1996 LAND ROVER DEFENDER lock

12ENGINE
2
REPAIR ENGINE OIL PRESSURE TEST
Service repair no - 12.90.09/01
WARNING: Use suitable exhaust
extraction equipment if an engine test is
being carried out in a workshop.
WARNING: If vehicle has been running,
engine wil be hot; care must be taken
when fitting test equipment to prevent
personal injury.
1.Check that engine lubricant is to correct level.
2.Remove oil pressure switch .
3.Connect pressure test gaugeLRT-12-052A,as
shown.
4.Start and run engine to normal operating
temperature.
5.With engine running at idle check oil pressure,
which should read 1.76 bar (25.87 lbf/in
2).6.If pressure is low it can be caused by the
following:-
Thin or diluted oil.
Low oil in sump.
Choked oil strainer.
Faulty oil pressure relief valve.
Excessively worn or damaged oil pump
displacement gears.
Excessive crankshaft bearing clearance.
7.If excessive pressure is indicated it can be
caused by :-
Overfilling engine with lubricant.
Sticking oil pressure relief valve.
Blockage in breather system.

ENGINE
3
REPAIR ENGINE
Service repair no - 12.41.01
Remove
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
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
orSee CHASSIS AND BODY, Repair,
Rear undertray
CAUTION: Seal all exposed pipe ends
against ingress of dirt after disconnection.
1.Ensure vehicle is level and apply park brake.
2.Disconnect battery.
NOTE: The vehicle may be fitted with an
alarm and immobilisation system using a
battery backed-up alarm sounder.
See ELECTRICAL, Repair, battery
3.Remove bonnet.
4.Remove cable ties securing gearbox harness to
breather pipes.
5.Disconnect harness from diff lock and reverse
light switches.
6.Manouvre harness into engine bay.
7.Remove air cleaner.
See FUEL SYSTEM,
Repair, Air cleaner
8.Remove radiator assembly.See COOLING
SYSTEM, Repair, Radiator
If air conditioning is fitted the condenser will
have to be removed, compressor pipes and
heater matrix hoses disconnected.
See AIR CONDITIONING, Repair, Condenser
9.Remove rocker cover insulation.
10.Remove feed pipe/hose from turbo-charger and
intercooler.
11.Disconnect heater hoses from cylinder head and
heater rails.
12.Disconnect electrical feed plug at rear of cylinder
head.
13.Disconnect heater plug feed wire.

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.

12ENGINE
10
REPAIR 17.Slacken belt tensioner securing bolt to finger
tight.
18.Insert 13 mm square drive extension bar in
tensioner plate.
NOTE: Belt tensioning should be carried
out using a dial type torque meter having a
range not exceeding
60 Nm (44 lbf/ft).The
torque meter should be used in the almost vertical
position.
19.Apply a tension of
15 Nm (11 lbf/ft)for a new
belt or
12 Nm (9 lbf/ft)for an original belt. When
tension is correct, tighten clamp bolt.
20.Tighten injection pump gear bolts.
21.Remove pin from injection pump gear.
22.Disengage timing pin from timing slot in flywheel
or ring gear.
23.Rotate crankshaft one and three quarter turns in
a clockwise direction; then continue rotation until
timing pin in timing tool can be engaged with slot
in flywheel.
24.Disengage timing pin.
25.Insert pin from special toolLRT-12-045in
injection pump gear and through into pump
flange.
26.Slacken injection pump gear retaining bolts.
27.Slacken tensioner and retension belt.
28.Tighten injection pump gear retaining bolts.
29.Remove pin from injection pump gear.
30.Remove timing tool and refit plug.
31.Fit front cover plate using new gaskets.
See Front cover plate and seal
CRANKSHAFT GEAR
Service repair no - 12.65.25
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.If the crankshaft gear cannot be removed by
hand, use special toolLRT-12-078with main
body and thrust button from special tool
LRT-12-031, as illustrated . Withdraw gear
complete with 'O' ring seal.
Refit
3.Lubricate new 'O' ring seal with petroleum jelly
and slide onto crankshaft, taking care not to
damage seal on woodruff keys.
4.Fit crankshaft gear and tap fully home ensuring
'O' ring seal is properly seated.
5.Fit camshaft drive belt.
See Camshaft drive
belt

