Land Rover Defender 90 110 Workshop Book 6 Supplement Rover

							.. e DEFENDER ENGINE 
-? ASSEMBLE ENGINE 2, 9 .I 
Ensure that the cylinder  block and all oilways  are 
thoroughly  clean using  an air line, 
if available,  prior 
to  assembly. 
12 
Refitting  cylinder lubrication  jet tubes 
Oil jet  tubes  are fitted  to lubricate  the pistons  and 
bores  directly  from the main 
oil gallery. 
,.,-.  ~ .I. ., . . , ... 
1. Assemble 
and fit the  jet tube  as illustrated 
ensuring  that the dowls  locate  in the  holes  in 
the  cylinder  block, and that  the larger  diameter 
washer  fits under  the bolt  head.  Tap the jet 
blocks  down to ensure  that the locating  dowel 
is fully home.  Fit and  tighten  the retaining 
bolts  to the  correct  torque. 
ST2980M 
Crankshaft  bearings. 
Main  bearing  nip 
clearaqce 
Clean the protective  coating from new bearings 
before 
fittin. 
1. 
3 L. 
3. 
4. 
Fit  the  bearing  halves to the  cylinder  block 
ensuring  full engagement 
of the  location  tags. 
Instal! the othei half shells into the main 
bearing caps, again  ensuring  that the tags 
locate  correctly. 
Fit  all the  main  bearing  caps to their  original 
locations  tightening  the bolts 
to the  correct 
torque,  then 
release one bolt  on each  cap. 
Check  the clearance  between the cap  and  the 
block  as illustrated.  The 
nip clearance  which ensures  that the bearings 
are  correctly  clamped,  must be within 
0,IO to 0,15 
mm (0.004 to 0.006 in).  Investigate  and correct  any 
nip  clearance  errors before  removing  the main 
bearing  caps prior  to fitting  the crankshaft. 
Fitting  crankshaft 
1. Insert two standard  thickness  thrust washers 
each 
side of the  centre  main bearing  location 
with  the 
oil grooves  towards the crank  thrust 
faces. 
carefully  install the crankshaft. 
2. Lubricate  the cylinder  block bearing  shells and 
57  
						

							12 
Crankshaft end float 
e DEFENDER ENGINE 
3. To determine  the crankshaft  end-float mount  a 
dial  test  indicator  to read-off  the end 
of the 
crankshaft.  Move the crankshaft  away from the 
indicator  and 
zero the dial,  then  Move  the 
crankshaft  in the  opposite  direction and note 
the  indicator  reading. The end-float  should be 
0,05 to 0,15 mm (0.002 to 0.006 in). 
Alternatively  measure the clearance  with a 
feeler 
gauge. If adjustment is required  substitute  with 
oversize  thrust washers.  Variation 
of thrust washer 
thicknesses  at each  side 
of the crankshaft  joumal 
must  not exceed 
0,08 mm (0.003 in) to ensure  that 
the  crankshaft  remains centralised. 
Main bearing  caps 
4. 
5. 
6. Ensure that number  five main  bearing  cap is 
clean  and 
free from old seal  material.  Attach 
the  seal  guides  number 
270304 to the 
crankcase, 
as illustrated,  and ensure  that they 
are  parallel  to the  crankcase  edge. 
Sl 
Lubricate and fit the  centre  main bearing  cap, 
tighten  both bolts 
to the correct  torque and 
ensure  that the shaft 
is free to rotate before 
fitting  the next  bearing  cap. 
Lubricate  and 
fit 1-2 and 4 main bearing  caps 
tightening  the bolts 
for each. 
7. To prevent  any seal  material  becoming  trapped 
between  the bearing  cap and  crankcase, 
chamfer  the inner  edge 
of the seal 0,40 to 
0,80 mm wide as illustrated.  Smear the seals 
with  engine 
oil and fit them  to the  bearing 
cap. 
8. Fit the  bearing  cap complete  with shell  bearing 
to  the  crankcase  and secure  with new 
bolts 
and tighten  to the  appropriate  torque. Remove 
seal  guides  and check  that the shaft 
is free  to 
checking 
that the shaft 
is free te rdate after 
c-?: 
rorate. e2 
58  
						

