1996 LAND ROVER DEFENDER belt

ENGINE
13
REPAIR FRONT COVER GASKET
Service repair no - 12.65.10
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.Remove crankshaft gear.See Crankshaft gear
3.Remove camshaft gear.See Camshaft gear
4.Remove injection pump gear.See Injection
pump gear
5.Remove fuel injection pump.See FUEL
SYSTEM, Repair, Fuel injection pump
6.Remove engine oil sump.See Engine oil
sump
7.Remove oil pick up strainer.See Oil pick-up
strainer
8.Remove 10 bolts securing timing gear housing to
block.
9.Withdraw timing gear housing complete with
gasket.
10.Clean all gasket material from mating faces.
Refit
11.Fit slave guide studs to locate gasket.
12.Fit new gasket to cylinder block.
13.Align flats on oil pump with flats on crankshaft.
14.Fit front cover to block taking care not to damage
oil seal.15.Secure with bolts of correct length in locations
where slave studs are not fitted, see J6149.
16.Remove slave studs and fit correct length bolts.
17.Tighten all bolts to
25 Nm (18 lbf/ft).
1- 25 mm,2- 35 mm,3- 80 mm.
18.Fit oil pick-up strainer.
See Oil pick-up
strainer
19.Fit oil sump.See Engine oil sump
20.Fit fuel injection pump.See FUEL SYSTEM,
Repair, Fuel injection pump
21.Fit injection pump gear.See Injection pump
gear
22.Fit camshaft gear.See Camshaft gear
23.Fit crankshaft gear.See Crankshaft gear
24.Fit camshaft drive belt.See Camshaft drive
belt

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

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
3
ADJUSTMENT INJECTION PUMP TIMING - CHECK AND ADJUST
Service repair no - 19.30.01
1.Viewing the valve mechanism through oil filler
aperture, turn crankshaft clockwise until inlet
valve of No.1 cylinder has just closed. No.1
cylinder is now just before TDC.
2.Remove blanking plug from flywheel housing
and insert timing toolLRT-12-044, locating
centre pin on flywheel.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
adjustments or remove and refit procedures are
required, it may be necessary to remove the
undertray and/or integral access panels.
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
3.Cearfully rotate crankshaft clockwise until centre
pin engages timing slot in flywheel.
4.Remove injection pump access plate, complete
with gasket, from front cover plate.
5.Fit locking pinLRT-12-045/2to injection pump
gear. If difficulty is experienced in inserting pin,
adjustments will be needed to correctly set
injection pump timing as follows:
6.Support injection pump retaining nut to prevent
strain on timing belt.
7.Slacken the 3 keeper plate retaining bolts.
8.Carefully turn fixing nut and keeper plate until
locking pin can be inserted, without restriction,
into injection pump gear.
9.Tighten keeper plate bolts to
25 Nm (18 lbf/ft)
and remove locking pin.
10.Refit injection pump access plate plate and
gasket.
11.Remove flywheel timing tool and refit blanking
plug.
12.Run engine until normal operating temperature is
reached and check that idle speed adjustment,
See low and high idle speed adjustmentand
throttle cable adjustment
See Throttle cable
are correct.

FUEL SYSTEM
1
REPAIR FUEL INJECTION PUMP
Service repair no - 19.30.07
Remove
1.Disconnect battery.
2.Disconnect and remove high pressure fuel
injection pipes, pump to injectors.
3.Viewing valve mechanism through oil filler cap
aperture, turn crankshaft clockwise until No. 1
cylinder is just before TDC.
4.Remove blanking plug from flywheel housing
and fit timing toolLRT-12-044, locating centre
pin on flywheel.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
adjustments or remove and refit procedures are
required, it may be necessary to remove the
undertray and/or integral access panels
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
5.Carefully rotate crankshaft clockwise until centre
pin engages with timing slot in flywheel.
6.Remove injection pump access plate, complete
with gasket, from front cover plate.
7.Fit pin fromLRT-12-045to injection pump gear.
8.Restrain pulley nut to prevent straining timing
belt and remove drive gear to pump hub fixing
bolts and retaining plate.
9.Remove pin from pump gear.
10.Fit gear retaining toolLRT-12-045with an 8 mm
washer, 1,5 - 2 mm thick, under each bolt head
in addition to the existing washer.
11.Remove throttle cable and hand throttle cable, if
fitted.
12.Disconnect lead from fuel cut-off solenoid, and
EGR throttle position sensor multi-plug, if fitted.

