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Land Rover Defender 90 110 Workshop Book 6 Supplement Rover

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    							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 securing  the thermostat 
    cover  and lift out  the thermostat.  The 
    thermostat  may be tested  by immersing  it in 
    hot  water 
    of a known  temperature  and 
    comparing  its operation  with the temperature 
    range  stamped  on the  flange.  Any leakage 
    of 
    wax (which is the colour of copper)  from 
    around  the 
    center pin of the thermostat, 
    indicates  that it 
    is faulty  and should  be 
    renewed. 
    n 
    0.024 
    to 
    0.0275 
    0.0279 
    to 
    0.0314 
    ST3022M 
    25.  The  thermostat  housing may be removed  from 
    the  cylinder  head at this  stage  and 
    if necessary 
    the  gasket  renewed. 
    26.  The 
    jiggle  pin which  allows  any air to escape 
    from  below  the thermostat,  may be fitted  in 
    any  position.  Renew the gasket  when fitting 
    the  thermostat  and apply  a little  Hylomar 
    sealant 
    to the  threads of temperature  sensor 
    and  transmitter  before screwing  into position. 
    FITTING CYLINDER HEAD 
    Piston  protrusion  and gasket  selection 
    Before fitting the cylinder  head, the protrusion of 
    the pistons  above the block  face must  be checked 
    in  order  that the correct  thickness  gasket may be 
    selected  from the range 
    of three.  The height of all 
    the  pistons  above the cylinder  block must be 
    measured  and the thickness 
    of the gasket  selected 
    is based upon the largest  value of dimension A, as 
    illustrated.  This dimension,  however, must not 
    exceed 
    0,8 mm (0.032  in). - _. _- - 
    Al 
    ST2646M 
    Three thicknesses of gasket  are available  and each 
    size  can be recognised  by the  number 
    of 
    identification  holes punched  in the  side of the 
    gasket 
    as illustrated.  The table  below  gives the 
    details 
    of the  gaskets  available.  The thickness of 
    gasket  fitted can be seen when  the cylinder  head is 
    fitted since the identification  holes can be seen 
    protruding  from the right  hand  side 
    of the engine 
    towards  the rear. 
    Number 
    of holes  Metric  Imperial I I Gasket 
    ERR0382  ~ 
    ERR038 
    ERR0384 
    77  
    						
    							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 
    on  the  cylinder  block 
    so that the identification 
    holes  are towards  the rear  on the  right
    -hand 
    side. 
    2 
    3. Clean  the cylinder  head face and if preferred, 
    guide  studs may 
    be fitted to the cylinder block 
    to facilitate  the lowering of the  head  into 
    position.  Locate the head  over the 
    two 
    dowels. 
    oil, and fit to  the  positions  illustrated 
    according  to length  and diameter.  Tighten the 
    bolts  down 
    so that the heads  just make 
    contact  with the cylinder  head. 
    Now, in the 
    sequence  shown, tighten 
    all the holtr down tc! 
    40 Nm with a suitable  torque wrench. 
    4. Lubricate  the threads of new  bolts,  with light 
    Bolt sizes: 
    M1 0 locations 3, 5, 12 and 13 
    M12 locations 1, 2, 4, 6: 7, 8, 9, 10, 1Ii 14,  15, 
    16, 
    17, 18 
    ST2619 M 
    5.  Attach  the special  service tool degree disc 
    LST122 to a power  bar. Make  a suitable  pointer 
    from  welding  rod and  attach  it to  a bolt 
    screwed  into a 
    rocker shaft  securing  bolt hol. 
    6. Tighten  all the  bolts down through  an angle of 
    60 strictly  in the  sequence  illustrated. As each 
    bolt 
    is tightened  scribe a line  across  the head 
    with  a piece 
    of chalk  or crayon  to identify 
    which  bolts have been  tightened,  then tighten 
    each  bolt a further 
    60 again  in the  correct 
    sequence  to complete  the tightening 
    procedure.  Re-positioning 
    of the pointer will, 
    no doubt, be necessary  to reach  all bolts. 
    CAUTION: It is important  that the double 
    torquing  procedure 
    is observed  and that  on 
    no  account  should the total  angle 
    of 120 
    be performed  in one  operation  otherwise 
    damage  and distortion 
    of the cylinder  head 
    may  occur. 
    78  
    						