							DEFENDER ENGINE n 12 
Fitting connecting rods and pistons 
1. Ensure  that the essentric  headed big end  bolts 
and  shell  bearings  are correctly  located in the 
connecting 
rods and as a  precaution  against 
possible  damage to the  crankshaft  journals 
during  installation 
of the pistons,  cover the 
bolt  threads  with a layer 
of adheasive  tape. 
Check  that the number  on the  connecting  rod 
is the same as the piston  and cylinder  and that 
they  are correctly  orientated. 
2. With the cylinder  block vertical,  and 2 and 3 
crankshaft  journals at BDC  lubricate  and install 
2 and 3 piston  connecting rod assemblies so 
that the piston  rings are resting  on the  block 
face. 
illustrated,  then using  a suitable  tool compress 
the  piston  rings and gently  push each piston 
4. Pull both  connecting  rod big ends  on to the 
journals  and 
fit the caps  ensuring  the the 
numbers  match and orientation 
is correct. 
Retain  the caps  with  new nuts  but 
do not 
tighten  at this  stage. 
at  BDC  and install  the pistons  and connecting 
rods 
as previously  discribed. 
the  correct  torque and check  that the 
crankshaft 
is free  to rotate  before  securing  the 
next  connecting  rod cap  nuts. 
which  when tightened  restricts the freedom 
of 
the  crank  shaft. 
sideways  on its journal  and 
if necessary  check 
the  actual 
side clearance  using a feeler gauge. 
The  correct  clearance 
is given in the  data 
section. 
9. To  allow for shrinkage  after fitting  leave the 3. Stagger  the piston  rings on both  pistons as seals standing  proud of the crankcase  face 
then  using  a  sharp blade,  trim the seals 
off to 
face. 
.. approximately 0,80 mm above  the crankcase 
into the cylinder  bore. 
5. Tum the crankshaft so that I and 4 journals  are 
7. Tighten  both nuts on one connecting rod to 
8. Investigate  and rectify  any big end  bearing 
9. Check  that each  big end is free to move 
59  
						

							. 
ENGINE DEFENDER 
Fitting rear main oil seal to flywheel  housing 
The oil seal is manufactured  from P.T.F.E.  and is 
supplied  with a former  to maintain  the correct  shape 
which  must not be removed  until the seal  is to  be 
fitted. 
18G 134-11 
 
1. Make  sure the  seal housing is clean  and dry 
and  free  from  burrs. 
Do not touch  the seal  lip 
and  ensure  that the outside  diameter 
is clean 
and  dry. 
2. Using  special  seal replacer 18C134-I 1 and with 
the  lip side  leading  drive-in  the seal  as far 
as 
the  tool  allows. If the tool is not  available  fit 
the  seal  to the  bottom 
of the  housing  to 
ensure  squareness. 
Fitting flywheel  housing 
3. Clean  the rear  face of the cylinder  block and 
flywheel  housing,  then apply  a bead 
of Hylosil 
102  sealant  to the  dimensions  and 
configuration,  illustrated. 
The  illustration  has been  produced  full size 
so that  a 
template  may be made  to facilitate  the application 
of the  sealant.  The bead  should be 2,O mm diameter 
and  must  extend  around  the periphery 
of the 
bearing  cap 
so that the joint  between  cap and  block 
is sealed. 
~-__ 
L,** 
I 
ST2988M 
60  
						

							a DEFENDER ENGINE n 12 
4. Examine the seal  guide,  number 18G1344 
ensuring  that it is perfectly  smooth and not 
damage  or scratched. 
Also check that  the 
crankshaft 
oil seal  journal is smooth and clea. 
5. Locate  the seal  guide  on to the  crankshaft  and 
lubricate  the seal,  guide  and journal  with 
concentrated  Oildag in a 
25% solution  with 
clean  engine 
oil. 
6. Carefully  locate the flywheel  housing over the 
seal and  on to the dowels. 
7. Remove  the seal  guide and secure  the flywheel 
housing,  evenly tightening  the retaining  bolts 
to  the  correct  torque. 
OVERHAUL  AND FITJING FLYWHEEL 
Inspection 
Normal  wear and  scores on the  flywheel  clutch face 
can  be repaired  by machining  provided  that the 
overall  width 
of the flywheel is not reduced  below 
36,96 mm (1.453 in) therefore  check that  the 
flywheel  has not  been  previously  machined  before 
proceding  further. The ring  gear  may 
be renewed if 
the teeth  are chipped or damage. 
Reface  the flywheel 
1. Remove  the clutch  cover locating  dowels. 
Machine  the flywheel 
over the entire  clutch 
face  removing  only the minimum 
of material 
necessary  to achieve  a smooth  surface parallel 
with  the crankshaft  mating face within  the 
dimensions  given above. 
Renew  Ring gear 
WARNING:  Wear industrial 
goggles to 
protect  the eyes 
from flying  fragments. 
2. To renew  the ring  gear,  drill a 8 mm hole 
between  the root 
of any two teeth  and the 
inner  diameter 
of the ring  gear  deep  enough 
to  weaken  the gear.  Take care not 
to allow  the 
drill to enter  the flywheel. 
ST2973M 7 
61  
						

