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  to damage the  seal housing.  Examine the 
cover 
for damage,  cracks and distortion.  Check 
the  mating 
face of the cylinder  block and  the 
cover  plate for burrs. 
2. Clean  the front  face of the cylinder block and 
use  a little  grease  to hold  in position  a new 
joint washer. 
3. Also fit  a new  joint  washer  to the  coolant 
aperture and 
to the  tapped  hole for the jockey 
pulley  clamp  bolt. 
4. 
Fit the  front  cover  locating  it over  the single 
stud  and secure  with the three  retaining  bolts 
tightening  evenly 
to the correct torque.  The 
correct  bolt length 
for each  hole is given  in 
the  following  chart. 
- ST3005M 
Front cover seals 
5. Lubricate  a new  crankshaft oil seal.  With  the lip 
side  leading,  drive
-in the  seal,  squarely,  using 
special  service  tool 
18C1456. 
6.  Similarly,  lubricate and drive-in  a  new  camshaft 
oil seal, lip side leading,  using  special service 
tool 
18G1482. 
67  
						

							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 renforceing  plate. 
Do not 
overtighten  the bolts  at this  stage. 
Injection pump,  valve timing  and drive  belt. 
Drive  belt. 
During  use, a belt  develops  a wear pattern relative 
to its  running  direction,  therefore, if the original  belt 
is to be re-used  it must  be fitted so that  it continues 
to rotate  in the  original  direction,  otherwise the belt 
must  be renewed.  Cleanliness 
and accuracy  are vital  when  carrying  out 
the  timing  operations  and fitting  the drive  belt. 
1. Check  the gear  wheels  are not  damaged or 
scratched  and that  they  are thoroughly  clean 
and  dry. 
2. Ensure  that the belt  adjustment  idler bearing is 
sound  and not leaking  lubricant. 
3. Fit the  crankshaft  and camshaft  gears ensuring 
that  the camshaft  gear 
is retained with the 
special  bolt, washer  and new 
0 ring  but do 
not  tighten  at this  stage. 
4. Rotate  the camshaft so that  the centre  dot on 
the  camshaft  gear is aligned  with the arrow  in 
the  front  cover. 
5. Temporarily  refit the crankshaft  pulley and turn 
th  crankshaft 
so that  one  and four  pistons  are 
at  TDC  and the crankshaft  key 
is aligned with 
the  arrow  in the  front  cover. 
Drive  belts must  be stored  on edge on  a clean  flat 
surface  and in such  a manner  that bends  are not 
less than 50 mm (2 in) radius. Do not  bend  the belt 
at  an  acute  angle or radius 
less than 50 mm (2 in) 
otherwise  premature  failure 
of the fibre 
reinforcement 
could result. 
68  
						

							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 
carried  out carefully  and accuratly.  The 
procedure  involves tensioning  the belt 
twice.  New and original  delts are tensioned 
to  different  figures. 
8. Ensure that the crankshaft,  camshaft and in 
jection pump are correctly  aligned then 
carefully  fit the  belt  observing  any rotational 
marks  made during  removal.  Feed the delt  over 
the  gears  keeping 
it tight on the  drive  side. 
9. Fit the belt  tensioner  with the special  washer 
and  single  bolt. Insert  a 
13 mm (0.5 in) square 
drive  extension  into the tensioner  plate and 
with  a dial  type  torque  meter, apply a tension 
of 21.7 Nm (16 Lbf ft) for a  new  belt,  or 16.3 
Nm for an original  belt. When  the tension  is 
correct  and the meter 
is in the  vertical 
position,  tighten the clamp  bolt. 
Note: 
To ensure  correct  belt tension  it is 
very  important  that the tensioner 
is clamped 
when  the torque  meter 
is in the  vertical 
position  and the applied  tension is correct. 
10. Tighten  the three  bolts that secure  the pump 
gear  and reinforcing  plate to the  pump  hub to 
the  correct  torque and remove  the timing  pin 
LSTI 2912. 
CAUTION:  Unlock the injection  pump and 
fit  the  keeper  plate before  attempting  to 
turn  the crankshaft. 
Also ensure  that the 
flywheel  timing pin 
LST128 is clear of the 
flywheel  slot. 
11. Rotate the crankshaft two complete  revolutions 
and  slacken  the tensioner  clamp bolt and 
tension  the belt  again,  as previously  described. 
ST301 OM 
69  
						

