1996 LAND ROVER DEFENDER length

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
4
ADJUSTMENT TURBOCHARGER BOOST PRESSURE - CHECK
Service repair no - 19.42.06
1.Disconnect actuator hose from turbocharger and
insert a suitable 'T' piece connector.
2.Connect a short length of suitable hose to
turbocharger and 'T'piece.
3.Connect further hose to 'T' piece and pressure
gaugeLRT-12-011. The pressure gauge hose
must be long enough to reach into the vehicle
cab so that the gauge can be observed by driver
or passenger.
4.To check maximum boost pressure, drive
vehicle normally, but in such a manner that full
throttle can be maintained whilst climbing a hill
with engine speed held steady between 2,500
and 3,000 rev/min. Under these circumstances
boost pressure should read 0,95 - 1,09 Kgf/cm
2
(13.5 - 15.5 lb/in2).PRIMING THE FUEL SYSTEM
Service repair no - 19.50.01
NOTE: If the fuel system has been
completely drained carry out the
procedures for priming both the
sedimentor, if fitted, and fuel filter and injection
pump.
Sedimentor and fuel filter
If the sedimentor or fuel filter have been dismantled
and air has entered the fuel system carry out the
following procedure:
1.Slacken fuel filter bleed screw.
2.Operate hand priming lever on fuel lift pump until
fuel, free from air, emerges from filter.
NOTE: Ensure that the fuel pump lever is
on the bottom of operating cam when
priming, otherwise maximum movement of
the lever cannot be achieved.
3.Tighten filter bleed screw whilst fuel is still
emerging.

STEERING
3
ADJUSTMENT FRONT WHEEL ALIGNMENT
Service repair no - 57.65.01
Checking Toe-out dimensions
NOTE: Recognised front wheel alignment
and tracking equipment should be used
for this operation. Only the use of basic
equipment is described below. No Adjustment is
provided for castor, camber or swivel pin
inclinations.
1.Set vehicle on level ground with road wheels
positioned straight ahead.
2.Push vehicle back and forwards to settle linkage.
3.Set up the equipment to manufacturers
instructions and check alignment as advised by
equipment supplier.
4.Position trammel probes on inner face of wheel,
not the rims, if the latter are damaged.
5.Measure toe-out at horizontal centre-line of
wheels.
6.Check tightness of clamp bolt fixings. Tighten to
14 Nm (10lbf/ft).
Adjust
7.Slacken clamps at both ends of track rod.
8.Rotate track rod to increase or decrease its
effective length until correct toe-out is obtained
See GENERAL SPECIFICATION DATA,
Information, Steering
.
9.Push vehicle rearwards turning steering wheel
from side to side to settle ball joints. With road
wheels set in straight ahead position, push
vehicle forward a short distance.
10.Recheck track and adjust if necessary.
11.When alignment is correct, tap ball joints in
direction of arrows to maximum of travel, to
ensure full unrestricted movement of track rod.
12.Tighten clamp bolts to
14 Nm (10 lbf/ft).
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.01
Adjust
NOTE: For details of drive belt adjust
procedure.
See ELECTRICAL, Repair,
Auxiliary Drive Belt

STEERING
3
REPAIR REV: 05/99
NOTE: The steering column is a non
serviceable component and can only be
serviced as a complete assembly.
25.Fit main support bracket and padding to steering
column and manoeuvre column into position in
vehicle.
26.Loosely secure main support bracket and
harness bracket to bulkhead.
27.Loosely fit clamp and rubber packing strip to
column.
28.Loosely secure lower end of column to lower
support bracket.
29.Loosely secure clamp bracket to main support
bracket.
30.Working inside vehicle cab, fit tie-bar to column
bracket and secure with single bolt to
22 Nm (16
lbf/ft).
31.Finally, tighten main support bracket, clamp
bracket, upper clamp, and lower support bracket
nuts and bolts. (M6 bolts
9 Nm (6 lbf/ft),M8
bolts
22 Nm (16 lbf/ft).
32.Fit brake pedal boxSee BRAKES, Repair,
Brake pedal
.
33.Fit steering lock/switch in position and rotate
steering column inner shaft to line up slot with
switch plunger.
34.Secure lock to column with clamp and shear
bolts. Evenly tighten bolts but do not shear them.
35.Temporarily fit steering wheel and operate
switch and lock mechanism several times to
ensure it functions correctly.
36.Fully tighten switch retaining bolts until heads
shear.
37.Connect electrical leads to rear of switch. Fit
alarm system passive coil, if applicable.
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.
38.Fit switch assembly on steering column and
tighten clamping screw.
39.Connect switch assembly multi-plugs and
electrical leads to main harness.
40.Offer up instrument panel, connect speedometer
cable, multi-plugs and electrical leads to main
harness. If applicable, fit vehicle alarm system
connections.
See ELECTRICAL, Repair,
Vehicle immobilisation and alarm system
.
41.Secure panel with 4 screws.
42.Locate top half of nacelle in position and fit to
switch gaiters/grommets.43.Fit lower half of nacelle and loosely tighten fixing
screws.
44.Ensure switch gaiters/grommets are correctly
located and fully tighten fixings.
45.Turn indicator cancelling ring so that slots are
vertical and lug with arrow points to the left, in
direction of indicator switch.
46.Fit steering wheel with finisher attachment lug at
bottom, ensuring that indicator cancelling forks
locate in cancelling ring slots.
47.Secure wheel with nut and new shake-proof
washer. Tighten to
43 Nm (32 lbf/ft).
48.Fit steering wheel decal.
49.If necessary, fit new universal joints to support.
Note that long joint is fitted to short length of
shaft and short joint to long end. Joints can only
be fitted one way to shaft.
50.With steering lock engaged and road wheels in
straight ahead position, align reassembly marks,
and fit collapsible shaft assembly with long leg of
shaft to steering box. Fit pinch bolts and tighten
to
25 Nm (18 lbf/ft).