    							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 the clearance  exceeds 
    0,127 
    mm (0.005 in).  Press  in replacements 
    ensuring  that the pre
    -drilled  holes align with 
    those  in the  rockers  and machine  the inside 
    bore 
    of the  bushes to 18,018 mm. The  rocker 
    arm  and bush 
    oil drillings  are shown  in the 
    cross  section  illustration. 
    Examine  the tappet  adjustment  screws and 
    check  that the ball  end 
    is not worn or pitted 
    and  that 
    the lubrication  hole is clear. 
    Assemble  the rockers,  bearing caps, new 
    springs  and washers 
    to the shaft  noting  where 
    the  washers  are fitted.  Hold the assembly 
    together  with 
    the five rocker shaft retaining 
    bolts. 
    Push rods 
    1.  Examine  the push  rods and renew  any that are 
    bent or where  the ball or cup  ends  are worn 
    or pitted. 
    2. Fit the  push  rods to the engine  ensuring  that 
    the  ball
    -end  locates  properly  in each 
    camfollower  slide. 
    FlITlNG ROCKER SHAIT 
    1. Ensure that a new  cap is fitted to each  valve 
    stem  before  fitting the rocker  shaft. 
    2. Fit the rocker shaft  to the  cylinder  head 
    ensuring  that the retaining  bolts and push  rods 
    are  correctly  located then evenly  tighten 
    the 
    bolts to correct  torque. 
    5 
    ST3131M 
    ST3129M 
    79  
    						
    							. 
    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 in) feeler gauge  adjust 
    the  clearance 
    of number  one valve. 
    Continue  to adjust  the remaining  tappets in the 
    following  sequence: 
    Set 
    No. 3 tappet  with No. 6 valve fully open. 
    Set 
    No. 5 tappet  with No. 4 valve fully open. 
    Set 
    No. 2 tappet  with No. 7 valve fully open. 
    Set 
    No. 8 tappet  with No. 1 valve fully open. 
    Set 
    No. 6 tappet  with No. 3 valve fully open. 
    Set 
    No. 4 tappet  with No. 5valve fully open. 
    Set 
    No. 7 tappet  with No. 2 valve fully open. 
    Rocker cover  and crankcase  ventilator 
    7. If necessary release the single  bolt and remove 
    the 
    oil separator  ventilation  valve  unit, from 
    the 
    side of the  rocker  cover and thoroughly 
    clean. 
    Its  function 
    is to separate  the oil from the crankcase 
    ventilation  atmosphere,  allowing the 
    oil to retum  to 
    the sump and  the residues  to 
    be drawn into the 
    combustio:! chamber  where they are  bumed. The 
    unit  also  contains  a diaphragm  valve which  controls 
    the  purge  rate 
    of the crankcase  fumes. The 
    operation 
    of the  valve  may be tested as follows. 
    Test 
    2. 
    procedure  crankcase ventilator 
    With the unit  removed  from  the rocker cover 
    seal 
    off the two ports  illustrated  and apply  a 
    vacuum  to the  third  por. 
    As the vacuum  pump 
    is operated the  diaphragm valve will be heard 
    to  seat.  While  holding  the vacuum  unseal 
    either 
    of the  other two ports and  the diaphram 
    valve  will 
    release. 
    test, indicates  that the diaphragm is punctured 
    and  the unit  should  be renewed. 
    3. Failure of the  diaphragm  valve to seat  during 
    4. Refit the unit  using  a new  rubber 0 ring. 
    Fitting rocker cover 
    5. 
    Apply  a  continuous  bead of RW Hylosil which 
    starts and  finishes 
    10 mm each side of the half 
    moon  grooves  at both ends 
    of the rocker  shaft 
    and  press  the seals into  position. 
    6. Locate a new  seal in the  rocker  cover  and fit 
    the 
    cover to  the  cylinder  head securing  with 
    the  three  special bolts  and conical washers. 
    Tighten  the bolts  evenly  to the  correct  torque 
    &- E .-*I  
    and  reconnect  the ventilation  hoses. 
    80  
    						
