1996 LAND ROVER DEFENDER battery

19FUEL SYSTEM
12
REPAIR HEATER PLUG CONTROL UNIT
Service repair no - 19.60.33
Remove
1.Disconnect battery.
2.Remove screw securing control unit to bulkhead.
3.Disconnect multi-plug and release control unit.
Refit
4.Fit harness multi-plug to control unit.
5.Secure control unit to bulkhead.
6.Reconnect battery.AIR CLEANER
Service repair no - 19.10.01
Remove
1.Slacken hose clip and detach outlet hose.
2.Release clips and open air cleaner retaining
straps.
3.Lift up air cleaner, slacken hose clip and detach
inlet hose.
4.Remove air cleaner.
Refit
5.Position air cleaner and connect inlet hose.
6.Close air cleaner retaining straps and secure
lock clips.
7.Connect outlet hose.
NOTE: If an EGR fuel system is fitted,
ensure the modulator valve vacuum spill
pipe is secure in the outlet hose.
AIR CLEANER ELEMENT
Service repair no - 19.10.10
For remove and refit procedure.
See SECTION 10,
Maintenance, Under bonnet maintenance

FUEL SYSTEM
13
REPAIR THROTTLE CABLE
Service repair no - 19.20.06
Remove
1.Disconnect battery.
2.Remove split pin and clevis pin securing throttle
cable to injector pump throttle lever .
3.Depress ferrule retaining tags, release ferrule
from abutment bracket and withdraw throttle
cable.
4.Release throttle cable from clip on bulkhead.
5.Remove pin and clevis pin securing throttle
cable to pedal lever.
6.Release grommet from bulkhead.
7.Withdraw throttle cable from engine
compartment.Refit
8.Feed throttle cable through bulkhead from
engine compartment and fit grommet.
9.Secure throttle cable to pedal lever. Use new
split pin to secure clevis.
10.Secure throttle cable in bulkhead clip.
11.Guide throttle cable through abutment bracket
and fit ferrule.
12.Secure cable to injection pump throttle lever.
Use new split pin to secure clevis.
13.Adjust throttle cable.
See Adjustment,
Throttle cable
THROTTLE PEDAL
Service repair no - 19.20.01
Remove
1.Remove throttle cable from pedal.
See Throttle
cable
2.Remove 6 bolts securing throttle pedal assembly
to engine bulkhead.
3.Remove pedal assembly from footwell, complete
with trim retainer.
4.Release return spring from pedal lever.
5.Remove roll pin securing pivot shaft to pedal
assembly.
6.Withdraw pivot shaft and remove pedal from
mounting bracket.
7.Remove return spring from pedal boss.
Refit
8.Fit return spring to pedal boss.
9.Fit pedal to mounting bracket and locate return
spring.
10.Fit pivot shaft to pedal assembly and secure with
roll pin.
11.Locate return spring on pedal lever.
12.Secure throttle pedal assembly and trim retainer
to bulkhead. Tighten bolts to
9 Nm (7 lbf/ft).
13.Fit throttle cable to pedal.See Throttle cable
14.Adjust pedal, if necessary.See Adjustment,
Throttle pedal adjustment

19FUEL SYSTEM
14
REPAIR TURBOCHARGER INLET HOSE
Service repair no - 19.42.11
Remove
1.Disconnect battery.
2.Slacken retaining clip and disconnect intake
hose from turbocharger.
3.Slacken retaining clip and disconnect hose from
air cleaner.
4.If fitted, disconnect EGR modulator valve
vacuum spill pipe from inlet hose.
5.Slacken retaining clip and disconnect breather
valve hose from inlet hose.
6.Remove inlet hose.
Refit
7.Fit inlet hose to air cleaner.
8.Fit cyclone breather hose to inlet hose.
9.If applicable, fit vacuum spill pipe to inlet hose.
10.Fit inlet hose to turbocharger.
11.Reconnect battery.TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1.Disconnect battery.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3.Remove banjo bolt securing oil feed pipe to
turbocharger and discard 2 joint sealing
washers.
4.Unscrew union and remove feed pipe from
cylinder block.
5.Plug connections to prevent ingress of dirt.
Refit
6.Using new joint washer, fit oil feed pipe to
cylinder block. Tighten union connector to
25
Nm (18 lbf/ft).
7.Fit a new joint washer to both sides of banjo and
secure feed pipe to turbocharger. Tighten banjo
bolt to
20 Nm (15 lbf/ft).
8.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
9.Check/top-up engine oil level.See SECTION
10, Maintenance, Under bonnet maintenance
10.Reconnect battery.

