine speed from speedometer.
When all correct signals are received, the EGR
solenoid allows vacuum to open EGR valve and
recirculate a portion of the exhaust gas. See J6196 for
the EGR system component location and 'Operation'
for full system function.

FUEL SYSTEM
9
DESCRIPTION AND OPERATION OPERATION
Diesel engines operate by compression ignition. The
rapid compression of air in the cylinder during the
compression cycle heats the air and when fuel is
injected into the heated air, it ignites instantaneously.
During cold tarting, automatically controlled heater
plugs assist in raising the temperature of the
compressed air to ignition point.
A cold start advance unit advances the injection timing
to further assist starting. Idle quality is improved by
the high idle setting.
The engine is supplied with pre-compressed air by a
single stage turbocharger.
Exhaust gases passing over a turbine cause it to
rotate, driving a compressor mounted on the turbine
shaft. Air drawn from the cold air intake passes, via
the air cleaner, to the turbocharger where it is
compressed. Compression in the turbocharger warms
up the air considerably, so that it expands. As a result
the air mass per cylinder is reduced, having a
negative effect on power output. By fitting a charge-air
intercooler, located on the LH side of the radiator, the
air is cooled before reaching the cylinders. This
increases power output through increased mass of
oxygen in the combustion process, as well as
maximising engine durability, through maintaining
lower piston and head temperatures.
Fuel is drawn from the tank by a mechanical lift pump
and passes to the injection pump via a filter. In
addition to removing particle contamination from the
fuel, the filter incorporates a water separator, which
removes and stores water.
The sedimentor/s, when fitted, is located adjacent to
the fuel tank/s and separates contamination and water
particles in the fuel before reaching the fuel lift pump.
The injection pump meters a precisely timed, exact
quantity of fuel to the injectors in response to throttle
variations, injection timing varying with engine speed.
Any excess fuel delivered to the injection pump is
passed back to the tank via the spill return line.
Fuel is injected in a finely atomised form into the main
combustion chamber, the burning fuel expands
rapidly, creating extreme turbulence which mixes the
burning fuel thoroughly with the compressed air,
providing complete combustion.Cold Starting is assisted by heater plugs, a cold start
advance unit and a high idle setting.
Heater plugs
Heater plug operation is controlled by a timer unit,
start relay and resistor. When the ignition is turned on
the timer unit is energised, the heater plugs start to
operate and a warning light on the dashboard
illuminates, remaining on until the heater plugs are
automatically switched off.
The length of time the heater plugs will operate is
dependent on under bonnet temperature, which is
monitored by a sensor located in the timer unit.
Starting the engine results in the power supply to the
heater plugs passing through the resistor, which
reduces their operating temperature. The heater plugs
are cut out either by the temperature sensor in the
timer, or by a microswitch on the injection pump which
operates when the throttle is depressed.
Cold start advance
The cold start advance unit is connected to the engine
cooling system via hoses. It contains a temperature
sensitive element which is retracted when cold and
pulls the advance lever, via cable, towards the rear of
the pump against spring pressure. As coolant
temperature rises, the cold start element expands
releasing tension on the cable and allowing spring
pressure to move the advance lever forwards.
Exhaust gas recirculation (EGR), when fitted
Operation of the EGR system is dependent on the
following:
·Engine temperature - must be between 20°C and
100°C approx.
·Engine speed - must be between 630 and 2850
rev/min.
·Engine load - calculated by throttle position
sensor.
·EGR valve lift position.
·Duration of engine idling.

19FUEL SYSTEM
14
REPAIR TURBOCHARGER INLET HOSE
Service repair no - 19.42.11
Remove
1.Disconnect battery.
2.Slacken retaining clip and disconnect intake
hose from turbocharger.
3.Slacken retaining clip and disconnect hose from
air cleaner.
4.If fitted, disconnect EGR modulator valve
vacuum spill pipe from inlet hose.
5.Slacken retaining clip and disconnect breather
valve hose from inlet hose.
6.Remove inlet hose.
Refit
7.Fit inlet hose to air cleaner.
8.Fit cyclone breather hose to inlet hose.
9.If applicable, fit vacuum spill pipe to inlet hose.
10.Fit inlet hose to turbocharger.
11.Reconnect battery.TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1.Disconnect battery.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3.Remove banjo bolt securing oil feed pipe to
turbocharger and discard 2 joint sealing
washers.
4.Unscrew union and remove feed pipe from
cylinder block.
5.Plug connections to prevent ingress of dirt.
Refit
6.Using new joint washer, fit oil feed pipe to
cylinder block. Tighten union connector to
25
Nm (18 lbf/ft).
7.Fit a new joint washer to both sides of banjo and
secure feed pipe to turbocharger. Tighten banjo
bolt to
20 Nm (15 lbf/ft).
8.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
9.Check/top-up engine oil level.See SECTION
10, Maintenance, Under bonnet maintenance
10.Reconnect battery.

FUEL SYSTEM
15
REPAIR TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1.Disconnect battery.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3.Unscrew union and disconnect oil drain pipe
from cylinder block.
4.Remove 2 bolts securing oil drain pipe to
turbocharger.
5.Remove drain pipe and discard gasket.
6.Plug connections to prevent ingress of dirt.
Refit
7.Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
8.Using new gasket, fit oil drain pipe to
turbocharger. Tighten bolts to
25 Nm (18 lbf/ft).
9.Fit drain pipe to cylinder block and tighten union
connector to
38 Nm (28 lbf/ft).
10.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
11.Check/top-up engine oil level.See SECTION
10, Maintenance, Under bonnet maintenance
12.Reconnect battery.