Land Rover Defender 90 110 Workshop Book 2 Rover

							V8 CYLINDER ENGINE 112) 
6. Clean the combustion  chambers with a soft  wire 
brush. 
7. Clean the valves. 
8. Clean the valve  guide bores. 
wv 7 m- 
Fit new valve guides 
9. Regrind or fit new valves  as necessary. 
10. If a valve  must be ground to a knife-edge  to obtain 
11. The  correct angle for the valve  face  is 45 degrees. 
12. The correct  angle for the seat is 46 + /4 degrees, 
and 
the seat  witness  should  be towards  the outer 
edge. 
a true  seat,  fit a new valve. 
ST 793M 
13. Check  the valve  guides  and fit replacements  as 
necessary.  Using the valve  guide  remover 
274401, 
drive out the  old guides  from  the  rocker shaft side 
of the cylinder  head. . ?: 
14. Lubricate  the new  valve  guide  and  place in 
position. Using guide drift 600959  drive the guide 
into  the  cylinder head 
until it protrudes 19 mm 
(Xi in) above the valve  spring  recess in the head. 
NOTE: Service valve guides  are 0,02 mm (0.001 in) 
larger  on  the  outside  diameter  than  the  original 
equipment to ensure interference  fit. 
Examine and 
fit new  valve  seats 
15. Check  the valve  seats for  wear,  pits  and  burning 
and renew the  inserts 
if necessary. 
continued 
97  
						

							12 
16. Remove  the old seat inserts  by grinding them  away 
until  they are thin  enough to  be cracked  and prised 
out. 
17.  Heat  the cylinder  head evenly  to approximately  65 
degrccs C (1 50 degrees F). 
18. Press thc new  insert  into the recess in the cylinder 
head. 
V8 CYLINDER ENGINE 
NOTE: Service  valve  seat  inserts  are  available  in 
two  over
-sizes: 0,25 and 0,50 mm (0.010 and 0.020 
in)  larger on the  outside  diameter  to  ensure 
interference  fit. 
19. If necessary, cut the valve  seats to 46 + 14 degrees. 
20. The  nominal  seat width  is 1,5 mm (0.031 in). If the 
seat exceeds 2,O mm (0.078  in) it should  be 
reduced  to the  specified  width 
by the use of 20 and 
70 
degrec cutters. 
21.  The inlet valve  seat diameter,  A is 37,03 mm 
(1.358 ins)  and the exhaust  valvc seat is 31,50 mm 
(1.240  ins) diametcr. 
ST797M 
22. Ensure  that the cutter  blades  are correctly  fitted  to 
the  cutter  head with 
the angled  end  of the blade 
downwards  facing 
the work, as illustrated. 
Check  that  the  cutter blades are adjusted 
so that 
the  middle  of the  blade  contacts  the  area 
of 
material to be cut.  Use  the  key provided in the 
hand  set 
MS 76. Use  light  pressure,  and  remove 
only 
the minimum  material necessary. 
ST1024M 
23. Smear  a small  quantity of engineers  blue round the 
valve  seat and revolve  a  properly  ground valve 
against  the seat. 
A continuous  fine  line should 
appear  round the valve. 
If there IS a  gap of not 
more  than 12 
mm it can be correctcd by lapping. 
24. Alternatively,  insert a strip of cellophane  between 
the valve  and seat,  hold the valve  down  by thc stem 
and  slowly  pull  out the cellophane. 
If there is a 
drag  the seal  is satisfactory  in that  spot. Repeat  this 
in at least  eight  places.  Lapping-in will correct a 
small  open spot. 
Assemble valves  to cylinder head 
25.  Before  fitting the valves  and springs  the height  of 
each  valve  above the  head must  be checked.  Insert 
each  valve 
in turn in its  guide  and whilst  holding 
the  head  firmly  against  the seat,  measure the  height 
of 
the stem  above  the  valve spring  seat surface. 
This  dimension  must 
not exceed 47,63 mm 
(1.875 ins). If necessary  renew the valve or grind 
the  end  of the  valvc 
stem. 
26.  Lubricate the valve stcms and assenible the valves, 
springs  and caps  and  secure with the collets  using 
valve  spring  compressor  276102. 
NOTE: Seals  are fitted  to the inlet  valves on later 
engines,  but these can also 
be fitted to early engines 
if required. 
P;; $.. .* -2 
98  
						

