Land Rover Defender 90 110 Workshop Book 6 Supplement Rover

e DEFENDER ENGINE 
. ... . 22. Fit a spring  and cup to each  valve  and 
compress  with special  service  tool 
MS1519A or 
a suitable  altemative.  Retain with the 
multi-groove  cotters ensuring  that they  are 
fully  located  in the  valve  stem and cup. 
L. ;:.:it .. . . . . . . .::::Y:.. ., ..., . .. 
12 
Thermostat  and housing 
0.70 
0.61 
2 to 
0.80 
0.71 
3 to 
23. 
If necessary 
remove the temperature 
transmitter  and temperature  sensor from the 
housing. 
24. 
Release the  three  bolts...

ENGINE e DEFENDER 
Clean the cylinder  block combustion  face and 
turn the crankshaft so that  number  one and 
number  four pistons  are at 
. D.C. Use  a dial 
test  indicator  to determine  the highest  travel 
of the piston  then zero the gauge  and move 
the  stylus  over to the  cylinder  block and note 
the  reading.  Repeat the procedure  on the 
remaining  pistons. The highest  figure obtained 
will  determine  the gasket  selected. 
ST2581M 
2. Place the selected  the head  gasket  in position...

4!83 DEFENDER ENGINE 
OVERHAUL ROCKER SHAn 
12 
1. 
2. 
3. 
4. 
5. 
* 
6. 
Remove the five  rocker  shaft retaining  bolts 
and  withdraw  the bearing  caps, 
rockers, 
washers  and springs  from the shaft. 
Examine 
the rocker  shaft for wear  and discard 
if the bearing  surface is wom, scored or pitted. 
Check  also that 
the oilways  are clear. 
Inspect 
the rockers  and discard if the pads  are 
worn.  It is 
not permissible to grind  pads in an 
attempt  to reclaim  rockers. 
Renew  the bushes 
if...

. 
12 
Adjust tappet  clearances 
ENGINE a DEFENDER 
WARNING If the crankshaft is rotated  with 
excessive  valve clearances,  it is  possible  that 
the  push  rods may become  dislodged  from 
the  tappet  seating  and fracture  the tappet 
slide. 
To  prevent  damage,  eliminate  all clearance  from any 
loose rockers before tuming  the crankshaft  to adjust 
clearances. 
1. Tum  the engine over  until number eight  valve 
(counting  from front 
of engine) is fully open. 
2. Using  a 0,20 mm (0.008...

- -.. . . .. ..,.. , . ... .. , , 
42%D DEFENDER ENGINE 12 
n 
ST2948 M 
FIITlNG HEATER PLUGS 
1. 
2. 
If necessary  check the operation of each 
heater  plug before  fitting and  tighten  to the 
correct  torque,  do not  over
-tighten. 
Connect  the electrical  harness to the  plugs  and 
secure  with the single  nut and  washer.  Ensure 
that  each  spade terminal 
is fitted so that 
neither  the terminal  nor the insulation  touches 
the  cylinder  head, or 
oil separator. 
FllTlNG INJECTORS  AND...

a DEFENDER 19 FUEL SYSTEM ... 
FUEL INJECTION PUMP 
Service Repair No. 19.30.07 
Remove and refit 
Special  tools:- 
Flywheel  timing pin  LST 128 
Pump  gear retaining  tool  LST 
12911 
Pump timing  pin  LST 12912 
1. Remove the bonnet  and disconnect  the 
battery. 
2. Drain  the cooling  system. 
3. Remove  the fan and  viscous  coupling  assembly 
see operation  26.25.19 
4. Remove the fan cowl see operation  26.25.11. 
5. Disconnect  the lower  cooling  hose from  the 
waterpump. 
6. Remove  the...

e DEFENDER FUEL SYSTEM 
11. Slacken  the pump  locking  screw and remove 14. Remove  the injector  pipes and disconnect  the 
the  keeper  plate. Tighten  the screw  to 
lock the 
pump. 
CAUTION: Once the timing  pin LST 129/2 is 
inserted  and the pump  shaft locked, no 
attempt  must be made to rotate  the 
crankshaft. 
Main fuel supply  pipe. 
following 
items from the injector  pump. 
Throttle  cable. 
stop  control  solenoid  lucar. 
Spill  return  pipe. 
Turbo  charger  boost hose. 
19 
. 
12....

19 
Reff iting 
FUEL SYSTEM DEFENDER 
19. 
20. 
21. 
Clean  the pump  flange  and front  cover  mating 
face  and place  a new  gasket  in position  over 
the  the  studs. 
Fit  the  timing  pin LST 
129/2 to the pump, if 
necessary,  rotate the pump  to enable  the pin 
easily  and fully. 
Slacken  the pump  locking  screw, remove  the 
keeper  plate and tighten  the screw  to 
lock the 
pump- - 
ST3043M 21 20 
22. 
23. 
24. 
25. 
26. 
Fit the  pump  to the  front cover and  drive  gear 
and  secure...

-- /p:+ ,::- ,” .. ..... . , ...... , ,,.... ~: . .. 
e DEFENDER FUEL SYSTEM 119 I 
34. Place the fan cowl  in position  but do not 
secure  it to  the  radiator  until the fan and 
coupling 
is fitted. 
35.  Fit the  fan and  viscous  coupling  assembly  to 
the  waterpump  spindle. Tighten the 
left hand 
thread  to the  correct  torque using a 
Tommy 
bar in the  hole  provided  in the  fan pulley  to 
restrain  the coupling. 
36.  Secure  the fan cowl  to the  radiator  with the 
two nuts. 
37. Fit...

19 
TURBO CHARGER 
FUEL SYSTEM DEFENDER 
Service Repair No. 19.42.01 
Remove and refit 
1. Remove the bonnet  and disconnect  the 
battery. 
2. Remove  the turbo charger heat  shield. 
3. Disconnect the exhaust  front pipe from the 
turbo  charger 
elbow. 
4. Release the front  exhaust pipe from the 
support  bracket attached  to the  cylinder 
block. 
5. Remove  the five  nuts  and  remove  the elbow 
from  the turbo  charger. 
6. Remove  the air inlet  hose  from the air cleaner 
and  turbo  charger....