1996 LAND ROVER DEFENDER Bonnet release

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.

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.

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

76CHASSIS AND BODY
32
REPAIR BONNET LOCK
Service repair no - 76.16.21
Remove
1.Open bonnet.
2.Mark position of guide plate and lock to bonnet
platform.
3.Remove 8 screws securing grille.
4.Remove grille.
5.Remove 2 bolts securing guide plate and lock.
6.Remove guide plate.
7.Release spring securing lock to bonnet platform.
8.Slacken clamping bolt securing bonnet release
cable.
9.Remove lock.
Refit
10.Fit spring between lock and bonnet platform.
11.Position lock and guide plate to bonnet platform
and nip up bolts.
12.Position guide plate and lock to position marks
and tighten bolts to
10 Nm (7 lbf/ft).
13.Fit cable to lock and tighten clamping bolt.
14.Check operation of release cable and adjust if
necessary.
15.Fit grille and tighten securing screws.
16.Close bonnet.BONNET RELEASE CABLE
Service repair no - 76.16.29
Remove
1.Open bonnet.
2.Remove 8 screws securing grille.
3.Remove grille.
4.Slacken clamping bolt securing bonnet release
cable.
5.Remove cable from lock.
6.Release cable from clip on underside of bonnet
platform.
7.Feed cable through valance and collect
grommet.
8.Release cable from clip fixed to wheelarch under
expansion tank.
9.Loosen clamping nut securing bonnet release
handle to mounting bracket.
10.Remove bonnet release handle from mounting
bracket.
11.Withdraw cable through bulkhead.
Refit
12.Feed cable through bulkhead and fit bonnet
release handle to mounting bracket. Tighten
clamping nut.
13.Route cable behind expansion tank and fit to
securing clip.
14.Feed cable through valance.
15.Fit grommet between cable and valance.
16.Fit cable to securing clip on underside of bonnet
platform.

CHASSIS AND BODY
33
REPAIR 17.Fit cable to lock and tighten clamping bolt.
18.Check operation of release cable and bonnet
lock and adjust if necessary.
19.Fit grille and tighten screws.
20.Close bonnet.

82AIR CONDITIONING
4
REPAIR
8.Remove 4 bolts and large packing washers
securing fan cowling brackets to wing sides.
9.Remove 4 nuts securing fan cowling to lower
mounting bracket and lift complete assembly
from condenser.
10.Remove 2 bolts securing bonnet striker support
plate and cross braces to grille top panel.
11.Remove 2 bolts securing cross braces to front
wings.
12.Lift condenser, from bottom mounting lugs and
carefully ease forwards to clear top grille panel.
13.Lift condenser, complete with receiver/drier, from
vehicle taking care to clear high and low
pressure hose/pipes at side of radiator.
14.Disconnect condenser and receiver/drier pipes.
15.Remove clamp bolts and release receiver/drier if
a new condenser is to be fitted.
16.Discard all pipe connection 'O' rings. Cap or plug
all connections to prevent ingress of dirt and
moisture.Refit
17.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
18.Secure receiver/drier to mounting clamps.
19.Fit condenser and receiver/drier pipes.
20.Lower condenser into position ensuring high and
low pressure pipes are located between radiator
and front wing.
21.Secure cross braces and bonnet striker support
plate to top grille.
22.Secure cross braces to front wings.
23.Secure fan cowl assembly to lower mounting
bracket and front wings.
24.Fit high pressure pipe at evaporator.
25.Fit condenser low pressure pipe at compressor.
26.Connect multi-plug at receiver/drier dual
pressure switch.
27.Connect fan motor lead multi-plug.
28.Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
29.Reconnect battery.
30.Fit grille panel.

ELECTRICAL
7
REPAIR BONNET SWITCH
Service repair no - 86.55.89
Remove
1.Disconnect bonnet switch harness multi-plug.
2.Release harness retaining clip from switch
mounting bracket.
3.Press in retaining clips and remove switch from
mounting bracket.
Refit
4.Insert harness multi-plug and bonnet switch into
mounting bracket. Push switch firmly down to
secure in position.
5.Connect harness multi-plug.
6.Fit harness retaining clip in mounting bracket.ULTRASONIC SENSOR
Service repair no - 86.77.32
Remove
1.Carefully prise ultrasonic sensor from cantrail
trim.
2.Disconnect harness plug and remove sensor.
NOTE: Position of sensor will change
according to vehicle type.
Refit
3.Connect harness plug to sensor.
4.Fit sensor to cantrail trim.