1996 LAND ROVER DEFENDER lock

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

19FUEL SYSTEM
2
ADJUSTMENT LOW AND HIGH IDLE SPEED ADJUSTMENT
NOTE: The high idle speed (cold start idle)
is automatically set by the setting of the
low idle speed and cannot be adjusted
individually.
1.Check and adjust throttle cable.
See Throttle
cable
2.Start engine and run it until normal operating
temperature is reached.
3.Using a suitable tachometer, check the engine
idle speed,
See ENGINE TUNING DATA,
Information, 300Tdi
4.If adjustment is necessary, first slacken the
locknut on injection pump.
5.Turn adjustment screw clockwise to increase
engine speed or anti-clockwise to decrease the
speed. Run engine at an increased speed for a
few seconds then check idle speed again.
6.When correct speed has been achieved, hold
adjuster screw steady while tightening locknut.
NOTE: The low idle speed control is the
only permitted adjustment in service. Any
additional adjustments required must be
entrusted to authorised Bosch agents.THROTTLE PEDAL ADJUSTMENT
Adjust
1.First ensure that throttle cable is correctly
adjusted
See Throttle cable
2.Depress throttle pedal, by hand, to full extent of
injection pump lever travel. Slacken locknut and
adjust throttle pedal stop screw to take up
clearance between screw and bulkhead. Ensure
no strain is placed upon throttle cable and pump
lever.
3.Retighten locknut.

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.

19FUEL SYSTEM
2
REPAIR
13.Remove banjo bolts securing spill return, main
fuel and boost signal pipes, refit banjo bolts after
disconnecting pipes.
14.Remove 2 bolts securing rear of pump to
mounting bracket.
15.Remove 3 pump securing nuts at flange and
withdraw pump and gasket.
16.Fit suitable caps to pipe connections to prevent
ingress of dirt.
Refit
17.Clean mating faces of pump and front cover and
fit new gasket into position over pump mounting
studs.
18.Remove pump blanking plugs.
19.Slacken the 3 bolts, securing injection pump
mounting bracket to cylinder block, sufficiently
enough to allow bracket to move.
20.Fit pump to cover and secure with 3 nuts.
Tighten to
25 Nm (18 lbf/ft).
21.Loosely attach pump to mounting bracket with
nuts and bolts, then tighten bolts securing
bracket to cylinder block and bolts securing
pump to bracket, finger tight only.
22.To ensure correct fitting and alignment of
injection pump, first tighten the 2 bolts securing
pump to mounting bracket to
25 Nm (18 lbf/ft).
Then tighten the 3 bolts securing mounting
bracket to cylinder block, also to
25 Nm (18
lbf/ft).
23.Connect spill return and main fuel pipes and
secure with banjo bolts. Tighten to
25 Nm (18
lbf/ft).
24.Connect boost signal pipe and secure with banjo
bolt. Tighten to
10 Nm (7 lbf/ft).
25.Connect fuel cut-off solenoid lead and throttle
position sensor multi-plug, if fitted.
26.Connect throttle cable and where applicable,
hand throttle cable.
27.Remove pump gear retaining toolLRT-12-045.
28.Carefully turn the pump hub nut in a clockwise
direction, sufficiently enough to enable timing
tool pin to be inserted into injection pump.
29.Fit gear retaining plate and secure with 3 bolts.
Tighten to
25 Nm (18 lbf/ft).
30.Remove timing pin.
31.Ensure flywheel timing pin is disengaged from
slot in flywheel.
32.Turn crankshaft two complete revolutions, check
timing pin fromRT-12-045can be fully and
easily inserted into the pump. At the same time
check flywheel timing pinLRT-12-044can also
be inserted in the flywheel slot.
33.If, with the flywheel timing pin located, the timing
pin cannot be inserted cleanly into the injection
pump, carry out the following:
a.Ensure flywheel timing pin is disengaged from
slot in flywheel.
b.Slacken the 3 pump gear retaining bolts.
c.Turn the pump hub nut in a clockwise
direction, sufficiently to enable timing tool pin to
be easily inserted into the injection pump.
d.Keeping the tension on the hub nut, check
that flywheel timing pin locates with slot in
flywheel.
e.Tighten the 3 pump gear retaining bolts to
25
Nm (18 lbf/ft).
f.Remove timing pins from pump and flywheel
housing.
34.Using a suitable anti-seize compound, fit the
blanking plug to flywheel housing. Tighten to
12
Nm (9 lbf/ft).
35.Fit access plate with gasket to front cover plate.
Tighten bolts to
25 Nm (18 lbf/ft).
36.Refit injector pipes.
37.Reconnect battery.

