Land Rover Defender 90 110 Workshop Book 6 Supplement Rover

e DEFENDER ENGINE n 12 
Fitting rear cover 
9. Fit the  rear  cover  also using  a new  gasket and 
secure  with six bolts tightened  to the  correct 
torque. 
Fitting fuel lift pump 
10.  Check  that the lift pump is serviceable  and refit 
using  a  new gasket,  ensuring  that  the pump 
actuating  lever  locates correctly  onto the 
camshaft 
. 
, I,, ST3003M 
FllTlNG FRONT COVER TIMING  BELT AND GEARS 
1. Clean the front  cover and remove  the 
crankshaft  and camshaft 
oil seals  taking  care 
not...

112) ENGINE e DEFENDER 
Fitting injection  pump 
1. Insert the timing  pin in the  pump  hub and 
body.  Fit the  injection  pump and secure  with 
the  three  nuts and tighten  evenly to the 
correct  torque. 
2. Fit the  pump  rear support  bracket to the front 
side  cover  and secure  to the  pump  with 
two 
bolts and nuts. 
3. Inspect  the pump  drive gear for wear and 
damage,  ensure it 
is thoroughly  clean and dry 
before  fitting 
to the pump.  Retain the gear 
with  three  bolts and...

e DEFENDER ENGINE n 12 
-_ 
1 I :,,..,L l’, i 
6. Screw the body of timing  pin LST128 into the . \ bottom of the flywheel  housing and check  that 
the  pin will  locate  into the flywheel  slot. It is 
important  to note  that there  are 
two slots in 
the  flywheel  and that  the narrowest  is the 
one 
that  must  be used  for this  direct  injection 
engine. 
. %? 
0 
ST2641 M 
Fitting  and tensioning  belt drive 
Note:  It is vitally  important  that the 
following  belt tensioning  procedure it...

1 121 ENGINE DEFENDER 
CAUTION: 
The double  tensioning  procedure is vital 
otherwise  the belt  could  fail resulting  in serious 
damage  to the  engine. 
12. Tum the crankshaft  again in a clockwise 
direction  until the flywheel  timing  pin  locates 
in  the 
T.D.C. slot. 
check  that the crankshaft  key aligns  with the 
arrow  on the  front  cover. 
Also check  that the 
dot  on the  camshaft  gear aligns  with the arro. 
if the  timing  pin cannot  be inserted  fully into 
the  pump  hub slot,...

DEFENDER ENGINE 
..,.,. i _.,. !-., ,& .. i:;.;:: :.i WATER PUMP INSPECTION  AND FllTlNC 
The water  pump is not a reconditionable  unit but its 
condition  can be determined  by the  following 
checks 
. 
, . . .. ... .. ,::..::!..v I*^ 
L 
12 
1. 
2. 
Spin  the pump  spindle  and listen for bearing 
noise,  also push  and pull the spindle  and 
check  for sideways  movement. 
If the bearing is 
in good  condition  the clearance  between the 
impeller and the pump  body should  not vary. 
Inspect  the...

12 I ENGINE e DEFENDER 
J 
6. Clean all the  components  then install  both  
gears into the body  ensuring  that the recessed 
end 
of the  driving  gear is uppermost. 
7. Place a straight  edge across  both gears  as 
illustrated  to measure  the end  float 
of each 
using  a 
feeler gauge. Also check  the gear 
backlash  and the clearance  between the gears 
and  pump  body. The correct  clearances  are 
given  in the  data  section. 
8. Examine  the gear  thrust  face on the  pump 
cover,  any slight...

DEFENDER ENGINE n 12 
Fitting oil pump 
15. Ensure that the oil pump  drive shaft is located 
in  the  appropriate  spiines and fit the 
oil pump 
and  strainer  assembly  into the cylinder  block 
using  a new  gasket,  tighten the 
two bolts to 
the  correct  torque. 
Fitting the sump 
16. Ensure  that all traces of old sealant  are 
removed  from the sump  joint face and that  the 
sump 
is thoroughly  clean inside  and out. 
17. Remove  the two two bolts securing  the ladder 
frame  to the  cylinder...

L 
12 
2. Discard the valve  springs  and valve  guide oil 
seal. Remove  carbon deposits  from the valves 
and  combustion  chambers and degrease  all 
parts  ready  for examination. 
3. Examine  the cylinder  head for damage  and 
distortio.  Inspect the valve  seat inserts 
for 
damage.  Seat inserts  that are beyond  repair 
and  require  renewal  should be replaced  by a 
skilled  specialist  in this  type 
of work. 
4. Examine  each valve  guide  and valve  stem for 
wear and damage.  Suspect...

DEFENDER ENGINE 
.I r.. ;.. .L,._ ..U .;, 10. insert  the assembled  pilot into the valve  guide 
from  the combustion  chamber  side 
of the 
cylinder  head until the shoulder  contacts the 
valve  guide  and the whole 
of the  collet is 
inside  the guide.  To lock  the pilot  in the  guide 
turn  the 
tommy bar  clockwise  whilst holding 
the  knurled  knob. 
,..._. ..,. 2 .i,....* .:,*, ,,.;. ....... . 
12 
Valve refacing 
ST2670M 
11. Check that the seat cutter MS621 is assembled 
correctly  using...

E[ ENGINE e DEFENDER 
Lapping valves 
15. To ensure a gas tight seal between  the valve 
face  and valve  seat it 
is necessary  to lap-in the 
appropriate  valve to its  seat.  It 
is essential  to 
keep  the valve  identified  with its seat  once  the 
lapping
-in  operation  has been  completed. 
Unless  the faces  to be  lapped  are in poor 
condition 
it should  only be necessary  to use 
fine  valve  lapping  paste. 
16. Smear a small  quantity of paste  on the  valve 
face  and lubricate  the...