							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,  it 
is necessary  toslacken 
the  three pump  gear retaining 
boltsand slightly 
turn  the hub,  in the  appropriate  direction, to 
allow  the pin to locate.  Retighten  the bolts  to 
the  correct  torqu. 
13. insert the timing  pin in the pump  hub and 
Fitting  front cover  plate 
14. Remove  the wom  seal from  the cover  and 
clean  the 
recess. Support  the cover on a flat 
surface  and using  service  tool 1861456  press 
in  the  new  seal into  the location,  lip side 
leading, 
so that  when  fitted the lip faces  away 
from  the crankshaft.  15. 
Ensure  that the front  cover and  plate joint 
faces  are clean  and 
fit a new  gasket  to the 
front  cover  using  a  little  grease. 
cover  plate  and  locate in position  by inserting 
a  bolt.  Then fit  the plate  to the  cover securing 
with  the eleven  retaining  bolts using  the 
location  chart  showing the various  lengths. 
Tighten  the bolts  evenly  to the  correct  torque. 
16. Fit a new  gasket  to the  centre  hole in the 
100 
ST2 91 8M 75 
Fitting  front damper  and pulley 
17. Check  that the damper rubber is in good 
condition  then locate  the unit  on the 
crankshaft  key and  secure  with the distance 
piece  and special  bolt. Apply 
a little Loctite 
242  to the  bolt  threads  and tighten  to the 
correct  torque using service  tool 
LST127 to 
restrain  the crankshaft, 
as illustrated. 
18.  Refit  the pulley  securing  with the four  bolts 
and  tighten 
to the correct  torque. 
. 
ST3 1 25M 
70  
						

							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 vent  hole in the  pump  body 
for 
signs of coolant or lubricant  leaks. If there is 
any  evidence 
of leakage,  the pump  should  be 
renewed. 
Fitting  water pump 
3. Lightly  grease  a new  joint  washer  and place  it 
in  position  on the  timing  cover. 
4. Clean the threads of the water  pump  retaining 
bolts  and apply  Loctite 
572 thread  lubricant 
sealant  to the  threads 
of the long  bolts  which 
penetrate  into the cylinder  block. 
5. Fit the  pump  to the  cylinder  block and secure 
in  accordance  with the bolt  chart.  Tighten  the 
six bolts and one  nut evenly  to the  correct 
torque. 
- . 
35 
6. If separated,  fit the  fan blades  to the  viscous 
coupling  with the four  screws.  Fit the  fan and 
viscous  coupling  assembly  to the  water  pump 
spindle  noting that it is  secured  with a 
left
-hand  thread. If air conditioning is fitted  do 
not  at this  stage  fit the  drive  belt until  the 
compressor  belt 
is fitted. 
Fitting ladder frame 
Since the sealant  specified  to seal  the ladder  frame 
to the crankcase  cures within  fifteen  minutes  it is 
important  to fit sufficient  bolts to ensure adequate 
compression  while the 
sealeant cures. 
1. Clean  both sides of the ladder  frame and 
remove  all traces 
of old sealant.  Check that the 
frame 
is not  distorted  and is free from burrs 
and  damage  on the  mating  faces that could 
cause 
oil or  bypass gas to  leak. 
2. Coat  both faces  with Hylogrip  Primer to clean 
and  hasten  curing then apply  a bead 
of 
Hylogrip 2000 3,O mm wide  to the  mating 
face  with  the crankcase. 
3. Fit ten  securing  bolts through  the ladder  frame 
flange  and 
two more through  the sump  face as 
illustrated.  Tighten all bolts  evenly to the 
correct  torque. 
3 
ST3012M 
OIL 
1. 
2. 
3. 
4. 
5. 
* 
PUMP OVERHAUL 
Bend back the lock washer  and release the nut 
securing  the strainer  to the 
oil pump  body and 
remove  the. strainer  and sealing  ring. 
Remove  the four  bolts  and washers,  lift 
off the 
oil pump cover and remove  the driving  and 
driven  gear. 
Remove  the 
oil pressure relief valve plug and 
sealing  washer.  Withdraw  the relief  valve  spring 
and  plunger  and examine 
for wear  and scores. 
Examine  the gears 
for wear,  scores  and pitting 
and  renew 
if necessary.  Note: Gears  must be 
renewed  in pairs  only. 
If showing  signs of wear the driven  gear 
spind!e may be renewed. 
71  
						