FUEL SYSTEM
15
REPAIR TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1.Disconnect battery.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
front pipe
3.Unscrew union and disconnect oil drain pipe
from cylinder block.
4.Remove 2 bolts securing oil drain pipe to
turbocharger.
5.Remove drain pipe and discard gasket.
6.Plug connections to prevent ingress of dirt.
Refit
7.Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
8.Using new gasket, fit oil drain pipe to
turbocharger. Tighten bolts to
25 Nm (18 lbf/ft).
9.Fit drain pipe to cylinder block and tighten union
connector to
38 Nm (28 lbf/ft).
10.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust front
pipe
11.Check/top-up engine oil level.See SECTION
10, Maintenance, Under bonnet maintenance
12.Reconnect battery.

19FUEL SYSTEM
16
REPAIR INTERCOOLER
Service repair no - 19.42.15
Remove
1.Disconnect battery.
2.Remove 2 nuts securing fan cowl to radiator top
cover.
3.Remove 4 bolts securing radiator top cover to
side covers.
4.Remove 2 bolts from both sides, securing
radiator top cover mounting brackets to bonnet
platform.
5.Detach radiator top cover, complete with
mounting brackets.
6.Slacken retaining clip and disconnect top hose
from intercooler.
7.Slacken 2 clips and disconnect bottom hose
from intercooler.
8.Manoeuvre intercooler upwards and remove
from vehicle.
9.Check condition of foam pads fitted to top and
bottom of intercooler and renew if necessary.
10.Check condition of intercooler locating grommets
in radiator top cover and renew if necessary.
Refit
11.Manoeuvre intercooler into position at LH side of
radiator.
12.Carefully lower intercooler and locate bottom
lugs into radiator bottom support frame.
13.Fit bottom and top hoses to intercooler.
14.Fit radiator top cover and secure mounting
brackets to bonnet platform.
15.Secure radiator top cover to side covers.
16.Fit fan cowl to top cover.
17.Reconnect battery.

COOLING SYSTEM
1
REPAIR VISCOUS COUPLING AND FAN
Service repair no - 26.25.19 - Viscous coupling
Service repair no - 26.25.05 - Fan
Remove
NOTE: The viscous coupling has a LH
thread.
1.Disconnect battery.
2.Using special pulley restraining toolLRT-12-094
and special spannerLRT-12-093unscrew
viscous coupling from pulley hub adaptor thread.
3.Remove viscous coupling and fan from vehicle.
NOTE: If air conditioning is fitted, the fan
cowl will also need removing,
See Fan
cowl
, with the viscous fan unit.
4.If required, remove 4 screws and release
viscous unit from fan blade.
Refit
5.Fit viscous unit to fan blades.
6.If applicable, fit fan cowl.
See Fan cowl
7.Carefully position viscous coupling and fit onto
pulley hub adaptor thread.
8.Using special pulley retaining tool, spanner and
a suitable torque wrench, tighten assembly to
45
Nm (33 lbf/ft).

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.

COOLING SYSTEM
3
REPAIR WATER PUMP
Service repair no - 26.50.01
Remove
1.Disconnect battery.
2.Drain cooling system.
See Adjustment, Drain
and refill cooling system
3.Remove radiator top hose.
4.Remove intercooler top hose.
5.Slacken water pump and power steering pump
pulley retaining bolts.
6.Remove drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
7.Unscrew flange nut and remove belt tensioner.
8.Remove oil filler cap and remove rocker cover
insulation.
9.Slacken retaining clip and disconnect hose at
heater rail.
10.Unscrew 3 bolts and remove water pump pulley.
11.Unscrew 3 bolts and remove power steering
pump pulley.
12.Remove 8 bolts securing water pump, noting
location of 3 through bolts into cylinder block.
13.Withdraw pump and gasket from auxiliary
mounting bracket.
14.Clean all gasket material from mating faces.
Refit
15.Using new gasket, fit water pump to mounting
bracket. Tighten bolts to
25 Nm (18 lbf/ft).
16.Fit power steering pump pulley.
17.Fit water pump pulley. Tighten bolts of both
pulleys to
25 Nm (18 lbf/ft).
18.Fit drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
19.Fit hose at heater rail.
20.Fit rocker cover insulation and oil filler cap.
21.Fit drive belt tensioner. Tighten retaining nut to
45 Nm (33 lbf/ft).
22.Fit intercooler top hose.
23.Fit radiator top hose.
24.Refill cooling system.
See Adjustment, Drain
and refill cooling system
25.Reconnect battery.