							V8 CYLINDER ENGINE 1121 
-- Reclaiming cylinder head threads 
Damaged or stripped threads in the cylinder  head can 
be  salvaged  by fitting  Helicoils 
as follows: 
I~Ioles A -These threc holes may be drilled  0.3906 in. 
dia. x 0.937 + 0.040 in. deep. Tapped with Helicoil  Tap 
No. 6 CPB or 6CS x 0.875 in. (min.)  deep (g UNC 1%D 
insert). 
Holes B - These eight holes  may be drilled  0.3906 in. 
dia. x 0.812 + 0.040 in. deep.  Tapped  with Helicoil  Tap 
No. 6 CBB  0.749  in. (min.)  deep (a UNC 1MD insert). 
Holes  C 
- These four holes may be drilled  0.3906 in. 
dia. x 0.937 + 0.040 in. deep.  Tapped  with Helicoil  Tap 
No. 
6 CPB or 6CS x 0.875 in. (min.)  deep ($ UNC 1 %D 
insert). 
Holes D - These  four holes  may be drilled  0.261 in. 
dia. x 0.675 + 0.040 in. deep. Tapped with Helicoil  Tap 
No. 4CPB or 4CS x 0.625 in. (min.) deep (% UNC 
1 KD insert). 
Holes 
E - These six holes may be drilled  0.3906 in. 
dia. x 0.937 + 0.040 in. deep. Tapped  with Hclicoil  Tap 
No. 6 CPR or 6CS x 0.875 in. (min.)  deep (i UNC lW3 
insert). 
- 
NOTE: Right-hand cylinder head illustrated. 
American projection. 
F Exhaust  manifold  face 
G Inlet manifold  face 
H Front face 
I Rear face 
J Front of engine 
F 
A 
 
I I 
/ 
I 
ST 799M G 
99  
						

							El V8 CYLINDER ENGINE 
REMOVE AND OVERHAUL FLYWHEEL 6. Place a chisel  immediately  above the drilled 
hole  and strike 
it sharply  to split  the starter  ring 
gear. 1. Remove  the retaining  bolts and withdraw  the 
flywheel  from the crankshaft. 
2. Examine  the flywheel  clutch face for cracks,  scores 
and  overheating. 
If the overall  thickness of the 
flywheel 
is in excess of the  minimum  thickness i.e. 
39,93 mm (1.572 in) it can be refaced  provided  that 
after  machining 
it will not be below  the minimum 
thickness.  Remove the three  dowels  before 
machining. 
3.  Examine  the ring  gear  and 
if worn or the teeth  are 
chipped  and broken  it can  be renewed 
as follows: 
3 
 
7. Heat  the new  ring gear  uniformly  to between  170 
degrees  and 
175 degrees C (338 degrees to 347 
degrees 
F) but  do not  exceed  the higher 
temperature. 
8. Place  the flywheel,  clutch side down, on a flat 
surface. 
9. Locate  the heated  starter ring gear  in position on 
the  flywheel,  with the chamfered  inner diameter 
towards  the flywheel  flange. 
If the starter  ring gear 
is chamfered  both sides,  it can be  fitted either  way 
round. 
10. Press  the starter  ring gear  firmly  against  the flange 
until  the ring  contracts  sufficiently 
to grip the 
flywheel. 
11. Allow  the flywheel  to cool  gradually. Do NOT 
hasten  cooling  in any  way or distorting  may occur. 
12. Fit new  clutch  assembly  location dowels to the 
flywheel. 
I ST803M 2 
4. Drill  a 10 mm (.375 in) diameter  hole axially 
between  the 
diameter 
of the  starter  ring sufficiently  deep to 
weaken the ring.  Do NOT allow  the drill to enter 
the  flywheel. 
and 
piace a  cioth  over the fiywheei to protect rhe 
operator  from flying  fragments. 
root 
of any 
tooth  and the inner 7 
5. Secure  the flywheel in a vice fittcd with soft jaws 9 
WARNING:  Take adequate  precautions  against 
flying fragments when splitting the  ring gear. I 
ST804M 
f-3 :.v 
100  
						

							V8 CYLINDER ENGINE 
REMOVE TIMING GEAR COVER AND WATER 
PUMP 
1. Place an oil  drip-tray  beneath  the timing  cover and 
2. Remove  the crankshaft  pulley bolt and special 
3. Remove  the two bolts securing  the sump  to the 
remove 
the oil filter 
element. 
washer and  withdraw the pulley. 
bottom 
of the  timing  cover. 
ST805M 1 
Renewing timing  cover oil seal 
S. Remove the seven  drive screws  and withdraw  the 
mud  shield  and the oil seal. 
6. Position the gear  cover  with the front  face 
uppermost  and the underside  supported  across 
the 
oil seal  housing  bore on a suitable  wooden  block. 
7. Enter the oil seal,  lip side  leading,  into the housing 
bore. 
8. Press in the  oil seal  until  the plain  face is 1,s mm 
(0.062 in) approximately  below thc gear cover 
face. 
9. Fit  the  mud  shield  and secure  with the screws. 
4.  Remove  the remaining  timing cover retaining  bolts 
and  withdraw  the cover  complete  with 
oil pump. 
REMOVE AND OVERHAUL  THE OIL PUMP 
1. Remove  the bolts  from the oil pump  cover. 
2. Withdraw the oil pump  cover. 
3. Lift off the cover  gasket. 
4.  Withdraw  the oil pump  gears. 
101  
						

