Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual
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12ENGINE 22 REPAIR 28.Lower cylinder head onto block ensuring correct location with dowels. NOTE: Cylinder head retaining bolts can be used up to a maximum of five times. 29.Lubricate threads of bolts with light oil and fit to positions shown below. (Fit air cleaner mounting bracket at positions 6 and 14). Bolt sizes: M10 x 117mm locations 3, 5, 12, and 13. M12 x 140mm locations 1, 2, 7, 8, 9, 10, 15, 16, 17, and 18. M12 x 100mm locations 4, 6, 11, 14. 30.Tighten bolts so that underside of heads just make contact with cylinder head. 31.Following the sequence indicated, tighten all bolts to 40 Nm (30 lbf/ft). 32.Attach angle gaugeLRT-12-007. 33.Make a suitable pointer from welding rod and attach to a bolt screwed into a rocker shaft securing bolt hole. 34.Tighten all bolts through 60°strictly in sequence illustrated. 35.Repeat 60°tightening procedure, again strictly in sequence illustrated. 36.Tighten the 10 longer bolts (M12 x 140mm) a further 20°, again following the sequence illustrated. NOTE: Repositioning of the pointer will be necessary to reach all bolts, the pointer can be fitted to the rocker shaft securing studs using 2 nuts. CAUTION: The double tightening procedure MUST be carried out, on no account should the bolt tightening be performed in one operation, otherwise damage to the cylinder head may occur. 37.Fit valve stem caps. 38.Fit push rods to locations from which they were removed. 39.Position rocker shaft assembly over locating studs and fit retaining nuts and bolts, but do not tighten at this stage. 40.Attach angle gaugeLRT-12-007. 41.Make a suitable pointer and attach to one of the rocker shaft locating studs. 42.Tighten all fixings in turn to 5 Nm (4 lbf/ft).Then tighten a further 50°in same sequence. NOTE: Repositioning of the pointer will be necessary to reach all fixings.
ENGINE 23 REPAIR 43.Check and adjust valve clearances. See Adjustment, Valve clearances - check and adjust 44.Fit rocker cover, ensuring oil seal is satisfactory for continued use, and renew if necessary. 45.Secure rocker cover with special seal washers and nuts. Tighten to 10 Nm (7 lbf/ft). 46.Fit rear engine lifting bracket, securing breather pipe and multi-plug retaining clips. Tighten fixing bolts to 25 Nm (18 lbf/ft). 47.Fit engine harness bracket to cylinder head. 48.Secure air cleaner mounting bracket to support strut. 49.Connect heater hose to rear of cylinder head. 50.Position heater rail and connect hose from water pump. 51.Fit exhaust manifold and turbocharger assembly. See MANIFOLD AND EXHAUST SYSTEM, Repair, Exhaust manifold 52.Fit induction manifold.See MANIFOLD AND EXHAUST SYSTEM, Repair, Induction manifold 53.Connect water temperature sensor lead. 54.Connect water pump hose at thermostat. 55.Fit bleed hose at thermostat. 56.Connect radiator top hose at thermostat. 57.Fit heater plugs. See FUEL SYSTEM, Repair, Heater plugs 58.Fit fuel injectors.See FUEL SYSTEM, Repair, Fuel injectors 59.Fit crankcase ventilation valve and side breather hose. 60.Fit air cleaner. See FUEL SYSTEM, Repair, Air cleaner 61.Refill cooling system.See COOLING SYSTEM, Repair, Drain and refill cooling system 62.Fit bonnet. 63.Reconnect battery.OIL PUMP Service repair no - 12.60.26 Remove 1.Remove engine front cover. See Front cover gasket 2.Remove 7 screws and release oil pump retaining plate from engine front cover. 3.Mark oil pump inner gear rotor, outer gear rotor and front cover housing for reassembly. 4.Check for rotor clearances: Outer rotor to housing, 0,025 - 0,075 mm (0.010 - 0.030 in). Inner rotor to outer rotor, 0,025 - 0,075 mm (0.010 - 0.030 in). Rotor end float, 0,026 - 0,135 mm (0.010 - 0.054 in). 5.Remove inner and outer rotors. 6.Check condition of oil pump components. NOTE: If the oil pump seating in the front cover or retaining plate is badly worn, pitted or scored, a new front cover must be fitted. See Front cover gasket Always renew oil pump rotors as a pair. 7.Clean sealant from pump retaining plate and front cover.