12ENGINE
12
REPAIR CAMSHAFT OIL SEAL
Service repair no - 12.13.05
Remove
1.Remove camshaft gear.
See Camshaft gear
2.Remove camshaft oil seal from front cover using
special toolLRT-12-083.
Refit
3.Lubricate a new camshaft oil seal with clean
engine oil.
4.With lip side leading, drive in seal squarely using
special toolLRT-12-082.
5.Fit camshaft gear.
See Camshaft gear
INJECTION PUMP GEAR
Service repair no - 19.30.06
Remove
1.Remove camshaft drive belt.
See Camshaft
drive belt
2.Slacken 3 bolts on front of injector pump gear.
3.Remove special tool pin from gear.
4.Remove 3 bolts and withdraw gear and retaining
plate.
Refit
CAUTION: It is important to ensure that
when the injection pump is locked no
attempt must be made to rotate it. Take
care not to allow the crankshaft to be turned.
5.Fit gear and retaining plate. Tighten bolts to
25
Nm (18 lbf/ft).
6.Insert pin from special toolLRT-12-045in
injection pump gear and through into pump
flange.
7.Fit camshaft drive belt.
See Camshaft drive
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
14
REPAIR ENGINE OIL SUMP
Service repair no - 12.60.44
Remove
1.Disconnect battery.
2.Drain engine oil.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
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
orSee CHASSIS AND BODY, Repair,
Rear undertray
3.Slacken sump securing bolts.
4.Break sealant around sump flange, using a
sharp knife.
5.Remove 22 bolts and withdraw sump.
Refit
6.Clean mating faces of sump, timing gear housing
and cylinder block.
7.Apply a 2,0 mm bead of 'Hylosil RTV102' to the
sump flange, ensuring bead is applied inboard of
the bolt holes.
8.Secure sump to block with 22bolts. Tighten to
25
Nm (18 lbf/ft).
9.Refill engine oil.See LUBRICANTS, FLUIDS
AND CAPACITIES, Information, Capacities
10.Reconnect battery.OIL PICK-UP STRAINER
Service repair no - 12.60.20
Remove
1.Disconnect battery.
2.Drain engine oil.
3.Remove engine oil sump.
See Engine oil
sump
4.Remove 2 bolts securing pipe support bracket to
main bearing cap fixings.
5.Remove bolts from pipe flanges.
6.Withdraw pick-up strainer assembly.
Refit
7.Postion pick-up strainer assembly, fitting a new
'O' ring seal at oil pump connection.
8.Apply Loctite 242E to threads of bolts at main
bearing cap. Fit bolts, tighten to
9 Nm (7 lbf/ft).
9.Fit bolts to pipe flanges. Tighten to25 Nm (18
lbf/ft).
10.Fit sump.See Engine oil sump
11.Reconnect battery.

12ENGINE
16
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing, the complete housing
assembly (1) must be renewed. Housing and seal
assemblies are supplied with their own
former/seal guide (2) already fitted. This former
must not be removed before fitting the assembly
to the engine. If a seal and housing assembly is
received without a former/guide fitted it must be
returned to the supplier. Used formers/guides
must be discarded immediately after use, under
no circumstances should they be reused on other
assemblies.
NOTE: A different rear oil seal housing,
with integral 'O' ring seal and gasket, was
fitted on earlier engines. They must be
replaced with the current housing and gasket (3)
shown below.
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Remove flywheel.See Flywheel
5.Remove 5 bolts and withdraw seal housing,
complete with gasket.
Refit
NOTE: The raised side of groove at the
bottom of seal housing gasket must be
fitted to cylinder block face.
6.Insert slave studs to locate seal housing gasket.
7.Position new gasket over slave studs and
crankshaft flange onto cylinder block.
8.Fit new seal housing assembly, with
former/guide in-situ, over crankshaft flange. This
action will eject former/guide.
9.Secure assembly to cylinder block, removing
slave studs individually and inserting bolts.
Tighten to
25 Nm (18 lbf/ft).
10.Refit flywheel.See Flywheel