							12 
Dismantle pump  Assemble pump 0 ,,-,-.. ..__ . ...
						

							V8 CYLINDER ENGINE 112 
/, ,d.%:h. 2. Withdraw the chaln wheels complete  with timing 
6.  Measure the camshaft journals for overall  wear, 
ovality  and  taper. The diameters  of the  five 
journals  are as follows  commencing 
from the front 
of  the  shaft. 
c. 3 chain. 
3. Withdraw thc camshaft  whilst taking particular 
carc not to daniagc thc bearings in the cylinder 
block. 
 
_. ... , .... ., . : “I. . 
Examine components 
4. Visually  examine  all parts for wear.  Check the 
camshaft  bearing  journals and cams for wcar,  pits, 
scores  and  overheating.  Should any of these 
conditions 
be present  the shaft should  be renewed. 
5.  Examine  the 
links and  pins  of the  timing  chain for 
wcar  and compare  its condition  with that of a I.ew 
chain.  Similarly  the teeth of the chain wheels 
should  be  inspected 
and if necessary the wheels 
should  be renewed.  Number 
1 journal 
1.786 to  1.785  ins 
Number 
2 journal 1.750 to  1.755 ins 
Number 
3 journal  1.726 to 1.725 ins 
Number 
4 journal  1.696 to 1.695 ins 
Number 
5 journal  1.666 to 1.665 ins 
7. 
To check  the camshaft for bow,  rest the two end 
journals  i.e. 
numbers 1 and 5 on ‘V’ blocks  and 
mount  a dial  gauge 
on the centre  journal.  Rotate 
the shaft and note  the  reading. If the run out is 
more  than 
0,05 mm (0.002 in) it should  be 
renewed. 
REMOVE  AND OVERHAUL  CONNECTING-RODS 
AND 
PISTONS 
1. Withdraw  the remaining  bolts  and remove [he 
2. Remove  the sump  oil strainer. 
3. Removc the  connccting-rod  caps and retain  them 
in sequence for reassembly. 
4. Screw  the guide  bolts 605351 onto the connecting- 
rods. 
sump. 
continued 
103  
						

							V8 CYLINDER ENGINE 
5. Push the connecting-rod  and  piston  assembly  up 
the  cylinder  bore and withdraw 
it from  the top. 
Retain  the connecting
-rod  and  piston  assemblies in 
sequence  with their  respective  caps. 
6. Remove  the guide  bolts 605351 from the 
connecting
-rod. 
Overhaul 
NOTE: The  connecting-rods,  caps and bearing  shells 
must  be retained  in sets,  and in the  correct  sequence. 
Remove  the piston  rings over the crown 
of the piston. If 
the  same  piston is to be refitted,  mark it relative  to its 
connecting
-rod  to ensure  that the original  assembly  is 
maintained. 
7. Withdraw  the gudgeon  pin, using  tool 18G 1150 as 
follows: 
a. Clamp  the hexagon  body 
of 18G 1150 in a vice. 
b. Position the large  nut flush  with the cnd of the 
c.  Push 
the screw  forward  until the nut contacts  the 
centre 
scrcw. 
thrust  race. 
ST777M 
104 
d. Locate  the piston  adaptor 18G 1150 E with its e 
long spigot  inside the bore  of the  hexagon  body. 
e. Fit the remover/replacer bush of 18G 1150 on 
the centre  screw with the flanged  end away from 
the gudgeon  pin. 
f.  Screw  the stop
-nut  about  half-way onto  the 
smaller  threaded  end of the  centre  screw, 
leaving 
a gap ‘A’ of 3 mm (B in)  between  this nut 
and  the 
remover/replacer bush. 
ypJ 
g. Lock  the stop-nut  securely  with the lock  screw. 
h.  Check  that the remover
-replacer  bush is 
correctly  positioned 
in the bore of the piston. 
i. Push  the connecting-rod to the right  to expose 
the  end 
of the gudgeon  pin, which  must be 
located 
in the  end of the  adaptor ‘d’. 
j. Screw  the large  nut up to the  thrust  race. 
k. Hold the lock  screw  and turn  the large  nut until 
the  gudgeon  pin has  been  withdrawn  from the 
piston.  Dismantle 
the tool. 
continued 
d a c b!  
						