    							- -.. . . .. ..,.. , . ... .. , , 
    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 PIPES 
    1. Ensure that the injector and  seating  in the 
    cylinder  head is clean  then lightly  grease  a new 
    copper  washer  in position  on the  injector. 
    2. Fit the  injectors  with the spill  return  outlet 
    facing  towards  the rear 
    of the  engine  and 
    secure each  with  a clamp and nut. The  clamps 
    are  slightly  curved and the convex 
    side should 
    be  fitted  uppermost.  Tighten the nuts  to the 
    correct  torque. 
    3. Fit the  spill  return  rail to the  injectors,  noting 
    that  there  are 
    two copper  washers  and one 
    must  be fitted  each side 
    of the retaining  union 
    screw.  The in
    -board  washer  locates  in a recess 
    in  the  injector. 
    Do not  over-tighten  the screws. 
    4. Fit the banjo-union  end of the spill return  rail 
    to  the  rear 
    of the injector  pump and  secure 
    with  a  copper  washer each  side 
    of the banjo 
    and  the union  bolt. 
    5. Fit the  injector  fuel supply pipes  securing each 
    end 
    of the  pipes  to their  respective  locations 
    loosely,  then tighten  evenly. 
    Do not, however, 
    over-tighten. 
    Commencing  at the  front of the engine  connect 
    the pipes  as 
    follows: 
    A. To number 1 injector. 
    B. To number 2 injector. 
    C.  To  number 
    3 injector. 
    D. To number 4 injector. 
    81  
    						
    							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 oil filler cap so that the position of 
    number  one cylinder  valve rockers can be seen 
    to  assist  in obtaining  T.D.C. 
    7. Tum the crankshaft to align  the T.D.C mark  on 
    the  crankshaft  damper with the the  web on the 
    front  cover  plate. At the  same  time check  that 
    the  valves 
    of number  one cylinder  are closed. 
    ST3044M 
    8. Remove  the blanking  plug from  the bottom of 
    the flywheel  housing and fit the  timing  pin LST 
    128. Check  that the pin can  be inserted  into 
    the  appropriate  slot in the  flywheel.  Note that 
    there  are 
    two slots in the  flywheel  the 
    narrowest  one being  that which  determines 
    T.D.C. 
    for this  engine.  9. 
    Remove  the injector  pump hub blanking  plate. 
    Through  the 
    U shaped slot in the  pump  hub 
    into  the pump  body. Ensure  that the pin fits 
    easily  and 
    is fully inserted. 
    10. Insert  the injector  pump timing  pin LST 12912 
    / LST 129/2 
    Continued 
    82  
    						
    							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. Remove  the pump  drive gear three  retaining 
    bolts  and remove  the 
    lock plate and timing 
    pin. 
    13.  Fit the  pump  gear retaining  tool 
    LST 129/1 and 
    align  and tighten  the 
    two bolts. insert the 
    timing  pin 
    LST 129/2, again, through  the hole 
    provided  in the  retaining  tool. 
    ST3037M 
    15. Remove the injector  pump rear support 
    bracket. 
    16. Remove  the oil filter adaptor  rear attachment 
    bolt  to allow  clearance  for the  pump  to be 
    withdrawn. 
    17. Remove  the pump  three retaining  nuts and 
    withdraw  the pump  and gasket,  with 
    LST 12912 
    18. Fit blanks  to the  inlet  and outlet  ports to 
    prevent  entry 
    of dirt. Slacken  the locking 
    screw, 
    fit the  keeper  plate and tighten the 
    screw. 
    83  
    						