12ENGINE 24 REPAIR Refit 8.Fit oil pump rotors in front cover. 9.Apply a bead of RTV sealant around retaining plate. 10.Fit oil pump retaining plate to front cover, securely tighten screws. 11.Fit front cover to cylinder block. See Front cover gasket OIL PRESSURE RELIEF VALVE Service repair no - 12.60.56 Remove 1.Remove engine oil sump. See Engine oil sump 2.Unscrew relief valve retaining plug from base of front cover. 3.Withdraw valve spring and plunger and check for wear. Valve spring free length, 68.00 mm (2.68 in). NOTE: If the valve plunger sleeve is badly worn, pitted or scored, a new front cover must be fitted. See Front cover gasket Always renew valve spring and plunger as a pair. Refit 4.Insert valve plunger and spring into sleeve in front cover and secure with retaining plug. 5.Fit engine oil sump. See Engine oil sump
ENGINE 1 SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Engine block Bearing cap 133............................................................................................... Blanking plug, oil gallery, rear 37.................................................................... Oil squirt jet assembly 17................................................................................ Drain plug, cylinder block 25........................................................................... Oil squirt jet, vacuum pump cam 7................................................................. Connecting rod to cap 59................................................................................ Oil pick up assembly to bearing cap 9........................................................... Oil pick up assembly to front cover 25............................................................ Camshaft thrust plate 9.................................................................................. Oil drain pipe to block (internal) 25................................................................. Oil drain pipe to block (external) 25................................................................ Sump to cylinder block and front cover 25...................................................... Drain plug, oil sump 35................................................................................... Tappet guide 14.............................................................................................. Breather side cover assembly 25.................................................................... Baffle plate to breather side cover 4.............................................................. Vacuum pump 25............................................................................................ Fuel lift pump 25............................................................................................. Flywheel housing 45....................................................................................... Flywheel housing clutch cover stud 10........................................................... Plug, flywheel housing 12............................................................................... Rear oil seal assembly 25............................................................................... Oil filter adaptor 45.......................................................................................... Waxstat adaptor to oil filter adaptor 9............................................................ Oil pressure switch 17..................................................................................... Oil filter, spin on 13......................................................................................... Oil cooler unions to filter adaptor 45............................................................... Oil level tube 25.............................................................................................. Engine mounting foot to cylinder block 85...................................................... Engine mounting foot to flywheel housing 45................................................. Engine mounting foot rubber to mounting foot (bolt and nut) 85..................... Flywheel to crankshaft 146.............................................................................. Clutch cover plate to flywheel 34.................................................................... Flex drive plate to crankshaft (auto) 146.......................................................... Flex drive plate to ring gear (auto) 25............................................................. Flex drive plate to torque converter (auto) 45.................................................