							V8 CYLINDER ENGINE 
. 8. As an alternative  to tool 18G 1150, press the 
gudgeon  pin from  the piston  using an hydraulic 
press  and the components  which comprise  tool 
605350 as follows: 
a.  Place  the base 
of tool 605350 on the bed of an 
hydraulic  press which  has 
a capacity of 8 tons (8 
tonnes). 
b. Fit the guide  tube into the bore of the  base  with 
its  countersunk  face uppermost. 
c.  Push  the piston  to one  side 
so as to expose one 
end  of the  gudgeon  pin and  locate  this end in the 
guide  tube. 
d. Fit the spigot  end of the  small  diameter  mandrel 
into  the gudgeon  pin. 
e. Press out the gudgeon  pin, using the hydraulic 
press. 
_.. .  ... . .:  ...._-.. >.W .: .... _.., .. 
E 
-. 
New pistons 
Pistons  are available in service  standard sizc and in 
oversizes  of 0,25 mm (0.010 in) and 0,50 mm 
(0.020 in).  Service  standard  size pistons  are 
supplied 
0,0254 mm (0.001 in)  oversize.  When 
..fitting  new service  standard  size pistons  to 
a 
cylinder  block, check for correct  piston to bore 
clearance,  honing the bore 
if necessary.  Bottom of 
piston skirt-bore clearance  should be 0,018 to 
0,033 mm (0.0007 to 0.0013 in). 
NOTE: The temperature of the piston  and cylinder 
block  must be the  same  to ensure  accurate 
measurement.  When reboring  the cylinder  block, 
the  crankshaft  main bearing  caps 
must be fitted  and 
tightened  to the  correct  torque. 
9. Check the cylinder  bore dimension  at right  angles 
to the gudgeon  pin, 40 to 50 mm (1/2 to 2 in) from 
the  top. 
10. Check  the piston  dimension  at right  angles  to the 
gudgeon  pin, at 
the bottom  of the  skirt. 
11. The  piston  dimension  must be 0,018 to 0,033 mm 
(0.0007 to 0.0013 in) smaller  than the cylinder. 
12. If new  piston  rings arc to be  fitted  without 
reboring,  deglaze the cylinder  walls 
with a hone, 
without 
incrcasing the  bore  diameter  to provide  a 
cross
-hatch  finish. 
Original  pistons 
Remove  the carbon  deposits,  particularly  from the 
ring  grooves. 
Examine 
the pistons for signs of damage or 
excessive  wear; refer to new  pistons for the 
pistons 
if necessary. 
-0thnA n$ he,- r; tha w..,r-;on ,- -.-Y~-,-- E:+ -a. IIILLLIVU I CIILAllt; LIIL 1 IIIIIIE) LILJLPIILL. I ,I IlLvv 
continued 
105  
						

							lz[ V8 CYLINDER ENGINE 
13. Check  the  compression ring gaps in the  applicable 
cylinder, 
held square to thc bore  with the piston. 
Gap  limits: 
0,44 to 0,56 mm (0.017  to  0.022  in). 
Use a fine-cut  flat  file to increase  the gap if 
required.  Select a new  piston  ring if the gap 
exceeds the  limit. 
NOTE: Gapping does not apply to oil control  rings.  Fit 
piston  rings 
17. Fit the expander  ring into  the bottom  groove 
making  sure that 
the ends  butt and do not  overlap. 
18. Fit two  ring  rails to the bottom  groove, one  above 
and  one 
below the expander  ring. 
19. Fit the second  compression  ring with the  marking 
‘TOP’ uppermost and the chrome compression ring 
in the top groove, either  way round. 
ST819M / 
14. Temporarily fit the compression  rings to the piston. 
15. The  ring marked ‘TOP’ must  be fitted with  the 
marking  uppermost  and  into 
the second groove. 
The chrome  ring is for the top  groove  and  can  be 
fitted  either  way round. 
16. Check the compression ring clearance in the piston 
groove. 
Clearance limits: 0,Oj to O,~O mm (0.002 to 
0.004  in). 
ST821M 
Examineconnec*ing-rods 
20. Check  the alignment of the connecting-rod. 
21. Check  the connecting-rod  small  end, the  gudgeon 
pin  must  be 
a press fit. 
106 
cont inucd