							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  scratches  may be erased  by 
rubbing 
on fine  emery  cloth on a flat  surface. 
ST3014M 
Pump assembly. 
9. With  gear tolorances correct,  lubricate  and fit 
the  driven  gear to the  spindle  and install  the 
driving  gear with the counter  bored splined 
end 
of the  gear  uppermost  in the  pump 
housing. 
10. Fit  the  cover  locating  it over  the two  dowels 
and 
loosley secure  with the four bolts  until the 
strainer 
is fitted. 
11. Install  the spring  into the relief valve  then 
lubricate  and insert  the valve  into the relief 
valve  bore retaining  with the sealing  washer 
and  plug. 
12. Fit a new 0 ring  to the oil strainer  pipe and 
insert  into the pump  body and loosely  secure 
with  the 
lock washer  and nut. 
13. Secure  the strainer  bracket  to the  pump  body 
and  tighten  the four 
screws. Tighten  the 
strainer  pipe nut and  secure  with the 
lock tab. 
14. Insert  the pump  drive shaft and check  that the 
gears  are 
free to operate  before refitting  to the 
engine. 
72  
						

							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  block to allow  fitting 
of 
the sump. 
18. Apply  a 2,O mm wide bead of Hylosil RN102 
black  to the  sump  face and fit the sump. 
19. Install  and tighten  the twenty  remaining  bolts 
to  the  correct  torque.  Note that the three  long 
bolts  pass through  the sump  and ladder  frame 
into  the front  cover. 
CYLINDER  HEAD OVERHAUL 
CAUTION: 
Since  the cylinder  head is 
manufactured  from an aluminium  alloy care 
must 
be taken  to ensure  that the 
combustion  face, in particular, 
is not 
damaged 
or scratched  by placing  it on a 
hard 
or abrasive  surface while carrying  out 
the  overhaul  operations. 
1. Using valve spring  compressor MS 151 9A or a 
suitable  altemative,  remove the valve  and 
spring  assemblies  identified to their  original 
locations. 
ST3016M 
73  
						

							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 guides should  be 
checked 
by inserting  a new  valve  into the 
guide  and 
with the valve  lifted approximatly 8 
mm clear of the seat  the valve  head should  not 
rock more than 0,15 mm (0.006 in). If the valve 
head  movement  exceeds 
0,15 mm (0.006 in) 
the  guide  should  be renewed. 
5. inspect  the valves for wear  and damage.  Valve 
heads  that are burnt  and cracked  should 
be 
renewed. So should valves which are bent  and 
distorted.  Insert the valve  into a new  guide  and 
check  the side  movement  as described  above 
to  determine  the wear  on the  valve  stem. 
ENGINE DEFENDER 
Renew  valve guides 
6. Support the cylinder  head, combustion 
chamber  uppermost  on pieces 
of timber of 
sufficient  thickness  to allow  clearance for the 
inlet 
or exhaust  for the  valve  guides  to be 
driven  out using  special  tool 
R0274400. 
.. . . 
 ST2598M 
7. Turn the cylinder  head over so that the 
combustion  face 
is downwards.  Lubricate the 
new  valve  guides  and using  special  service 
tool 
LST 130 and depth  gauge RO 60774A press 
the  guide  into position  to the  depth 
determined 
by the gmge d ?9,0 rrm (0.748 
in). 
Reface valve  seat inserts 
8. 
9. 
.c 1, The special  set of hand tools recommended 
tightly  into new 
or worn guides to ensure  that 
the  valve  seat 
is concentric  with the valve 
guide.  The refacing 
tool has tungsten  carbide 
cutters  and can be used  to cut  a new  seat in 
the  insert.  The valve  seat cutter 
is numbered 
MS621, the handle  set MS76B and the pilot 
Loosely  assemble  the pilot  in the  sequence 
illustrated.  Ensure that the chamfered  end 
of 
the expander is towards  the collet. 
for refacing  include expandable  pilots that fit Q q., 
MS150-8. 
U- 
ST2644M 
74  
						

