Land Rover Defender 90 110 Workshop Book 2 Rover
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V8 CYLINDER ENGINE )121 .. .. .,:.+ ~ ..” 4. Fit the rocker shaft assemblies. Ensure that the push -rods engage the rocker cups and that the baffle plates are fitted to the front on the left-hand side, and to the rear on the right-hand side. Tighten the bolts. .. .- ’ I, , ._ 3. Apply ‘Hylomar’ sealing compound SQ32M on the corners of the cylinder head, manifold gasket and manifold, around the water passage joints. 4. Fit the manifold gasket with the word ‘FRONT’ to the front and the open bolt hole at the front R.H. side. 5. Fit the gasket clamps but do not fully tighten the bolts at this stage. It should be noted that tappet noise can be expected on initial starting-up after an overhaul due to oil drainage from the tappet assemblies or indeed if the vehicle has been standing over a very long period. If excessive noise should be apparent after an overhaul, the engine should be run at approximately 2,500 rev/min for a few minutes (subject to the following caution), when the noise should be eliminated. CAUTION: Do not exceed 1,000 engine rev/min when first starting the engine, otherwise the crankshaft rear oil seal will be damaged. FIT THE INDUCTION MANIFOLD 1. Coat both sides of new manifold gasket seals with silicon grease. 2. Locate the seals in position with their ends engaged in the notches formed between the cylinder head and block. ST848 \% 6. Locate the manifold onto the cylinder head. 7. Clean the threads of the manifold securing bolts and apply Loctitc 572 to the threads. 8. Fit all the manifold bolts and tighten them a little at a time, evenly, alternate sides working from the centre to each end and finally tighten to the correct torque. 9. Tighten the gasket clamp bolts to the correct torque. 117
V8 CYLINDER ENGINE FIT THE TIMING COVER AND CRANKSHAFT PULLEY 1. Place a new timing cover joint washer in position and fit the timing cover locating it on the two dowels. 2. Clean the threads of the timing cover securing bolts, then coat them with Thread Lubricant- Sealant Loctite 572. 3. Fit and evenly tighten the timing cover bolts to the correct torque figure. 4. Fit the crankshaft pulley and tighten the retaining bolt to the correct torque. 5. Fit timing pointer. I W ST850M FIT THE SUMP 1. Clean the sump mating faces and at the joint between the timing cover and crankcase apply a coating of a universal jointing compound about 13 to 19 mm (Y2 to Y4 in) wide in the area illustrated. 2. Place the sump gaskct in position, fit the sump and ST849M FIT THE WATER PUMP 1. Lightly grease a new joint washer and place it in 2. Clean thc threads of the four long bolts and smear position on the the timing cover. them with Loctite 572 thread lubricant-sealant. Locate the water pump in posiiion. 3. Locate the alternator adjusting link on the water Pump. 4. Leave the alternator adjusting link loose and tighten the remaining water pump housing bolts evenly and to the correct torque. evenly tighten the retaining bolts to the correct torque. Hylosil is used on later engines instead of a 118
V8 CYLINDER ENGINE (12) -^ TEST AND FIT THERMOSTAT .I .... :: 1. Remove the two bolts securing the thermostat 2. Remove the housing gasket. 3. Withdraw the thermostat. housing to the induction manifold. ST858M ST856M 8. Clean the induction manifold and thermostat 9. Fit the thermostat with the jiggle pin uppermost at 10. Fit the housing using a new gasket, and evenly housing mating faces. 12 oclock. tighten the two bolts. . .. ,: ... .. .. .. . 4. Note the temperature stamped on the thermostat FIT THE DISTRIBUTOR - including electronic distributor at which it should be fully open. 4 ST857M c ni--- &L- &L &,., ,.