							El ENGINE DEFENDER 
3. Secure the flywheel  in a soft jawed  vice and 
cover it with  a  cloth to avoid  personal  injury. 
Place  a 
cold chisel  above  the drilled  hole and 
strike  it sharply 
to split  the ring  gear. 
4. Heat  the new  ring uniformally  to between 
225°C and  250°C but 
do not exceed  the 
higher  figure. 
5.  Place  the flywheel,  clutch face  down, on a flat 
surface  and  press  the starter  ring firmly  against 
the  flange  until the ring  contracts  sufficiently  to 
grip  the flywheel.  Allow the ring 
to cool 
naturally. Do not  hasten  cooling  in anyway 
otherwise  distortion may occur. 
5 
ST2640M 
Fitting  flywheel 
6. Locate  the flywheel  on the  crankshaft  and 
secure  with the reinforcing  plate and retaining 
bolts.  Temporarily  fit the  damper  to front 
of 
crankshaft  and  use special service  tool FRIOI 
or LST127 to restrain  the crankshaft  whilst the 
eight  retaining  bolts are being  tightened 
to the 
correct  torque. 
mount  a dial  test  indicator 
so that  the stylus 
rests,  in 
a loaded  condition,  on the  clutch 
pressure  face at a radius 
of 114 mm (4.5  in) 
from  the centre 
of the flywheel. 
8. Tum  the flywheel,  and check  that  run-out does 
not  exceed 
0,05 to 0,07 mm (0.002  to 0.003 
in). Should  any run-out be excessive,  remove 
the  flywheel,  and check  again 
for irregularities 
on  flywheel  and crankshaft  mating  faces  and 
dowel. 
7. To check  the flywheel for possible run-out, 
ST2991M 
Fitting  clutch 
If the original  clutch cover is being refitted,  ensure 
any  marks  made during  dismantling  are aligned  to 
maintain  original balance. 
1. Clean the flywheel  and  place  the friction  plate 
with  the raised  centre  section  outwards  away 
from  the flywheel. 
three dowels and  loosely secure with the six 
bolts. 
. 
3. Centralise  the centre  plate using  special tool 
R0605022 or a spare  primary  shaft and tighten 
the 
six bolts  evenly  to the  correct torque. 
4.  Remove  the tool  and  smear the splines 
of the 
centre  plate with Molybdenum  disulphide 
grease,  such 
as Rocol MTS1000. 
2. Fit the  clutch  assembly locating  it over the 
ST2611 M  
						

							e DEFENDER ENGINE n 12 
T . .. 
.... 
.. 
Fitting  camshaft 
Inspection  1.  Mount  the camshaft  on 
v blocks on a 
surface  plate for convenience  and examine  the 
cams 
for wear,  scores,  pitting and  chipped 
edges. 
2. Examine  the journals for obvious wear  and 
scores and  signs 
of overheating,  in particular, 
check  the thrust  plate. 
If the journals are visibly 
sewiceable, check  with a dial  gauge  or 
micrometer for  overall wear, ovality,  taper and 
runout. 
CAUTION: If the skew  gear is worn  and 
requires  renewal,  the camshaft  must also be 
renewed  even though  the camshaft  gear 
may  appear  satisfactory.  Once the 
two gears 
have  run together  they become  a matched 
pair. 
3. Lubricate  the camshaft  bearings  and journals 
with  clean  engine 
oil and carefully  insert the 
camshaft  into the cylinder  block. Fit the  thrust 
plate  and secure  with the 
two bolts and 
tighten  to the  correct  torque.  Fitting 
camfollowers 
1. Examine  all the  components for wear  and 
damage  particularly  the 
rollers and  pushrod 
seating  in the  slides  and ensure  that the tappet 
slides  move freely in the  guides. 
If the same 
parts  are being  refitted,  ensure that  they  are 
returned  to their  original  positions. 
Note:  The tappet  retaining  screws have a micro 
encapsulated  locking compound  applied to the 
threads  to ensure  that they 
do not become  loose. 
Once  the screw  has been  used the locking  ability 
is lost. 
\ - / ST2968M  
4. To check the camshaft  end-float,  temporarily  fit 
the  camshaft  gear and  mount  a dial  test 
indicator 
so that  the stylus  rests in a loaded 
condition  upon the machined  face 
of the gear. 
5. Zero  the dial  and  move the camshaft  back and 
forward  and note the  reading. The end
-float 
should  be within 
0,06 to 0,13 mm (0.0025) to 
0.0055 in) If necessary  fit another  thrust  plate 
to  achieve  the correct  end float. 
. , 1. 
63  
						