    							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  with the three  nuts  tightening 
    evenly  to the  correct  torqu. 
    Fit  the  rear  support  bracket to the  cylinder 
    block  and secure  the pump  to the  bracket. 
    Tighten  all bolts  the the  correct torque. 
    Fit  the 
    oil filter  adaptor  rear attachment  bolt. 
    Connect the  items listed in instruction 
    14. 
    Fit  the  injector  supply pipes  securing each end 
    to their respective  locations,  loosely then 
    tighten  evenly but 
    do not over  tighten. 
    Commencing  at the  the front 
    of the  engine 
    connect  the pipes 
    as follows:- 
    A to number  one injector. 
    B to number two injector. 
    C to  number  three injector. 
    D to number  four injector.  27. 
    28. 
    29. 
    30. 
    31. 
    1. 
    2. 
    3. 
    4. 
    5. 
    6. 
    7. 
    32. 
    33.  Remove 
    the pump  timing pin and  the pump 
    gear  retaining  tool 
    LST 129/1. 
    insert the pump  timing  pin  again  and fit the 
    gear 
    lock plate  and secure  with the three  bolts 
    and tighten 
    to the  correct  torque. 
    Remove  the timing  pin. Unlock  the pump,  fit 
    the 
    keeper plate  and tighten  the bolt. 
    To check  that  the pump  timing is correct,  turn 
    the  crankshaft 
    two complete  revolutions  and 
    check  that the timing  pin LST 
    129/2 can  be 
    inserted  easily and fully  into the pump.  at  the 
    same  time check  that  the flywheel timing  pin 
    can  also  be inserted  in the  flywheel  slot. 
    If, with the flywheel  timing pin located,  the 
    timing  pin  cannot be inserted  cleanly into the 
    pump, 
    carry out  the following  instructions:- 
    Turn the crankshaft  the small  amount  necessary 
    to enable the timing  pin to be  inserted  into 
    the  pump. 
    Remove  the 
    keeper plate and lock the pump. 
    Slacken  the three  pump  gear retaining  bolts. 
    Tum  the crankshaft 
    to T.D.C. 
    Check  that the timing  pin 
    is an easy  fit in the 
    pump  and that  the flywheel  timing  pin locates. 
    Tighten  the pump  gear retaining  bolts to the 
    correct  torque. 
    Unlock  the pump,  fit the  keeper  plate and 
    tighten  the bolt.  Remove  the timing  pin  from 
    the the  pump and the timing  pin tool  from  the 
    flywheel. 
    Fit  the  pump  aperture  cover with a new  gasket 
    and  secure  with the screws. 
    Connect  the cooling  system bottom  hose to 
    the  waterpump. 
    Continued 
    84  
    						
    							-- /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 the  top  coolant  hose. 
    38. 
    Refil the  cooling  system with the correct 
    concentration 
    of water  and anti-freeze  see 
    operation  26.10.01. 
    AIR CLEANER 
    Service Repair No. 19.10.01 
    . Remove and refit 
    1. Disconnect  the hose  from the turbo  charger 
    compressor  housing to air  cleaner. 
    2. Disconnect,  from the air cleaner,  the engine 
    breather  hose. 
    3. Disconnect from  the air cleaner,  the air inlet 
    5. To  release  and remove  the air cleaner  from its 
    mounting  cradle, twist the body 
    of the air 
    cleaner  anti
    -clockwise  (viewing  it from  the 
    front 
    of the  engine)  and remove  it from  the 
    vehicle. 
    Renewing  element 
    6. Unscrew the handwhee! anti-c!nckwise and 
    remove the end  cover. 
    7. Unscrew  the wing  nut  and  withdraw  the 
    8. Clean the interior of the  casing  and  cover. 
    9. Fit a new  element,  fins leading,  into the casing. 
    10.  Secure  the element  with the wing  nut. 
    11.  Fit the end  cover and aline  the two  arrows. 
    element. 
    Refitting  12.  The 
    two clips  on the  side of the casing locate 
    in  the  square slots  in the  air cleaner  mounting 
    cradle. 
    It is necessary therefore,  to twist the air 
    cleaner 
    clockwise into  its final  position  and 
    ensure  that the clips  engage  in the  slots. 
    13.  Secure  the air cleaner  with the two  fastners. 
    14. Connect  all the  hoses,  reversing  instructions 1 
    to 3. 
    15. Finally, reset the element  change indicator, 
    where  fitted, by  depressing  the button. 
    ST3036M 12’ 
    85  
    						
    							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. 
    7. Disconnect,  from the turbo  charger,  the 
    bottom  hose from the intercooler. 
    8. Remove  the boost  pressure pipe  from the 
    turbo 
    T piece. 
    9. Slacken  the turbo charger oil feed  pipe clamp. 
    10. Disconnect  the oil supply pipe from the turbo 
    charger  centre housing. 
    11. Release the oil return drain pipe from the 
    turbo  charger. 
    12. Remove  the four  nuts  and lift the  turbo 
    charger from  the exhaust  manifold  and retrieve 
    the steel  joint washer. 
    Refitting 
    13. Fit the  steel  joint washer  to the  to the  exhaust 
    manifold 
    e , .: . 
    86  
    						
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