Land Rover Defender 90 110 Workshop 1984 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...

. 
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...

- -.. . . .. ..,.. , . ... .. , , 
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...

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...

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....

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...

-- /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...

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....

..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...

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...