Land Rover Defender 90 110 Workshop 1984 Rover Manual

DEFENDER ENGINE n 12 
Fitting connecting rods and pistons 
1. Ensure  that the essentric  headed big end  bolts 
and  shell  bearings  are correctly  located in the 
connecting 
rods and as a  precaution  against 
possible  damage to the  crankshaft  journals 
during  installation 
of the pistons,  cover the 
bolt  threads  with a layer 
of adheasive  tape. 
Check  that the number  on the  connecting  rod 
is the same as the piston  and cylinder  and that 
they  are correctly  orientated. 
2. With the...

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ENGINE DEFENDER 
Fitting rear main oil seal to flywheel  housing 
The oil seal is manufactured  from P.T.F.E.  and is 
supplied  with a former  to maintain  the correct  shape 
which  must not be removed  until the seal  is to  be 
fitted. 
18G 134-11 
 
1. Make  sure the  seal housing is clean  and dry 
and  free  from  burrs. 
Do not touch  the seal  lip 
and  ensure  that the outside  diameter 
is clean 
and  dry. 
2. Using  special  seal replacer 18C134-I 1 and with 
the  lip side  leading...

a DEFENDER ENGINE n 12 
4. Examine the seal  guide,  number 18G1344 
ensuring  that it is perfectly  smooth and not 
damage  or scratched. 
Also check that  the 
crankshaft 
oil seal  journal is smooth and clea. 
5. Locate  the seal  guide  on to the  crankshaft  and 
lubricate  the seal,  guide  and journal  with 
concentrated  Oildag in a 
25% solution  with 
clean  engine 
oil. 
6. Carefully  locate the flywheel  housing over the 
seal and  on to the dowels. 
7. Remove  the seal  guide and secure  the...

El ENGINE DEFENDER 
3. Secure the flywheel  in a soft jawed  vice and 
cover it with  a  cloth to avoid  personal  injury. 
Place  a 
cold chisel  above  the drilled  hole and 
strike  it sharply 
to split  the ring  gear. 
4. Heat  the new  ring uniformally  to between 
225°C and  250°C but 
do not exceed  the 
higher  figure. 
5.  Place  the flywheel,  clutch face  down, on a flat 
surface  and  press  the starter  ring firmly  against 
the  flange  until the ring  contracts  sufficiently  to 
grip...

e DEFENDER ENGINE n 12 
T . .. 
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Fitting  camshaft 
Inspection  1.  Mount  the camshaft  on 
v blocks on a 
surface  plate for convenience  and examine  the 
cams 
for wear,  scores,  pitting and  chipped 
edges. 
2. Examine  the journals for obvious wear  and 
scores and  signs 
of overheating,  in particular, 
check  the thrust  plate. 
If the journals are visibly 
sewiceable, check  with a dial  gauge  or 
micrometer for  overall wear, ovality,  taper and 
runout. 
CAUTION: If the skew  gear...

112) ENGINE e DEFENDER 
2. Insert the tappet  guides  into the cylinder 
block,  retaining  each with a new  screw  which 
should 
be screwed  in sufficiently to allow  the 
rollers  and slides  to be  installed.  Ensure  the 
rollers  are fitted  in accordance  with any marks 
made  during  removal.  New rollers,  however, 
may 
be fitted  either  way around. 
3. Before  fitting the tappet  slides make sure the 
oilways  are clear  to the  running  surface 
of the 
roller  and the pushrod  seating....

e DEFENDER ENGINE 1121 
Fitting skew gear 
If the original skew gear and camshaft  are being 
re
-used it is important  that the gear teeth mesh in 
the original  position  as follows. 
1 . $:. d _. 
5. Turn  the camshaft so that  the key  aligns  with 
the 
oil groove as illustrated. 
* I. . .. .. . ,! .. 
6. Fit the  skew  gear assembly so that the 
ventilation  slot in the gear  housing is towards 
the 
front of the  engine  as illustrated  and 
ensuring  that any alignment  marks made during...

1121 ENGINE DEFENDER 
OVERHAUL AND FITTING OIL FILTER ADAPTOR 
Oil  temperature  thermostat 
1. Remove the two bolts and carefully  withdraw 
the  thermostat extension  housing complete 
with,  the 
’0’ ring (21,thermostat (3),washer (41, 
and  spring (5). 2. Clean  the adaptor  housing 
(6) with lint-free cloth. 
inspect  all the  parts  and renew 
as necessary. 
3.  Fit the  spring,  washer  and  thermostat  with the 
pin  uppermost. 
4. Fit the  extension  housing using a new ’0’ ring. 
Ensure  that...

e DEFENDER ENGINE n 12 
Fitting rear cover 
9. Fit the  rear  cover  also using  a new  gasket and 
secure  with six bolts tightened  to the  correct 
torque. 
Fitting fuel lift pump 
10.  Check  that the lift pump is serviceable  and refit 
using  a  new gasket,  ensuring  that  the pump 
actuating  lever  locates correctly  onto the 
camshaft 
. 
, I,, ST3003M 
FllTlNG FRONT COVER TIMING  BELT AND GEARS 
1. Clean the front  cover and remove  the 
crankshaft  and camshaft 
oil seals  taking  care 
not...

112) ENGINE e DEFENDER 
Fitting injection  pump 
1. Insert the timing  pin in the  pump  hub and 
body.  Fit the  injection  pump and secure  with 
the  three  nuts and tighten  evenly to the 
correct  torque. 
2. Fit the  pump  rear support  bracket to the front 
side  cover  and secure  to the  pump  with 
two 
bolts and nuts. 
3. Inspect  the pump  drive gear for wear and 
damage,  ensure it 
is thoroughly  clean and dry 
before  fitting 
to the pump.  Retain the gear 
with  three  bolts and...