19FUEL SYSTEM
4
REPAIR FUEL LIFT PUMP
Service repair no - 19.45.09
Remove
NOTE: Blank off pipe ends and
connections to prevent ingress of dirt.
1.Disconnect battery.
2.Remove high pressure fuel pipes, injection pump
to injectors.
3.Disconnect fuel inlet and outlet pipes from lift
pump.
4.Remove 2 bolts and withdraw lift pump and
gasket from cylinder block.
Refit
5.Clean mating faces of pump and cylinder block.
6.Fit lift pump to cylinder block with a new gasket,
ensure correct location of operating lever with
camshaft.
7.Secure with bolts. Tighten to
25 Nm (18 lbf/ft).
8.Connect inlet and outlet pipes using new nuts
and olives.
9.Refit injector pipes. Tighten union nuts to
28 Nm
(21 lbf/ft).
FUEL SEDIMENTOR
Service repair no - 19.25.01
Remove
1.Disconnect battery.
2.Disconnect inlet and outlet fuel pipes from
sedimentor.
3.Slacken drain tap and allow sedimentor to
completely drain.
4.Remove 2 bolts, washers and nuts and detach
sedimentor from chassis mounting bracket.
Refit
5.Secure sedimentor to chassis mounting with
fixing bolts.
6.Reconnect inlet and outlet fuel pipes to
sedimentor.
7.Slacken drain plug until diesel free from air
flows, then retighten plug.
8.Prime vehicle fuel system.
See Adjustment,
Priming the fuel system
9.Reconnect battery.

FUEL SYSTEM
7
REPAIR REV: 05/99
13.Remove single bolt fixing assembly securing
front of tank to chassis mounted bracket.
14.Remove 3 bolts securing tank mounting bracket
to chassis and release bracket.
15.Lower front of tank while turning anti-clockwise
and remove from vehicle.
16.If required, remove tank gauge unit.
See
INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank
orSee INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130
Refit
17.Fit filler hose and clip to tank but do not fully
tighten. Position clip screw so that it is
accessible when tank is fitted.
18.Fit breather hose and secure with clip.
19.Position fuel tank in vehicle and loosely secure
front mounting bracket to tank with special bolt
and rubber bushes.
20.Secure mounting bracket to chassis with 3 bolts
and fully tighten to
20 Nm (15 lbf/ft).
21.Secure rear of tank to chassis mounting and
tighten captive bolt plate fixings to
20 Nm (15
lbf/ft).
22.Fully tighten front fixing bolt assembly to20 Nm
(15 lbf/ft).
23.Fit spill return and fuel supply pipes and secure
union connections.
24.Fit fuel level unit electrical plug.
25.Fit hose to filler tube and tighten upper and lower
clips.
26.Check that drain plug is secure and fill fuel tank.
27.Reconnect battery.
28.Prime fuel system
See Adjustment, Priming
the fuel system
and start engine.
29.Check system for leaks and operation of fuel
gauge.
30.Fit seat base cover and seat cushion.SIDE MOUNTED FUEL TANK - 5 DOOR VEHICLES
Service repair no - 19.55.01
NOTE: This fuel tank is used on 110/130 5
door vehicles fitted with a twin tank
option.
WARNING: Before any attempt is made to
start the removal procedure it is vital that
the FUEL HANDLING PRECAUTIONS,
See
INTRODUCTION, Information, Fuel handling
precautions
are carefully studied and
implemented in the interests of safety.
Remove
1.Disconnect battery.
2.Remove tank drain plug, allow fuel to drain into a
clean container, and refit plug.
3.Remove RH seat cushion.
4.Remove retaining catch and remove seat base
cover to gain access to fuel tank.
5.Disconnect electrical plug from fuel gauge unit.
6.Disconnect fuel supply pipe from tank.
7.Disconnect spill return pipe from tank.
8.Remove 3 bolts securing tank to front mounting
bracket.
9.Support front of tank and remove single fixing
assembly securing tank to rear mounting
bracket.
10.Remove tank from vehicle.
11.If required, remove fuel gauge unit.
See
INSTRUMENTS, Repair, Fuel gauge tank unit
- side fuel tank
orSee INSTRUMENTS,
Repair, Fuel gauge tank unit - rear fuel tank,
110/130
Refit
12.Position fuel tank in vehicle and loosely secure
to rear mounting bracket with special bolt and
rubber bushes.
13.Secure tank to front mounting bracket and
tighten fixings to
20 Nm (15 lbf/ft).
14.Fully tighten rear fixing bolt assembly to20 Nm
(15 lbf/ft).
15.Fit spill return and fuel supply pipes to fuel tank
and securely tighten union connectios.
16.Fit electrical plug to fuel gauge unit.
17.Check that drain plug is secure and fill fuel tank.
18.Reconnect battery.
19.Prime fuel system.
See Adjustment, Priming
the fuel system
and start engine.
20.Check system for leaks and operation of fuel
gauge.
21.Fit seat base cover and seat cushion.

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