1996 LAND ROVER DEFENDER light

12ENGINE
22
REPAIR
28.Lower cylinder head onto block ensuring correct
location with dowels.
NOTE: Cylinder head retaining bolts can
be used up to a maximum of five times.
29.Lubricate threads of bolts with light oil and fit to
positions shown below. (Fit air cleaner mounting
bracket at positions 6 and 14).
Bolt sizes:
M10 x 117mm locations 3, 5, 12, and 13.
M12 x 140mm locations 1, 2, 7, 8, 9, 10, 15, 16, 17,
and 18.
M12 x 100mm locations 4, 6, 11, 14.
30.Tighten bolts so that underside of heads just
make contact with cylinder head.
31.Following the sequence indicated, tighten all
bolts to
40 Nm (30 lbf/ft).
32.Attach angle gaugeLRT-12-007.
33.Make a suitable pointer from welding rod and
attach to a bolt screwed into a rocker shaft
securing bolt hole.
34.Tighten all bolts through 60°strictly in sequence
illustrated.
35.Repeat 60°tightening procedure, again strictly in
sequence illustrated.
36.Tighten the 10 longer bolts (M12 x 140mm) a
further 20°, again following the sequence
illustrated.
NOTE: Repositioning of the pointer will be
necessary to reach all bolts, the pointer
can be fitted to the rocker shaft securing
studs using 2 nuts.
CAUTION: The double tightening
procedure MUST be carried out, on no
account should the bolt tightening be
performed in one operation, otherwise damage to
the cylinder head may occur.
37.Fit valve stem caps.
38.Fit push rods to locations from which they were
removed.
39.Position rocker shaft assembly over locating
studs and fit retaining nuts and bolts, but do not
tighten at this stage.
40.Attach angle gaugeLRT-12-007.
41.Make a suitable pointer and attach to one of the
rocker shaft locating studs.
42.Tighten all fixings in turn to
5 Nm (4 lbf/ft).Then
tighten a further 50°in same sequence.
NOTE: Repositioning of the pointer will be
necessary to reach all fixings.

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.

FUEL SYSTEM
3
REPAIR FUEL INJECTORS
Service repair no - 19.60.10
Remove
NOTE: When a fuel injector is considered
to be the cause of irregular running and
loss of power it will be necessary to fit a
donor set of injectors to determine which injector
is at fault. DO NOT attempt to dismantle or carry
out spray tests on the fuel injectors. This work
can only carried out by authorised Bosch dealers.
1.Remove oil filler cap and release sound
insulation cover from top of engine.
2.Disconnect high pressure fuel supply pipes from
injectors and injection pump. Remove in pairs.
3.Disconnect spill return hose(s) from injectors.
4.Plug pipes and injector connections to prevent
the ingress of dirt and foriegn matter.5.Remove retaining nut and release each injector
clamp plate from cylinder head.
6.Remove injector and discard copper washer.
Refit
7.Ensure injectors and seating in cylinder head are
clean.
8.Lightly grease a new copper sealing washer and
position on each injector.
9.Fit injectors in cylinder head with spill return
outlets facing outward.
10.Secure injector with clamp plate and nut. Tighten
nut to
25 Nm (18 lbf/ft).
NOTE: The clamp plates are slightly
curved and should be fitted with the
convex side uppermost.
11.Fit the spill return pipe with a single copper
washer under the head of the banjo bolt and 2
copper washers fitted between the injector and
the banjo. Tighten banjo bolt to
10 Nm (7 lbf/ft).
12.Fit high pressure pipes to injectors and injection
pump. Tighten union nuts to
28 Nm (21 lbf/ft).
13.Fit sound insulation cover and oil filler cap.

MANUAL GEARBOX
1
ADJUSTMENT GEAR CHANGE LEVER BIAS SPRING - ADJUST
Service repair no - 37.16.26
1.Remove gear lever and transfer box lever knobs.
2.Remove gear lever cover.
3.Remove nut and washer securing gear lever.
4.Mark gear lever spline setting, remove lever and
gaiter from lower lever.
5.Remove insulation pad from tunnel aperture.
6.Fit gear lever and select 3rd or 4th gear.
7.Slacken adjustment screw locknuts.
8.Adjust screws until both legs of bias springs are
approximately 0.5mm clear of gear lever cross
pin.
9.Apply a slight load to gear lever in a LH direction
and adjust RH screw downward until RH spring
leg just makes contact with cross pin.
10.Repeat procedure for LH adjustment screw.
11.Lower both adjustment screws equal amounts
until radial play is eliminated.
12.Tighten locknuts.
13.Return gear lever to neutral position and rock
across gate several times. The gear lever should
return to 3rd and 4th gate.
14.Remove gear lever.
15.Fit insulation pad.
16.Locate gaiter over lower lever and bias springs.
17.Fit gear lever to lower lever spline, secure with
new nyloc nut and tighten to
25 Nm (18 lbf/ft).
18.Fit gear lever cover.
19.Fit gear lever and transfer box lever knobs.

MANUAL GEARBOX
3
ADJUSTMENT
12.Slacken stop screw locknut.
13.Apply light pressure to gear lever towards LH
side and turn screw clockwise until it abuts yoke.
14.Turn screw anti-clockwise until 25 mm freeplay
is felt at gear lever knob. Ensure 5th gear can be
engaged.
15.Tighten stop screw locknut.
16.Check that all other gears are selectable.
17.Remove gear lever.
18.Manouvre tunnel cover into position and secure
with 16 screws.
19.Fit fuse box and cover.
20.Fit tunnel carpet.
21.Fit insulation pad into tunnel aperture.
22.Locate gaiter over lower lever and bias springs.
23.Fit gear lever to lower lever spline, secure with
new nyloc nut and tighten to
25 Nm (18 lbf/ft).
24.Fit gear lever cover.
25.Fit gear lever and transfer box lever knobs.