12ENGINE 2 SPECIFICATIONS, TORQUE REV: 05/99Nm Cylinder head Cylinder head to cylinder block M10 x 117 40 Nm + 60° .......................................................................................... M12 x 100 40 Nm + 60° .......................................................................................... M12 x 140 40 Nm + 60°+20° ...................................................................................... Stub pipe heater feed 22................................................................................. Water temperature sensor 14......................................................................... Blanking plug cylinder head 14....................................................................... Engine lifting brackets 25................................................................................ Electrical harness clip bracket 25................................................................... Exhaust manifold stud 10................................................................................ Exhaust manifold nut 45................................................................................. Inlet manifold stud 8....................................................................................... Inlet manifold nut and bolt 25.......................................................................... Air temperature sensor, inlet manifold 14....................................................... Blanking plug, inlet manifold 14...................................................................... Heatshield to inlet manifold 6......................................................................... Glow plug 20................................................................................................... Glow plug terminal nut 2................................................................................ Injector clamp (stud) 8................................................................................... Injector clamp (nut) 25.................................................................................... Thermostat housing 25................................................................................... Water outlet elbow to thermostat housing 25.................................................. Water temperature switch, thermostat housing 11.......................................... Plug thermostat housing 6............................................................................. Rocker shaft pedestal bolt 5 Nm + 50° .................................................................. Rocker cover (stud) 8..................................................................................... Rocker cover (fixing nut) 10............................................................................ Breather cyclone to rocker cover 9................................................................ Tappet adjusting nut 16.................................................................................. Front cover to cylinder block 25...................................................................... Front cover plate to front cover 25.................................................................. Static idler - timing belt (stud) 10..................................................................... Static idler - timing belt (nut) 45...................................................................... Tensioner (timing belt) 45............................................................................... Camshaft hub bolt 80...................................................................................... Timing pulley to camshaft hub 25................................................................... Fuel injection pump (stud) 8........................................................................... Fuel injection pump (nut) 25........................................................................... Abutment bracket to injection pump 25........................................................... Support bracket injection pump to cylinder block 25....................................... Fuel injection pump access plate to front cover plate 25................................ Timing pulley to injection pump hub 25........................................................... TV Damper pulley bolt to crankshaft 80 Nm + 90° .................................................. Fan pulley to hub 25....................................................................................... Fan and viscous coupling to hub 45............................................................... Auto tensioner, auxiliary drive (stud) 14.......................................................... Auto tensioner, auxiliary drive (nut) 45........................................................... Auxiliary mounting bracket to cylinder block (stud) 8..................................... Auxiliary mounting bracket to cylinder block (bolt and nut) 25........................ Water pump to block and mounting plate 25.................................................. Water pump pulley to hub 25..........................................................................
ENGINE 3 SPECIFICATIONS, TORQUENm Turbo charger oil drain adaptor to block 42.................................................... Oil drain pipe to turbocharger 25.................................................................... Turbocharger oil drain pipe to adaptor 38....................................................... Turbocharger oil feed pipe adaptor to block 25............................................... Turbocharger oil feed pipe to adaptor 25........................................................ Oil feed pipe to turbocharger 19..................................................................... Turbocharger to cylinder head (stud) 10......................................................... Turbocharger to cylinder head (nut) 45........................................................... Turbocharger to blanking plate 25.................................................................. Turbocharger to EGR valve 25....................................................................... EGR delivery tube to valve 25........................................................................ EGR delivery tube to mixing tube 25.............................................................. Fuel lift pump to filter (union) 15..................................................................... Fuel filter from lift pump (banjo bolt) 33........................................................... Fuel filter to fuel injection pump (banjo bolt) 33.............................................. Fuel injection pump from fuel filter (banjo bolt) 25.......................................... Injector pipes to injectors and fuel injection pump 29..................................... Spill rail to injectors (banjo bolt) 10................................................................. Spill rail to injection pump (banjo bolt) 25....................................................... Boost pipe injection pump (banjo bolt) 10....................................................... Plug, rear of injection pump 29....................................................................... PAS pump to mounting plate 25..................................................................... PAS pump mounting plate to auxiliaries mounting bracket 25........................ PAS pump pulley to hub 25............................................................................ Starter motor (bolt and nut) 45........................................................................ Air conditioning compressor Compressor mounting bracket to front cover 45............................................. Compressor to mounting bracket (stud) 8...................................................... Compressor to mounting bracket (nut) 25...................................................... Belt tensioner pulley to tensioner arm 45........................................................ Belt tensioner assembly to front cover plate 25.............................................. Idler pulley to front cover plate 45................................................................... Compressor belt guard (nut) 25...................................................................... Sensors to water outlet elbow (air/con) 25...................................................... Blanking plug, water outlet elbow (air/con) 25................................................ Generator Generator mounting bracket to front cover 45................................................ Generator to mounting bracket 85.................................................................. Generator pulley to hub 95............................................................................. Generator belt guard 25.................................................................................. Generator to auxiliaries mounting bracket 25................................................. Tachometer electrical connection 4...............................................................
