Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

12ENGINE
6
REPAIR GASKET - CYLINDER HEAD
Service repair no - 12.29.02
Remove
NOTE: The following procedures cover
engines fitted with or without an EGR
cooler. The EGR cooler is bolted to the
front of the cylinder head.
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain cooling system.See COOLING
SYSTEM, Adjustment.
3.Remove camshaft cover gasket.See this
Section.
4.Remove cooling fan.See COOLING SYSTEM,
Repair.
5.Release clips and disconnect air flow meter from
air filter.
6.Disconnect...

ENGINE
7
REPAIR
14.Disconnect MAP sensor multiplug from inlet
manifold.
15.Position engine harness clear of inlet manifold.
16.Disconnect vacuum hose from EGR valve.
17.Loosen clip screw and disconnect air intake
hose from EGR valve.
18.Release 3 clips and disconnect coolant hoses
from fuel cooler.
19.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Plug the connections.
20.Disconnect fuel hose from fuel cooler and secure
to connector block on cylinder head. This...

12ENGINE
8
REPAIR
NOTE: Non EU3 model illustrated.
21.Loosen vacuum pipe union from cylinder head
and discard’O’ring.
22.Loosen 2 bolts and release alternator support
bracket from cylinder head.
23. Pre EU3 model:-Remove bolt securing EGR
valve pipe to cylinder head.
24. EU3 model:-Release the clips and disconnect
the coolant hoses from the EGR cooler.
25.Release clips and disconnect top hose, heater
hose and heater feed hose.
26.Remove the nut and bolt securing the cuylinder
head to the timing chain...

ENGINE
9
REPAIR
30.Remove timing chain tensioner and discard
sealing washer.
31.Remove timing chain fixed guide Allen screw
from front of cylinder head.
32.Lever out camshaft sprocket access plug from
front of cylinder head and discard’O’ring.
33.Remove 3 bolts and release sprocket from
camshaft; discard bolts.
34.Using sequence shown, progressively loosen
then remove and discard 12 cylinder head bolts
together with their captive washers.
35.Using suitable lifting chains andLRT-12-138
carefully remove...

12ENGINE
10
REPAIR Refit
39.Clean mating faces of cylinder head and cylinder
block.
40.Check cylinder head for warping, across centre
and from corner to corner:
Maximum warp = 0.10 mm (0.004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head assembly if
warping exceeds figure given.
41.Ensure coolant and oil passages are clean.
42.Clean dowel holes and fit new dowels.
43.Fit new cylinder head gasket of the correct
thickness with the word’TOP’uppermost.
44.Using assistance, fit cylinder...

ENGINE
11
REPAIR 63. Pre EU3 model:-Fit bolt, EGR valve pipe to
cylinder head and tighten to25 Nm (18 lbf.ft).
64. EU3 model:-Connect coolant hoses to EGR
cooler and secure with clips.
65.Position air intake hose to EGR valve and
tighten clip screw.
66.Disconnect fuel hose from connector block and
connect to fuel cooler.
67.Connect fuel hoses to fuel cooler and connector
block on cylinder head.
68.Connect coolant hoses to fuel cooler and secure
clips.
69.Connect vacuum hose to EGR valve.
70.Position...

12ENGINE
12
REPAIR
5.Progressively loosen then remove and discard 6
bolts; remove rocker shaft assembly.
6.Remove and discard lock nuts and rocker
adjusting screws.Refit
7.Clean rocker shaft and mating faces.
CAUTION: If rocker arms or shaft are to be
replaced, ensure replacements are correct.
Engine Serial No. Prefixes 10P to 14P are
fitted with Type A rocker arms and shaft. Engine
Serial No. Prefixes 15P to 19P are fitted with Type
B rocker arms and shaft. Type B rocker arms and
shaft may be fitted to...

ENGINE
13
REPAIR 11.Before refitting the camshaft cover, the fuel
injector rockers must be adjusted.
12.RemoveLRT-12-058.
13.Rotate engine clockwise until No. 1 injector lobe
is at full lift.
14.Rotate rocker adjusting screw clockwise until the
injector plunger is felt to bottom out.
15.Rotate rocker adjusting screw anti-clockwise 1
complete turn to give the plunger the required
bump clearance and tighten rocker adjusting
screw locknut to16 Nm (12 lbf.ft).
CAUTION: Ensure screw does not turn as
locknut...

12ENGINE
14
REPAIR
9. Not EU3 model:-Apply two 3 mm diameter
beads of sealant, Part No.STC 5433 to areas’A’
shown on illustration.
CAUTION: Excessive use of sealant could
result in blockage of oil drain hole,
arrowed’B’in illustration.
10.Fit new gasket to camshaft cover. fit cover and
tighten bolts to10 Nm (7 lbf.ft).
11.Position breather hose and secure clip.
12.Fit engine acoustic cover.
13.Reconnect battery negative lead.
14.Fit battery cover.ENGINE AND ANCILLARIES
Service repair no - 12.41.01.99...

ENGINE
15
REPAIR
NOTE: Non EU3 model illustrated.
9.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Plug the connections.
10.Disconnect fuel hose from fuel cooler and secure
to connector block on cylinder head. This to
prevent contamination of the fuel system.
11.Release servo vacuum pipe, remove 4 bolts and
remove fuel cooler.
12.Release servo vacuum pipe from engine rear
cover clips and vacuum pump.
NOTE: Non EU3 model illustrated.
13.Disconnect vacuum hose...