-,I J. ridcc LIIC: LIIC;IIIIUSL~L diiu Centigrade thermomelcr in a laboratory beaker, or a suitable alternative, half full of water. 6. Heat the water and observe the temperature at which the thermostat opens. 7. If faulty discard the thermostat. 1. Turn the crankshaft to bring number one piston to T.D.C. on the compression stroke (both valvcs closed number one cylinder). 2. Turn distributor drive until rotor arm is approximately 30 anti-clockwise from number one sparking plug lead position on cap. 3. Turn the oil pump and distributor common drive shaft so that the tongue is in the approximate position as illustratcd. continued 119
1121 V8 CYLINDER ENGINE 4. Fit distributor to engine and check that centre line of rotor arm is now in line with number one sparking plug lead in cap. Reposition distributor if nccessary. The vacuum capsule should be at 90” to the camshaft. 5. If distributor does not seat correctly in front cover, oil pump drive is not engaged. Engage by lightly pressing down distributor while turning engine. 6. Fit clamp and bolt leaving both loose at this stage. 7. Rotate distributor anti-clockwise until contact points just start to open. 8. Secure distributor in this position by tightening clamp bolt. 9. Fit the distributor cap and spark plugs and connect the H.T. leads in accordancc with the illustration below. NOTE: The above distributor setting is to enable the engine to be run so that the correct setting given in ‘Engine Tuning data’ can be achieved once the engine is refitted to the vehicle. FIT ROCKER COVERS 1. Remove all traces of old gasket on the covers and cylinder heads. 2. Clean and dry the gasket mounting surface, using Bostik cleaner 6001. 3. Apply Bostik 1775 impact adhesive to the seal face and the gasket, using a brush to ensure an even film. Allow the adhesive to bccome touch-dry, approximately fifteen minutes. NOTE: The gasket fits one way round only and must be fitted accurately first time; any subsequent movement would destroy the bond. 4. Place one end of the gasket into the cover recess with the edge firmly against the recess wall; at the same time hold thc remainder of thc gasket clear; then work around the covcr, pressing the gaskct into place ensuring that the outer edgc firmly abuts the recess wall. 5. Allow the cover to stand for thirty minutes before fitting it to the engine. 6. Secure the rocker covers to the enginc with the four screws. Short screws - in board, long screws -out board. 120
V8 CYLINDER ENGINE FIT ENGINE OIL FILTER .,: 2 .;$., I. . .;:$ :U, 1. Clean oil pump mating face with filter. 2. Smear clean engine oil on the rubber washer of the new filter. 3. Fill the filter with new oil as far as possible, noting the angle at which the filter is to be fitted. 4. Screw on the filter until the sealing ring touches the oil pump cover face, then tighten it a further half turn by hand only. Do not overtighten. - *... ,: I.. I -:..: .,. ... ,., .. .. . ...,,. .. . .... .... ., FIT THE CLUTCH 1. Clean the flywheel and clutch assembly pressure plate. 2. Fit the centre plate and the clutch assembly and loosely secure to thc flywheel with the retaining bolts. 3. Insert centralising tool 18G 79 or a slave primary shaft and finally tighten the clutch assembly retaining bolts in a diagonal sequence, to the correct torque. 4. Smear the centre plate splines with Rocol MV3 or Rocol MTS 1000 grease. I . .. .. :;:. .. :, : . ..., . ., FIT THE FAN PULLEY, VISCOUS COUPLING AND FAN 1. Secure the fan to the viscous coupling with the four bolts and tighten evenly. 2. If removed, fit the pulley to hub assembly adaptor and secure with the four nuts. 3. Screw the viscous coupling onto the adaptor thread by inserting a tommy bar in the hole in the pulley to restrain it while tightening the coupling. 