12ENGINE 4 SPECIFICATIONS, TORQUEMETRIC Nm M5 6...................................................................................................... M6 9...................................................................................................... M8 25..................................................................................................... M10 45................................................................................................... M12 90................................................................................................... M14 105.................................................................................................. M16 180.................................................................................................. UNC / UNF 1/4 9...................................................................................................... 5/16 24................................................................................................... 3/8 39..................................................................................................... 7/16 78................................................................................................... 1/2 90..................................................................................................... 5/8 136.................................................................................................... NOTE: Torque values above are to be used as a guide where no torque is specified.
FUEL SYSTEM 1 DESCRIPTION AND OPERATION DESCRIPTION Fuel system The fuel system incorporates a supply and spill return line on all models as illustrated below. On 90 models, see J6191, the fuel tank is mounted at the RH side of the vehicle chassis under the front seat.On standard 110 and 130 models the fuel tank is located at the rear of the vehicle between the chassis longitudenal sections, as shown in J6192. As an option, a twin tank system fitted with a combined change-over tap and 3 way fuel supply and return system, can be installed on both 110 and 130 models, see J6193. The tank/s on all vehicles is vented by a 2 way valve in the filler cap. FUEL SYSTEM LAYOUT 1.Fuel tank 2.Fuel sedimentor, if fitted 3.Fuel lift pump 4.Fuel filter5.Fuel injection pump 6.Spill return line 7.Fuel injectors
19FUEL SYSTEM 2 DESCRIPTION AND OPERATION A mechanical lift pump, with a hand priming facility, is driven by the camshaft, and is mounted on the RH side of the engine. A fuel filter, with a replaceable element and incorporating a water separator, is mounted on the front RH side of the engine compartment. A fuel sedimentor may be fitted when the vehicle is operating in more arduous conditions, and is used to minimise water deposits in the fuel system before reaching the fuel pump and filter. Fuel injection is carried out by a Bosch direct injection pump, incorporating a cold start advance unit and a high idle setting. The pump is mounted on the RH side of the engine and is driven directly by gears in the front cover from the crankshaft. The pump meters and distributes fuel to 4 pintle type injectors located in pre-combustion chambers in the cylinder head. Four heater plugs, located in the cylinder head directly below each injector, are fitted to improve cold starting. An optional hand throttle, for use with a centre power take off, is located on the fascia to the LH side of the fuse box, and is linked independently to the fuel injection pump throttle lever. Air intake The air cleaner is mounted on the RH side of the engine and is connected by hoses to the cold air intake duct and turbocharger inlet. Fitted between the air cleaner and turbocharger is the crankcase breather hose which connects to a breather filter on the rocker cover. A single stage turbocharger, fitted between the exhaust manifold and exhaust down pipe, is connected by hoses to the air cleaner and an intercooler which is mounted on the LH side of the radiator. The intercooler is connected by a hose to the inlet manifold. When an EGR valve is fitted to the turbocharger, additional pipes/hoses are used to connect the components.Exhaust gas recirculation (EGR), when fitted. Exhaust gas recirculation is controlled by an ECU mounted under the front centre seat or cubby box and receives the following inputs: ·Engine temperature from coolant temperature sender unit on LH side of cylinder head. ·Throttle position from potentiometer on injection pump. ·Engine speed from speedometer. When all correct signals are received, the EGR solenoid allows vacuum to open EGR valve and recirculate a portion of the exhaust gas. See J6196 for the EGR system component location and Operation for full system function.
FUEL SYSTEM 3 DESCRIPTION AND OPERATION 90 FUEL SYSTEM 110 FUEL SYSTEM 1.Fuel filter 2.Supply pipe, lift pump to filter 3.Supply pipe, fuel filter to injection pump 4.Fuel injection pump 5.Fuel lift pump 6.Spill return pipe, injection pump to tank7.Supply pipe, sedimentor to fuel pump 8.Fuel tank 9.Supply pipe, fuel tank to sedimentor 10.Fuel filler pipe 11.Breather pipe 12.Sedimentor, if fitted NOTE: If a sedimentor is not fitted, the fuel supply pipe from the tank will connect directly to the fuel lift pump.