1996 LAND ROVER DEFENDER fuel filter

12ENGINE
20
REPAIR OIL FILTER HEAD GASKET
Service repair no - 12.60.03
Remove
1.Clean filter head adaptor.
2.Disconnect oil cooler pipes and plug to prevent
ingress of dirt.
3.Disconnect oil pressure switch lead.
4.Remove 4 bolts and withdraw filter head,
complete with gasket.
5.Clean mating faces of filter head and cylinder
block.
6.Fit head with new gasket.
7.Tighten bolts to
45 Nm (33 lbf/ft).
8.Reconnect oil pressure switch lead.
9.Reconnect oil cooler pipes.CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery
2.Remove bonnet.
3.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
4.Remove air cleaner.See FUEL SYSTEM,
Repair, Air cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove fuel injectors and pipes.
See FUEL
SYSTEM, Repair, Fuel injectors
7.Remove heater plugs.See FUEL SYSTEM,
Repair, Heater plugs
8.Disconnect radiator top hose from thermostat.
9.Disconnect bleed hose at thermostat.
10.Disconnect water pump hose at thermostat.
11.Disconnect water temperature sensor lead.

ENGINE
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine block
Bearing cap 133...............................................................................................
Blanking plug, oil gallery, rear 37....................................................................
Oil squirt jet assembly 17................................................................................
Drain plug, cylinder block 25...........................................................................
Oil squirt jet, vacuum pump cam 7.................................................................
Connecting rod to cap 59................................................................................
Oil pick up assembly to bearing cap 9...........................................................
Oil pick up assembly to front cover 25............................................................
Camshaft thrust plate 9..................................................................................
Oil drain pipe to block (internal) 25.................................................................
Oil drain pipe to block (external) 25................................................................
Sump to cylinder block and front cover 25......................................................
Drain plug, oil sump 35...................................................................................
Tappet guide 14..............................................................................................
Breather side cover assembly 25....................................................................
Baffle plate to breather side cover 4..............................................................
Vacuum pump 25............................................................................................
Fuel lift pump 25.............................................................................................
Flywheel housing 45.......................................................................................
Flywheel housing clutch cover stud 10...........................................................
Plug, flywheel housing 12...............................................................................
Rear oil seal assembly 25...............................................................................
Oil filter adaptor 45..........................................................................................
Waxstat adaptor to oil filter adaptor 9............................................................
Oil pressure switch 17.....................................................................................
Oil filter, spin on 13.........................................................................................
Oil cooler unions to filter adaptor 45...............................................................
Oil level tube 25..............................................................................................
Engine mounting foot to cylinder block 85......................................................
Engine mounting foot to flywheel housing 45.................................................
Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................
Flywheel to crankshaft 146..............................................................................
Clutch cover plate to flywheel 34....................................................................
Flex drive plate to crankshaft (auto) 146..........................................................
Flex drive plate to ring gear (auto) 25.............................................................
Flex drive plate to torque converter (auto) 45.................................................

ENGINE
3
SPECIFICATIONS, TORQUENm
Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Starter motor (bolt and nut) 45........................................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................
Generator to auxiliaries mounting bracket 25.................................................
Tachometer electrical connection 4...............................................................

FUEL SYSTEM
1
DESCRIPTION AND OPERATION DESCRIPTION
Fuel system
The fuel system incorporates a supply and spill return
line on all models as illustrated below.
On 90 models, see J6191, the fuel tank is mounted at
the RH side of the vehicle chassis under the front
seat.On standard 110 and 130 models the fuel tank is
located at the rear of the vehicle between the chassis
longitudenal sections, as shown in J6192.
As an option, a twin tank system fitted with a
combined change-over tap and 3 way fuel supply and
return system, can be installed on both 110 and 130
models, see J6193.
The tank/s on all vehicles is vented by a 2 way valve
in the filler cap.
FUEL SYSTEM LAYOUT
1.Fuel tank
2.Fuel sedimentor, if fitted
3.Fuel lift pump
4.Fuel filter5.Fuel injection pump
6.Spill return line
7.Fuel injectors

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
3
DESCRIPTION AND OPERATION
90 FUEL SYSTEM
110 FUEL SYSTEM
1.Fuel filter
2.Supply pipe, lift pump to filter
3.Supply pipe, fuel filter to injection pump
4.Fuel injection pump
5.Fuel lift pump
6.Spill return pipe, injection pump to tank7.Supply pipe, sedimentor to fuel pump
8.Fuel tank
9.Supply pipe, fuel tank to sedimentor
10.Fuel filler pipe
11.Breather pipe
12.Sedimentor, if fitted
NOTE: If a sedimentor is not fitted, the fuel
supply pipe from the tank will connect
directly to the fuel lift pump.

19FUEL SYSTEM
4
DESCRIPTION AND OPERATION
110/130 TWIN TANK FUEL SYSTEM - 5 DOOR
VEHICLES
1.Fuel filter
2.Supply pipe, lift pump to filter
3.Supply pipe, filter to injection pump
4.Fuel injection pump
5.Fuel lift pump
6.Spill return pipe, injection pump to change-over
tap
7.Supply pipe, fuel tank change-over tap to lift
pump
8.Spill return pipe, change-over tap to side tank
9.Change-over tap, spill return
10.Fuel filler cap
11.Side fuel tank12.Supply pipe, side tank to sedimentor
13.Sedimentor, if fitted, side tank
14.Supply pipe, sedimentor to fuel tank
change-over tap
15.Change-over tap, side and rear tanks
16.Supply pipe, rear sedimentor to fuel tank
change-over tap
17.Spill return pipe, change-over tap to rear tank
18.Rear fuel tank
19.Fuel filler pipe
20.Breather pipe
21.Supply pipe, rear tank to sedimentor
22.Sedimentor, if fitted, rear tank
NOTE: If sedimentors are not fitted, the
fuel supply pipe from the side and rear
tanks connects directly to the fuel tank
change-over tap.

FUEL SYSTEM
5
DESCRIPTION AND OPERATION
110/130 TWIN TANK FUEL SYSTEM - 2 DOOR
VEHICLES
1.Fuel filter
2.Supply pipe, fuel lift pump to filter
3.Supply pipe, filter to injection pump
4.Injection pump
5.Fuel lift pump
6.Spill return pipe, injection pump to change-over
tap
7.Supply pipe, fuel tank change-over tap to lift
pump
8.Side fuel tank
9.Spill return pipe, change-over tap to side tank
10.Change-over tap, spill return
11.Supply pipe, side tank to sedimentor
12.Fuel filler pipe13.Breather pipe
14.Sedimentor, if fitted, side tank
15.Supply pipe, sedimentor to fuel tank
change-over tap
16.Change-over tap, fuel tanks
17.Supply pipe, rear sedimentor to fuel tank
change-over tap
18.Spill return pipe, change-over tap to rear tank
19.Rear fuel tank
20.Fuel filler pipe
21.Breather pipe
22.Supply pipe, rear tank to sedimentor
23.Rear sedimentor, if fitted
NOTE: If sedimentors are not fitted, the
fuel supply pipe from the side and rear
tanks connects directly to the fuel tank
change-over tap.