1996 LAND ROVER DEFENDER engine

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

ENGINE
17
REPAIR 11.Refit clutch.
See CLUTCH, Repair, Clutch
assembly
12.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 gearbox
13.Reconnect battery.
CRANKSHAFT BEARING BUSH
Service repair no - 12.21.45
Remove
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 bearing bush.
NOTE: The bearing bush can be removed
by using one of the following methods.
Method 1.
Obtain a short length of steel rod of a diameter having
a good slide fit in the bore of the bush. Pack the bore
with grease and insert the steel rod into the end of the
bore, give a sharp blow with a hammer and the
grease should drive out the bush. It is recommended
that the bush and rod be covered by a suitable cloth
or rag to prevent grease from splashing.Method 2.
Thread the bore of the existing bush and using a
suitable bolt extract the bush. Thoroughly clean bush
location ensuring all swarf is removed.
Refit
1.Fit new bush using a suitable shouldered drift,
inserting bush flush with end of crankshaft.
2.Refit flywheel.
See Flywheel
3.Refit clutch.See CLUTCH, Repair, Clutch
assembly
4.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 gearbox
5.Reconnect battery.

12ENGINE
18
REPAIR FLYWHEEL HOUSING
Service repair no - 12.53.01
Remove
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 3 fixings and withdraw starter motor.
6.Remove 2 bolts from top of flywheel housing.
7.Remove 4 bolts securing bottom of flywheel
housing to engine mounting brackets.
8.Remove inner bolts and lift off flywheel housing.Refit
9.Clean rear face of housing and mating face on
block, ensuring all old sealant is removed.
10.Apply sealant to flywheel housing mating face on
cylinder block.
11.Fit housing to cylinder block. Tighten retaining
bolts to
45 Nm (33 lbf/ft).
12.Remove surplus sealant from block.
13.Fit starter motor.
14.Fit flywheel.
See Flywheel
15.Fit clutch.See CLUTCH, Repair, Clutch
assembly
16.Fit gearbox.See MANUAL GEARBOX, Repair,
R380 gearbox
17.Reconnect battery.

ENGINE
19
REPAIR OIL FILTER
Service repair no - 12.60.01
Remove
1.Place drain tray under oil filter.
2.Unscrew filter anti-clockwise, using a strap
wrench, if necessary.
Refit
3.Clean mating face of oil filter adaptor.
4.Coat rubber sealing ring of new filter with clean
engine oil.
5.Screw on filter until sealing ring touches
machined face, then tighten a further half turn by
hand only. DO NOT over tighten.OIL TEMPERATURE CONTROL VALVE
Service repair no - 12.60.69
Remove
1.Clean adaptor housing.
2.Disconnect oil cooler feed pipe from thermostat
extension housing and plug to prevent ingress of
dirt.
3.Remove 2 bolts and carefully withdraw
thermostat extension housing (1) complete with
'O' ring seal (2), thermostat (3), 2 washers (4)
and spring (5).
4.Inspect all parts and renew as necessary.
Refit
5.Fit thermostat to extension housing ensuring pin
locates in hole.
6.Fit two washers and spring to thermostat.
7.Fit a new 'O' ring to extension housing.
8.Insert spring into adaptor and secure extension
housing to adaptor. Tighten bolts to
9Nm(7
lbf/ft).

12ENGINE
20
REPAIR OIL FILTER HEAD GASKET
Service repair no - 12.60.03
Remove
1.Clean filter head adaptor.
2.Disconnect oil cooler pipes and plug to prevent
ingress of dirt.
3.Disconnect oil pressure switch lead.
4.Remove 4 bolts and withdraw filter head,
complete with gasket.
5.Clean mating faces of filter head and cylinder
block.
6.Fit head with new gasket.
7.Tighten bolts to
45 Nm (33 lbf/ft).
8.Reconnect oil pressure switch lead.
9.Reconnect oil cooler pipes.CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery
2.Remove bonnet.
3.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
4.Remove air cleaner.See FUEL SYSTEM,
Repair, Air cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove fuel injectors and pipes.
See FUEL
SYSTEM, Repair, Fuel injectors
7.Remove heater plugs.See FUEL SYSTEM,
Repair, Heater plugs
8.Disconnect radiator top hose from thermostat.
9.Disconnect bleed hose at thermostat.
10.Disconnect water pump hose at thermostat.
11.Disconnect water temperature sensor lead.

