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
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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
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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
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. 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
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- -.. . . .. ..,.. , . ... .. , , 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
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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
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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
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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
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-- /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
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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