							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 the 
key MS76  ensuring that  the 
angled  end 
of each cutter is towards  the seat 
and  set 
so that  the middle of the blade 
contacts the seat  first. One  end 
of the cutter  is 
angled  at 
45 and the other end is 30. 
ST2645M 
12.  Using very light  pressure  tum the cutter 
clockwise  until the angled  face 
is approximatly 
01,s mm wide. 
operation  smear a small  quantity 
of engineers 
blue  round  the valve  seat and revolve  a 
correctly  ground valve against  the seat. 
A good 
seating  will produce  a continuous  fine polished 
line  around  the valve  face. 
A slight  gap of not 
more  than 
12 mm in the polished  line, can be 
corrected  by lapping. 
13. To check  the effectiveness of the cutting 
,, I. 
14. Valves  that are satisfactory for further  service 
can  be refaced.  This operation should  be 
carried  out using  a  valve  grinding  machine. 
Only  the minimum 
of material  should be 
removed  from the valve  face 
to avoid  thinning 
of the valve  edge.  The valve is refaced 
correctly  whan all pits  are removed  and the 
face 
is concentric  with the stem. 
Inlet  valve  seat face 
- 
Exhaust  valve  seat face - 
30 + 0,25 
45 + 0,25 
Inlet  valve  face - 
Exhaust  valve face - 
30 - 0,25 
45 - 0,25 
75  
						

							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 valve  stem with engine 
oil. Insert  the valve  in the  appropriate  guide 
and  using  a suction type  valve lapping  tool 
employ  a light  reciprocating  action  while 
occasionally  lifting the valve 
off its seat  and 
turning  it 
so that the valve  returns  to a 
. . .-. __ - . different  position on the  seat. -. - I 17. Continue  the operation  until a continuous  matt I 
grey band round  the valve  face is obtained. To 
check  that the lapping  operation is sucessful, 
wipe 
off the  valve  paste  from the valve  and ! I 
seat and make a series of pencil  lines  across 
the  valve  face. 
18. Insert  the valve  into the guide  and while 
pressing  the valve  onto the seat  revolve  the 
valve  a quarter 
of turn  a few  times. If all the 
pencil  lines are cut  through  no further lapping 
is  necessary.  Thoroughly  wash the cylinder 
head  ensuring  no lapping  paste remains  before 
fitting  the valves. 
19. Position  the cylinder  head with the combustion 
face  uppermost,  lubricate and insert  the valves 
into their  respective  guides. To check the valve 
head  stand
-down or the correct dimension of 
the valve  head below  the combustion  face, use 
either  a dial  test  indicator 
or a straight  edge 
and 
feeler gauge as follows. 
20. Hold  the straight  edge across  the centre of 
each  valve  in turn  and  measure  the gap 
between  the valve  head and straight  edge. The 
correct  dimension  should be 
1,l to 0,9 mm (0. 
040 to 0.035 in). Using  a dial  gauge  zero the 
gauge  on the  combustion  face then move the 
stylus  across  to the  valve  head and  note the 
reading. 
ST2585M 
Assembling  valves to cylinder head 
21. Insert the valves  to their respective guides  and 
locate  a spring  protection washer 
over each 
guide.  Fit new 
oil seals  to all  the  valve  guides 
with  the garter  spring  uppermost.  Ensure that 
the  seals  fully locate  on valve  guides. 
76