ENGINE
21
REPAIR 12.Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Induction
manifold
13.Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust manifold
14.Disconnect heater hose from water pump and
move heater rail aside.
15.Disconnect heater hose from rear of cylinder
head.
16.Remove bolt securing air cleaner mounting
bracket to support strut.
17.Remove bolt securing harness bracket to
cylinder head.
18.Remove rear engine lifting bracket. This will also
release clips securing transmission and engine
breather pipes and multi-plug. Note loose spacer
beneath inner clip.
19.Unscrew 3 bolts, with sealing washers and
remove rocker cover.
20.Remove 3 nuts and 2 bolts and lift rocker shaft
assembly from cylinder head.
21.Remove push rods and store as an identified set
to allow refitment to same location.
22.Remove valve stem caps.
23.Evenly slacken and then remove cylinder head
to block retaining bolts in the sequence shown in
J6157. Two of the bolts also secure the air
cleaner mounting bracket.
24.Lift off cylinder head and remove gasket.
Refit
25.Thoroughly clean mating faces of cylinder block
and head.
26.Select new gasket of correct thickness.
CAUTION: Three gaskets, of different
thicknesses, are available and can be
identified by the number of small holes
punched in the RH side of the gasket. One hole
identifies the thinnest gasket, two holes the
middle thickness and three holes the thickest.
When renewing a gasket it must be of the same
thickness as the one removed.
27.Position gasket on cylinder block with
identification holes on RH side and TOP
identification mark uppermost.

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.

ENGINE
23
REPAIR
43.Check and adjust valve clearances.
See Adjustment, Valve clearances - check
and adjust
44.Fit rocker cover, ensuring oil seal is satisfactory
for continued use, and renew if necessary.
45.Secure rocker cover with special seal washers
and nuts. Tighten to
10 Nm (7 lbf/ft).
46.Fit rear engine lifting bracket, securing breather
pipe and multi-plug retaining clips. Tighten fixing
bolts to
25 Nm (18 lbf/ft).
47.Fit engine harness bracket to cylinder head.
48.Secure air cleaner mounting bracket to support
strut.
49.Connect heater hose to rear of cylinder head.
50.Position heater rail and connect hose from water
pump.
51.Fit exhaust manifold and turbocharger assembly.
See MANIFOLD AND EXHAUST SYSTEM,
Repair, Exhaust manifold
52.Fit induction manifold.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Induction
manifold
53.Connect water temperature sensor lead.
54.Connect water pump hose at thermostat.
55.Fit bleed hose at thermostat.
56.Connect radiator top hose at thermostat.
57.Fit heater plugs.
See FUEL SYSTEM, Repair,
Heater plugs
58.Fit fuel injectors.See FUEL SYSTEM, Repair,
Fuel injectors
59.Fit crankcase ventilation valve and side breather
hose.
60.Fit air cleaner.
See FUEL SYSTEM, Repair,
Air cleaner
61.Refill cooling system.See COOLING SYSTEM,
Repair, Drain and refill cooling system
62.Fit bonnet.
63.Reconnect battery.OIL PUMP
Service repair no - 12.60.26
Remove
1.Remove engine front cover.
See Front cover
gasket
2.Remove 7 screws and release oil pump retaining
plate from engine front cover.
3.Mark oil pump inner gear rotor, outer gear rotor
and front cover housing for reassembly.
4.Check for rotor clearances:
Outer rotor to housing, 0,025 - 0,075 mm (0.010
- 0.030 in).
Inner rotor to outer rotor, 0,025 - 0,075 mm
(0.010 - 0.030 in).
Rotor end float, 0,026 - 0,135 mm (0.010 - 0.054
in).
5.Remove inner and outer rotors.
6.Check condition of oil pump components.
NOTE: If the oil pump seating in the front
cover or retaining plate is badly worn,
pitted or scored, a new front cover must
be fitted.
See Front cover gasket
Always renew oil pump rotors as a pair.
7.Clean sealant from pump retaining plate and
front cover.