57STEERING
8
REPAIRREV: 05/99 LOWER STEERING SHAFT AND UNIVERSAL
JOINTS
Service repair no - 57.40.16
Remove
1.Remove vehicle bonnet.
2.Set road wheels and steering wheel in straight
ahead position.
3.Mark relationship of steering column inner shaft
to top universal joint.
4.Remove 2 bolts from top universal joint.
5.Remove lower bolt from bottom universal joint.
6.Slacken upper bolt of lower universal joint and
withdraw shaft.
7.Inspect upper and lower universal joints for wear
and excessive play, renew if necessary.
8.Inspect universal joints for stiffness, lubricate if
necessary.Refit
9.Fit universal joints so pinch bolt holes line up
with flat on shaft. Note that the long joint is fitted
to short length of shaft and short joint to long
end.
10.With steering lock engaged and road wheels in
straight ahead position, line up assembly marks.
11.Position shaft assembly onto steering column.
Move assembly up spline to enable lower
universal joint to fit onto steering box splines.
12.Align bolt holes with grooves in splines. Fit pinch
bolts and tighten to
25 Nm (18 lbf/ft).
STEERING WHEEL
Service repair no - 57.60.01
Remove
1.Set road wheels and steering wheel in straight
ahead position.
2.Prise decal from steering wheel pad.
3.Remove retaining nut and shakeproof washer.
Make alignment marks on column and wheel
pad.
4.Withdraw steering wheel from column spline.
Refit
5.Turn indicator cancelling ring so that slots are
vertical and lug with arrow points to the left, in
direction of indicator switch.
6.Ensure front road wheels are in straight ahead
position.
7.Fit steering wheel with finisher attachment lug at
the bottom, ensuring indicator cancelling forks
locate in cancelling ring slots. Align assembly
marks.
8.Secure wheel with retaining nut and new
shakeproof washer. Tighten to
43 Nm (32 lbf/ft).

STEERING
15
REPAIR REV: 05/99 DRAG LINK AND DRAG LINK ENDS
Service repair no - 57.55.17
Remove
1.Park vehicle on level ground and chock rear
wheels.
2.Set road wheels in straight ahead position.
3.Raise vehicle and fit axle stands or use a ramp.4.Remove front road wheel.
5.Disconnect steering damper at drag link bracket.
6.Remove split pin and castellated nut securing
drag link ball joint to swivel housing arm.
7.Disconnect drag link ball joints using
LRT-57-018.
8.Remove drag link.
9.Slacken clamp bolts.
10.Unscrew ball joints and remove from drag link.
11.Clean internal threads of drag link.
12.Fit new ends to drag link and loosely fit clamp
bolts.
13.Set ball joints to drag link measurement to 28,5
mm.
14.Adjust ball pin centres to nominal length of 924
mm, this length is adjusted during refit.

57STEERING
16
REPAIR 15.Centralise steering box
See Adjustment,
Centralise steering box
.
16.Align steering wheel, if necessary.
CAUTION: A drag link that is damaged or
bent must be renewed. DO NOT attempt
repair.
17.Fit drag link to swivel housing arms and tighten
nuts to
40 Nm (30 lbf/ft).Fit new split pins.
18.Ensure full steering travel is obtained between
lock stops
See Adjustment, Steering lock
stops
. Adjust drag link length to suit.
19.Tap ball joints in direction shown so both pins
are in same angular plane.
20.Tighten clamp bolts to
14 Nm (10 lbf/ft).
21.Refit road wheel and remove axle stands or
vehicle from ramp.
22.Road test vehicle.
23.If driving straight ahead and steering wheel is
offset by 0°±5°in either direction, correct by
adjusting drag link length.
WARNING: To correct steering wheel
deviations greater than±5°remove and
reposition steering wheel
See Steering
wheel
.

FRONT SUSPENSION
1
REPAIR SELF LOCKING NUTS
WARNING: Where self locking nuts are
removed, they must be replaced with new
nuts of same specification.
PANHARD ROD
Service repair no - 60.10.07.
Remove
1.Remove fixings at mounting arm.
2.Remove fixings at axle bracket.
3.Remove panhard rod.
4.Using a suitable length of steel tubing, press out
flexible bushes. Ensure tubing locates on outer
edge of bush and not on rubber inner.
Refit
5.Fit replacement bushes.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
6.Fit panhard rod to axle bracket and mounting
arm. Tighten fixings to
88 Nm (65 lbf/ft).
RADIUS ARM
Service repair no - 60.10.16.
Remove
1.Loosen road wheel retaining nuts.
2.Raise front of vehicle. Support chassis on stands
and remove wheel.
3.Support front axle weight with jack.
4.Remove radius arm to chassis side member
fixings.
5.Disconnect track rod at ball joint.