FUEL SYSTEM
11
REPAIR HEATER PLUGS
Service repair no - 19.60.31
Remove
1.Disconnect battery.
No.1 heater plug - air conditioning models:
2.Release drive belt from compressor pulley.See
AIR CONDITIONING, Repair, Compressor
drive belt
3.Remove 4 bolts securing compressor to front
cover, move compressor aside.
No.3 heater plug:
4.Remove retaining bolt and withdraw breather
valve from rocker cover. Remove and discard 'O'
ring.
All heater plugs:
5.Remove terminal nut and disconnect wire from
heater plug terminal.
6.Unscrew heater plug.
Refit
7.Clean heater plug and seating.
8.Coat threads of heater plug with suitable
anti-seize compound operational to a
temperature of 1000°C.
9.Fit heater plug, tighten to
23 Nm (17 lbf/ft).
10.Connect wire to heater plug terminal and secure
with nut.
NOTE: Feed wire must be connected to
No. 4 heater plug terminal.
No. 3 heater plug:
11.Lubricate new 'O' ring with engine oil and fit to
breather valve.
12.Fit valve to rocker cover, tighten to bolt to
15 Nm
(11 lbf/ft).
No. 1 heater plug - air conditioning models
13.Position compressor to front cover, fit bolts and
tighten to
25 Nm (18 lbf/ft).
14.Fit drive belt to compressor pulley and adjust
tension.
See AIR CONDITIONING, Repair,
Compressor drive belt
All models:
15.Reconnect battery.

26COOLING SYSTEM
2
DESCRIPTION AND OPERATION ENGINE (COOLANT) COOLING
Description
The 300Tdi engine uses a pressurised cooling system
and cross flow radiator which is supplied with coolant
from an expansion tank mounted on the RH side of
the engine compartment. A belt driven centrifugal
water pump, fitted to an auxiliary mounting assembly,pumps coolant to the engine crankcase, cylinder head
and vehicle heater unit.
An eleven bladed fan, incorporating a viscous
coupling, is driven by an independent pulley secured
to the front cover plate. The thermostat housing,
bolted to the front of the cylinder head, is fitted with a
vent valve that purges excessive air pressure and
coolant back to the expansion tank.
Engine coolant circulation (engine warm - thermostat open).
1.Radiator
2.Thermostat/housing
3.Radiator bottom hose
4.Viscous fan
5.Water pump
6.Radiator top hose
7.Heater return hose
8.Coolant supply hose9.By-pass hose
10.Radiator bleed (purge) hose
11.Thermostat housing bleed (purge) hose
12.'Y' piece ejector
13.Expansion tank
14.Heater rail
15.Heater unit
16.Heater feed hose

26COOLING SYSTEM
2
REPAIR FAN COWL
Service repair no - 26.25.11
Remove
1.Disconnect battery.
2.Drain coolant.
See Adjustment, Drain and
refill cooling system.
3.Slacken retaining clips and remove radiator top
hose.
4.Slacken retaining clip and remove top hose from
intercooler.
NOTE: On vehicles fitted with EGR system,
remove complete intercooler top hose
assembly.
5.Remove viscous coupling and fan
See Viscous coupling and fan.
6.Remove 2 nuts securing top of fan cowl.
7.Release expansion tank hose from clips at base
of fan cowl.
8.Lift and remove cowl .
NOTE: On vehicles fitted with air
conditioning, it will be necessary to
remove the cowl and viscous fan unit
together to enable clearance of the compressor.Refit
9.Position fan cowl.
10.Fit viscous fan unit.
See Viscous coupling
and fan
11.Fit expansion tank hose into fan cowl clips.
12.Secure top of fan cowl to radiator top cover.
13.Fit intercooler top hose.
14.Fit radiator top hose.
15.Refill cooling system.
See Adjustment, Drain
and refill cooling system
16.Reconnect battery.
FAN PULLEY
Service repair no - 26.25.04.
Remove
1.Disconnect battery.
2.Remove viscous fan unit.
See Viscous
coupling and fan
3.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
4.Unscrew 4 bolts and remove pulley from adaptor
boss.
Refit
5.Fit fan pulley to adaptor boss. Tighten bolts to
25
Nm (18 lbf/ft).
6.Fit drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
7.Fit viscous fan unit.See Viscous coupling
and fan
8.Reconnect battery.