4. Fit the fan and any other drive belts. FIT THE ALTERNATOR 1. Offer up the alternator to the mounting bracket and locate the pivot nuts and bolts noting that the fan guard is attached to the front nut and bolts. 2. Slacken the alternator adjustment bracket and attach alternator bracket. Note that the fan guard is attached to the adjustment bracket bolt. 3. Fit and tension the fan belt as follows: Pivot the alternator away from the engine but in doing so, do not apply any pressure to the slip-ring end bracket. Tighten the pivot nuts and bolts and adjustment bolt. The tension is correct when, with thumb pressure, the belt deflection is approximately 8 mm (A in) for non-air condition engines, 4 mm (& in) for air condition engines, Finally, tighten the fixings and connect the wiring plug to the alternator. hPt..,nP.. CIIWLCIII (IILbIILILVL oitP-..n+n- all --A the crankshaft pu!!ey. continued 3 ST854M 121
V8 CYLINDER ENGINE 3 ST855M FIT EXHAUST MANIFOLD AND AIR RAILS 1. Ensure that the mating surfaces of the cylinder head and exhaust manifold are clean and smooth and coat the faces with ‘Foliac J 166’ or ‘Moly Paul’ anti -seize compound. ‘Foiiac J 166’ is manufactured by Rocol Ltd., Rocol House, Swillington, Leeds, England. ‘Moly Paul’ is manufactured by K.S. Paul Products Ltd., Nobel Road, London N18. 2. Place the manifold in position on the cylinder head and fit the securing bolts, lockplates and plain washers. The plain washers are fitted between the manifold and lockplates. Evenly tighten the manifold bolts to the correct torque figure and bend over the lock tabs. 3. Fit pulse-air rails to cylinder heads. FIT THE CARBURETTERS If removed, fit the carburetters to the induction manifold, using new joint washers in the correct sequence as illustrated according to the engine serial number. See Section 19 for S.U. Carburetters. Illustration A from serial number 1400001A Non- detoxed. 1. Fit the liner. 2. Fit the two joint washers. 3. In between the washers fit the insulator. Illustration B from serial number 15G00001A detoxed. 4. Fit the three joint washers. 5. Fit the saw toothed deflector. 6. Fit the insulator. MISCELLANEOUS AND NON-STANDARD ITEMS Fit any other items of equipment and miscellaneous hoses, pipes, filters, clips and brackets to the positions noted during dismantling. @-:“ ‘K .,/ 122
12 I FAULT DIAGNOSIS SYMPTOM BURNED VALVES NOISY VALVE MECHANISM NOISE FROM HYDRAULIC TAPPETS 1. Rapping noise only when engine is started 2. Intermittent rapping noise 3. Noise on idle and low speed 4. General noise at all speeds - V8 ENGINE ONLY 5. Loud noise at normal operating MAIN BEARING RATTLE temperature only LOW 011. PRESSURE WARNING LIGHT REMAINS ON, ENGINE RUNNING RATTLE IN LUBRICATION SYSTEM ~ ENGINE OVERHEATING ~~ ~ MECHANICAL NOISES Medium low pitch knock Low pitch thud High pitch tap Intermittent thuds Continual tapping Continual slapping POSSIBLE CAUSE ~~ 1. Sticking valves 2. Weak valve springs 3. Excessive deposit on valve seats 4. Distorted valves 5. Excessive mileage between overhauls I. Excessive oil in sump, causing air bubbles in hydraulic tappets - V8 engine 2. Worn or scored parts in valve operating mechanism 3. Valves and seats cut down excessively, raising end of valve stem, 1,27 mm (0.050 in) above normal position 4. Sticking valves 5. Weak valve springs 6. Worn timing chain or chain wheels I. 2. 3. 