Land Rover 90 110 Workshop Rover Manual

							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  
						

							..1:;:: ... . , .>.:. ,. . ... .. 
Gl%B DEFENDER FUEL SYSTEM 
14. Fit the  turbo  charger  and secure  with the four 
nuts  and tighten  evenly to the  correct  torque. 
15.  connect  the 
oil feed and retum  pipes to the 
turbo  charger  and tighten  the 
feed pipe clamp. 
16.  Connect  the boost  pressure pipe to the 
T 
piece  and secure  with the clip. 
17. Connect the  intercooler hose to the  turbo 
inlet. 
18.  Fit the  hose  to air  cleaner  and turbo  charger. 
19. Fit the  turbo  charger  elbow. 
20.  Connect  the exhaust  front pipe to the  elbow 
using 
Holts Firegum to  seal  the joint. 
21.  Fit the  heat  shield  and secure  at the 
two fixing 
points. 
22. Fit  the  bonnet  and connect  the battery. 
INTERCOOLER 
Service Repair No. 19.42.15 
Remove,  clean and refit. 
1. Remove  the fan and  viscous  coupling 
assembly, 
see operation  26.25.1 9. 
2. Remove  the fan cowl, see operation  26.25.11. 
3. Disconnect  the top and bottom hoses  from 
the  Intercooler. 
4. Remove  the four  bolts (two each  side) 
retaining  the radiator  top support  brackets. 
5. Remove  the four bolts (two each  end) securing 
the  radiator  surround  top panel,  and remove 
the  panel. 
6.  Lift  out  the Intercooler. 
ST2928M 
Cleaning. 
7. Flush  the intercooler  with ICI GENKLENE 
propriety  cleaner,  following  the manufacturers 
instructions. 
no liquid  remains  in the  element. 
8. Dry the Intercooler  completely  ensuring  that 
Refitting. 
9. Slide the htercooler into position  taking care 
not  to damage the  insulation material on the 
sides. 
10.  Fit the  radiator  surround  top panel  and secure 
with  the four bolts. 
11. Fit the two top  brackets  and secure  with the 
four bolts. 
12.  Connect  the top and bottom  hoses. 
13.  Fit the  fan 
cowl. 
14. Fit the  fan and coupling  assembly. 
I .i . :. .$! . .. . !, ... 
87  
						

							COOLING SYSTEM DEFENDER 
COOLING SYSTEM 
Engine protection 
To prevent corrosion of aluminium  engine parts it is 
vital that the cooling  system is filled with  a solution 
of clean water  and  anti-freeze winter  and summer. 
Never 
fill or  top-up  with  water  only. always  add 
anti
-freeze.  Never  use salt water otherwise  corrosion 
will  occur.  In certain  territories  where the only 
available  water supply may  have some  salt content, 
use  only  clean  rain water  or distilled  water, with 
anti
- freeze  added. 
Use  only  Universal  anti
-freeze or permanent  type 
ethylene base, without methanol,  containing, a 
suitable  inhibitor 
for aluminiium  engine parts. Use 
one part of anti-freeze  to one  part  water. 
Anti
-freeze  should  be used  even  in climates  where it 
is not necessary. 
Anti
-freeze  can remain  in the  cooling  system  and 
will  provide  adequate  protection 
for two years 
provided  that the 
specific gravity of the coolant is 
checked  before the onset of the second  winter and 
topped
-up  with  new anti- freeze as required. 
Land  Rovers  leaving  the factory  have the cooling 
system 
filled with  a 50% anti- freeze  mixture.  This 
gives  protection  down to minus 
47 degrees 
Centigrade  (minus 
53 degrees  Fahrenheit). 
After  the second  winter the system  should be 
drained  and thoroughly  flushed. 
Before adding  new 
anti
-freeze  examine  all joints  and  renew  defective 
hoses  to make  sure  that the system  is leak  proof. 
See  section 
09 for protection  quantities. 
Service Repair No. 26.10.01 
Refilling. 
5. Make up a solution of anti-freeze  and water  in 
a  separate  container  in the  concentration 
required. 
To allow for topping-up,  and  for 
filling  the expansion  tank, prepare  a quantity  in 
excess 
of the  cooling  system capacity. 
6. Remove  the radiator filler cap  and fill the 
radiator  until the coolant  level 
is just below  the 
filler neck and refit  the cap. 
7. Fill the  expansion  tank to approximately  half 
full  and  refit  the cap. 
8. Connect  the battery  and run the engine  until 
normal  operating temperature 
is attained. 
Allow the engine  to cool completely  and 
removethe  radiator and expansion  tank caps. 
If 
necessary,  top-up the  the radiator  to just 
below  the filler  neck.  Top
-up the  expansion 
tank  to about  half full.  Fit both 
filler caps. 
Drain  and refil 
. 
WARNING: Do not remove  the radiator or 
expansion  tank filler  cap when  the engine is 
hot  because  the cooling  system is 
pressurized  and personal  scalding could 
result. 
1. Disconnect  the battery. 
2. Disconnect  the bottom  coolant hose from the 
radiator.  Allow to drain  and reconnect the 
hose. 
3. To drain  the cylinder  block,  remove the drain 
plug  which  is situated  on the  left hand 
side of 
the engine  immediately  below front core plug. 
Refit  the plug,  with  a  new washer,  when the 
draining 
is completed. 
4. To drain  the expansion  tank, remove  the cap 
and  disconnect  the expansion  hose from the 
radiator  and allow  it to  drain  into a suitable 
container.  Flush the tank  with  clean water  and 
reconnect  the hose. 
\- \- _,’ 
ST3032M 
88