							112) ENGINE e DEFENDER 
2. Insert the tappet  guides  into the cylinder 
block,  retaining  each with a new  screw  which 
should 
be screwed  in sufficiently to allow  the 
rollers  and slides  to be  installed.  Ensure  the 
rollers  are fitted  in accordance  with any marks 
made  during  removal.  New rollers,  however, 
may 
be fitted  either  way around. 
3. Before  fitting the tappet  slides make sure the 
oilways  are clear  to the  running  surface 
of the 
roller  and the pushrod  seating. insert the the 
tappet 
slides with  the word FRONT or F to 
the  front 
of the engine. 
4. Finally  tighten  the screws  to the  correct  torque 
to  secure  the guides. 
Fitting  skew gear bush. 
Inspect  the skew gear bush for wear  and renew if 
necessary. 
1. Insert  the bush  into the cylinder  block and 
secure  with a new  screw 
to the correct  torque. 
Do not over  tighten  as this  may  damage the 
bush. 
Overhaul  and fitting  skew gear 
1. Remove  the circlips  retaining  the skew  gear 
shaft  to the  bearing  and the bearing  in the 
housing. 
2. Press  the bearing  and  shaft assembly  from the 
housing  and the shaft  from  the bearing. 
Discard  both  rubber 
0 rings, examine  all 
components  especially the bearing  and 
skew gear 
for wear and damage  and renew if necessary. 
CAUTION: If the original  skew gear and 
camshaft  are 
to be re-used,  they must  be 
fitted 
so that  the teeth  on each,  mesh  in the 
original  position. 
If either the skew  gear or 
the camshaft  are renewed,  the mating 
component  must 
also be renewed. 
1 . h 
4, 
ST2995M 
Assembling 
3. Press  the bearing  into the housing  and secure 
with  the circlip.  Support  the housing  and press 
the  shaft  into position  and secure  with the 
circlip. 
4. Fit a new  rubber 0 ring to the  outside of the 
housing  and  to the  intemal  annular  groove in 
the  shaft  ready 
for installation. 
r- 
						

							e DEFENDER ENGINE 1121 
Fitting skew gear 
If the original skew gear and camshaft  are being 
re
-used it is important  that the gear teeth mesh in 
the original  position  as follows. 
1 . $:. d _. 
5. Turn  the camshaft so that  the key  aligns  with 
the 
oil groove as illustrated. 
* I. . .. .. . ,! .. 
6. Fit the  skew  gear assembly so that the 
ventilation  slot in the gear  housing is towards 
the 
front of the  engine  as illustrated  and 
ensuring  that any alignment  marks made during 
dismantling  are realigned. 
If both  components  are new  it is only necessary to 
correctly  align the ventilation  slot as described 
above. 
65  
						

							1121 ENGINE DEFENDER 
OVERHAUL AND FITTING OIL FILTER ADAPTOR 
Oil  temperature  thermostat 
1. Remove the two bolts and carefully  withdraw 
the  thermostat extension  housing complete 
with,  the 
’0’ ring (21,thermostat (3),washer (41, 
and  spring (5). 2. Clean  the adaptor  housing 
(6) with lint-free cloth. 
inspect  all the  parts  and renew 
as necessary. 
3.  Fit the  spring,  washer  and  thermostat  with the 
pin  uppermost. 
4. Fit the  extension  housing using a new ’0’ ring. 
Ensure  that the pin protruding  from the 
thermostat  locates  in the  hole  in the  extension 
housing and  secure with the 
two bolts  and 
.+ washers. 
1- ????  
- ST2596M 
5. Using  a new  joint  washer  fit the oil filter 
adapto.  Ensure that the retaining  bolts  pass 
through  the 
two small holes  in the  joint 
washer.  Tighten the 
two retaining  bolts evenly 
to  the  correct  torque. 
Oil filter 
6. Smear  the filter  sealing  ring with oil and screw 
the  filter  clockwise  until  the seal  touches  the 
machined  face, then  tighten  the filter  a  further 
half  turn  only. 
Do not over  tighten. see 
Maintenance  operations, section 10. 
Fitting vacuum  pump 
7. Using  a new gasket  fit the  vacuum  pump so 
that the brake servo connection is towards  the 
front 
of the  engine,  ensuring  that the cross-pin 
in  the  skew gear locates  in the  pump  drive 
shaft  then secure  with three  screws  tightened 
to  the  correct torque. 
I 
Fitting  front and rear  side  covers  and fuel  lift 
Pump 
8. Check  that the front  side cover  baffle plate is 
secure  and fit the cover  using a new  gasket 
securing  with only four 
of the six fixing  bolts at 
this  stage,  leaving  out the 
two which  secure 
the  injection  pump support  bracket 
as 
illustrated. 
P 
ST3000M 
66