4. Oil too heavy for prevailing temperature Excessive varnish in tappet Leakage at check ball Excessive leakdown High oil level in sump Leakage at check ball Worn tappet body Worn camshaft 5. Excessive leak-down rate or scored lifter plunger I. Low oil level in sump 2. Low oil pressure 3. Excessive bearing clearance 4. Burnt -out bearings 5. Loose bearing caps 1. Thin or diluted oil 2. Low oil level 3. Choked pump strainer 4. Faulty release valve 5. Excessive bearing clearance 6. Oil pressure switch unserviceable 7. Electrical fault 8. Relief valve plunger sticking 9. Weak relief valve spring 10. Pump rotors excessively worn I I. Excessively wom bearings: main, connecting rod, big end, camshaft. etc 12. Faulty skcw gear asscmbly, 4-cylinder engines 1. Oil pressure rclief valve plunger sticking I. Low coolant level 2. Faulty cooling system 3. Faulty thcrmostat d. Tncorrcct timing 5. Defcctive lubrication system 3ig-end bearing slack or run dain bearing slack or run Worn gudgeon pins aose tly wheel or excessive crankshaft end-float Zxcessive valve clearance .- NOT V8 iston clearance excessive. -more apparent vhen sngine cold may disappear when engine 101 Overhaul cylinder head 1 Drain and refill to correct level on dipstick Replace faulty parts Grind off end of valve stem or replace parts V8 engine only ] Overhaul cylinder head Renew worn parts Drain and refill with correct grade Replace tappet Replace tappet Replace tappet Drain and refill to correct level on dipstick Replace tappet Replace tappet Replacc camshaft Replace tappet ~~ Replenish as ncccssary to high mark on dipstick Worn bearings. Faulty skew, gear asscmbly. 4-cylinder enginc Renew bearings; grind crankshaft - NOT diesel Renew and investigate reason for failure Tighten to correct torque Drain and refill with correct oil and renew filter Replcnish to high mark on dipstick Clean Rectify Rectify Renew Check circuit Remove and ascertain cause Renew Overhaul oil pump Ascertain which bearings and rectify Check skew gear bearing. Chcck plug not leaking or seals in 2.5 diesel engine. See Zngine overhaul Remove and clean Chcck for leaks. Check expansion tank level Check fan and belt, pump, radiator fins ?ot blocked rest and renew, if necessary Check and adjust using electronic equipmcnt Renew filter. Check pump. Clean strainer. :heck oil circulation 124
FAULT DIAGNOSIS POSSIIILE CAUSE 1. Lack of fucl 2. Stop solenoid faulty 3. Wrong starting procedure 4. Air in fucl system 5. Fucl inlct restriction 6. Fuel contamination 7. Low cranking spccd 8. Starting aid ineffective 9. Injcction timing incorrect 10. Timing bclt slipped 1 I. Bxk Icakagc restricted 12. Fucl circuit incorrect I SYMPTOM CHECK Fuel level in tank Audible opcration when switched - Check electrical supply, replace solenoid Starting procedure correct -Throttle c!osed and heater plugs in operation All joints and unions arc tight Filter not chocked and feed pipes clear Diesel fucl being used. not pctrol, free of water. dirt, ice. wax. Battery, startcr, cable connections. Correct engine lubricating oil Correct functioning of heater plugs Punip to engine timing using timing tool Belt condillon and tcnsion. Pump rotor not seized Tank return clear, flow from cam box valve when cranking. Replace pump if blocked Inlet and back leak pipes correct way round. Banjo bolts of correct type for pump injector DIESEL ENGINE MECHANICAL FAULTS MAIN BEARING RATTLE ENGINE OVERHEATING LOW OIL PRESSURE WARNING LIGHT REMAINS ON, ENGINE RUNNING ___ ~ XATTLE IN LUBRICATION SYSIEM JOISY VALVE MECHANISM vlECHANICAL NOISES: ,ow pitch knock ,ow pitch thud ntermittent thuds 4igh pitch tap .ight tapping ;lapping POSSIBLE CAUSE 34. Low oil level in sump 35. Low oil pressure 36. Exccssive bearing clearance 37. Burnt-out bearings 38. Loose bearing caps 39. Low coolant level 40. Faulty cooling system 41. Faulty thermostat 42. Cracked cylinder head 43. Defcctive lubrication system 44. Thin or diluted oil 45. Low oil level 46. Choked pump strainer 47. Faulty release valve 48. Excessive bearing clearancc 49. Oil pressure switch unserviceable 50. Electrical Iault 51. Relicf valvc plunger sticking S2. Weak rclicfvalvc sprin: 53. Pump rotors excessively worn 54. Excessively worn bearings) main, connecting rod. big end, camshaft, ctc 55. Faulty skew gear assembly, 4-cylinder engines 56. Oil pressure relief valve plunger sticking 57. Sticking valves 5X. Weak valve springs 59. Tappet clearance too wide 60. Worn timing chain or chain wheels Big -end bearing slack or run Main bearing slack 01 run Loose flywhecl or excessive crankshaft end-float Worn gudgeon pins Excessive valve clearance Excessive piston clearance - more apparent whcn cold DIESEL ENGINE CURE Replenish as necessary to high mark on dipstick Worn bearings. Faulty skew, gear assembly. 