37MANUAL GEARBOX
4
REPAIR
37.Pull handbrake cable through heel board and tie
aside.
38.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer box.
39.Release speedometer cable from retaining clip
on transfer box.
40.Remove retaining nut and release battery earth
strap from transfer box.
41.Secure manufactured cradleLRT-99-007to a
suitable hydraulic hoist.
42.Raise hoist and secure to gearbox with 3 bolts in
location provided.
43.Lower hoist sufficiently to allow transfer lever to
clear transmission tunnel aperture.
44.Disconnect differential lock switch and reverse
light connectors.
45.Remove bolt and release earth leads from RH
side of transfer box.
46.Support engine under sump with a jack.
47.Remove 14 bell housing to engine fixings.
48.Withdraw transmission whilst ensuring all
connections to engine and chassis are released.
49.Lower hoist and remove gearbox assembly.

STEERING
3
FAULT DIAGNOSIS STEERING DAMPER
The power steering system, as well as reducing the
effort required to manoeuvre the vehicle when
parking, also helps to dampen any deflections of the
road wheels, being transmitted back to the steering
wheel.
When operating the vehicle off road, the road wheels
are often deflected by ruts and boulders causing the
steering wheel to turn left and right. This phenomenon
is known as 'steering kickback'. To subdue the effects
of 'steering kickback', a hydraulic damper is fitted in
the steering linkage between the track rod and the
differential casing. The damper, which offers the same
resistance in extension and compression, is sealed for
life.
Steering damper check
Check the condition operation of the hydraulic
steering damper as follows:
Check procedure
1.Inspect damper for casing damage or leaks.
2.Clamp one end of the damper horizontally in a
vice using soft jaws. Compress and extend the
unit by hand. Resistance should be equal in both
directions.
3.If it is felt that the unit is outside acceptable
limits, fit a new steering damperSTEERING FAULTS
Symptom:-
Excessive kickback through steering wheel - when
driven on rough terrain.
1.Is the steering damper in good working order?
See Steering Damper.
NO - Renew unit
See Repair, Steering
Damper
.
YES - Continue.
2.Is there any looseness or free play in the
steering ball joints and linkage?
YES -
See Steering Linkage Inspect.
NO - Continue.
3.Is there any looseness or worn bushes in front
suspension?
YES -
See FRONT SUSPENSION, Repair,
Radius Arm
.
NOTE: When replacing suspension bushes
ALL bushes and fixings must be replaced.
NO - Continue.
4.Is the steering exceptionally light/sensitive when
driven on good road surface?
YES - See fault symptom -Steering
excessively light/sensitive and freeplay at
steering wheel.
NO - Suspect axle swivel resistance.
5.Check the resistance of the axle swivels
See
FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing
.

STEERING
5
FAULT DIAGNOSIS REV: 05/99 Symptom :-
Steering excessively light/sensitive. Excessive
freeplay at steering wheel.
1.Are steering box adjustments correct?
NO -
See Adjustment, Power Steering Box.
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is within warranty, it must be
returned to manufacturer. No attempt must be
made to introduce backlash.
YES - Suspect worn panhard rod or radius arm
bushes. Check condition of ball joints and the
lower steering column shaft universal joints for
wear
See Repair, Lower Steering Shaft and
Universal Joints
.
Symptom :-
Steering vibration, road wheel shimmy - wobble.
Vibration through the steering linkage powerful
enough to induce high frequency oscillation of the
steering wheel, is generally caused by out of balance
road wheels. However there are a number of other
possible causes of this symptom which if severe, may
be described as shimmy or wobble. Regardless of the
terminology used by the owner/driver to describe the
symptoms, the following diagnostic checks should be
carried out in the order presented.
1.Check the tyres and balance of the road wheels
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres
,See
WHEELS AND TYRES, Fault diagnosis, Fault
- Symptoms See WHEELS AND TYRES,
Repair, Wheel Balancing .
2.Check the steering hydraulic damper function
See Steering Damper.
3.Check steering column universal joints for wear
and correct alignment
See Repair, Lower
Steering Shaft and Universal Joints
.4.Check steering linkage ball joints for wear,
correct alignment and security, including steering
box and tie rod
See Steering Linkage Inspect
.
5.Check all front suspension rubbers for wear.
Check all fixing torques, including radius arm
bushes, panhard rod and anti-roll bar
See
FRONT SUSPENSION, Repair, Panhard Rod
,
See FRONT SUSPENSION, Repair, Radius
Arm
,See FRONT SUSPENSION, Repair,
Anti-Roll Bar
,See FRONT SUSPENSION,
Repair, Front Shock Absorber
.
6.Fit new radius arm bushes using NTC 6781. Fit
new nuts, bolts and washers.
7.If problem persists fit damper kit STC 288 - 90,
STC 290 - 110/130 (2 off front) and STC 289 -
90, STC 291 - 110 levelled, STC 292 - 110
unlevelled, STC 293 - 130 (2 off rear). Road test
vehicle.
8.Check the power steering box adjustments and
operation
See Overhaul, Power Steering Box.
9.Check the hub bearing end floats and determine
the condition of the hub bearings as applicable
See FRONT AXLE AND FINAL DRIVE, Repair,
Front Hub Assembly
.
10.Check the resistance and condition of the
swivels
See FRONT AXLE AND FINAL DRIVE,
Description and operation, Description
.
If problem is not diagnosed: Repeat checks
starting at 1.
11.Carry out a full steering geometry check
See
GENERAL SPECIFICATION DATA,
Information, Steering
.