4 -cylinder engine Renew hearings; and or crankshaft Renew and investigate rcason for failure Tighten to correct torque Check for Icaks, check expansion tank level Check fan and belt, pump, radiator fins not blocked Test and renew, if necessary Renew Renew Filter, Check pump. Clean strainer. Check oil circulation Drain and refill with correct oil and renew filter Replenish to high mark on dipstick Clean Rectify Rectify Renew Check circuit Remove and ascertain cause Renew Overhaul oil pump Ascertain which bearings and rectify Check skew gear hcaring. Check plug not leaking or seals in 2.5 diesel engine. See engine overhaul Remove and clean ~~ ~ ~ Ovcrhaul cyliiidcr head I FAULT DIAGNOSIS DPA AND DIS PUMPS - 2.25 and 2.5 litre diesel engines SYMPTOM DIFFICULT STARTING 13. Engine condition 14. Fuel atomisation 15. Fucl tank blockage 16. HP pipe lcakirig 17. Injection pump defective intcrnally scating Cylinder compression, valve timing and clearances. Air filter not choked Injectors; correct type, opening pressure. spray condition Tank vent and outlet unrestricted HP pipe joint tightncss If all other relevant checks salisfiictory, replace pump 125 continued
1211 FAULT DIAGNOSIS SYMPTOM IRREGULAR IDLE INSUFFICIENT MAXIMUM SPEED ERRATIC RUNNING OR SURGING EXCESSIVE SMOKE EXCESSIVE NOISE LACK OF POWF,R EXCESSIVE FUEL CONSUMPTlON 3TALLING ~~ 3LOW ENGINE DIE DOWN ZNGINE WILL NOTSHUTOFF ~ SXCESSNE KNOCKING (DETONATION) , POSSIBLE CAUSE Any of the following items: 4,5,6,9,11, 12,13, 14, 16, 17. Plus: 18. HP pipe restriction 19. Idlingspeed incorrect 20. Anti-stall setting incorrect 21. Manual idle advance faulty 22. Accelerator linkage faulty 23. Engine vibration 24. Injection pump loose Any of items 4,5, 17,22. Plus the following: 25. Max. speed setting incorrect 26. Vehicle brakes binding Any of items I, 2,4,5,9,12,13, 14,155, 16, 17, 18.27.23.24. Anv of items 6.9. 13. 14 and 17 Any of items 9,14,24,23. Plus the following: 27. Cambox pressure IOW Anyofitcms4,5,6,9, 11, 12, 13, 14.IS.16, 18,22,24,25,26. Plus the following: 28. Exhaust system defective 29. L.P. leakage ~~ Anyofitems9,13, 14, 16.17, 19,26. Any of the following items; 4,5, 6,9, 11, 13, 17,19,20.21. Any of the following items; 17,20,22 Either of the following two items: 2 and 17. Plus: 30. Stop solenoid valve leaking Items 8,9, 13 or any of the following: 31, Injectors sticking 32. Lack coolant in radiator 33. Lack of oil in engine CHECK HP pipes not kinked or bore reduced at nipples Idling speed given in ‘engine tuning data’ Recovery from acceleration, engine warm (Reset idling and anti-stall) Cable and lever operation satisfactory Lever tight on pump reaches stop screws, linkage wear, adjustment Engine mountings tight and effective Tightness of pump drive mounting bolts and rear support bracket nut and bolt ~ Seal intact. Engine maximum speed in ‘Engine tuning data’ - adjust Brake freedom, all wheels in turn and transmission brake Pressure with gauge at control cover vent screw. Replace pump if pressure too low System is unrestricted Feed and return pipes, filter and tank for leak Engine stops when supply lead removed. Replace solenoid if faulty Injectors individually - see ‘Injector overhaul’ Cooling system and expansion tank level. Radiator fins not blocked Oil level on dipstick 126