Land Rover Defender 90 110 Workshop 1984 Rover Manual
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V8 CYLINDER ENGINE (12) -^ TEST AND FIT THERMOSTAT .I .... :: 1. Remove the two bolts securing the thermostat 2. Remove the housing gasket. 3. Withdraw the thermostat. housing to the induction manifold. ST858M ST856M 8. Clean the induction manifold and thermostat 9. Fit the thermostat with the jiggle pin uppermost at 10. Fit the housing using a new gasket, and evenly housing mating faces. 12 oclock. tighten the two bolts. . .. ,: ... .. .. .. . 4. Note the temperature stamped on the thermostat FIT THE DISTRIBUTOR - including electronic distributor at which it should be fully open. 4 ST857M c ni--- &L- &L &,., ,.-,I J. ridcc LIIC: LIIC;IIIIUSL~L diiu Centigrade thermomelcr in a laboratory beaker, or a suitable alternative, half full of water. 6. Heat the water and observe the temperature at which the thermostat opens. 7. If faulty discard the thermostat. 1. Turn the crankshaft to bring number one piston to T.D.C. on the compression stroke (both valvcs closed number one cylinder). 2. Turn distributor drive until rotor arm is approximately 30 anti-clockwise from number one sparking plug lead position on cap. 3. Turn the oil pump and distributor common drive shaft so that the tongue is in the approximate position as illustratcd. continued 119
1121 V8 CYLINDER ENGINE 4. Fit distributor to engine and check that centre line of rotor arm is now in line with number one sparking plug lead in cap. Reposition distributor if nccessary. The vacuum capsule should be at 90” to the camshaft. 5. If distributor does not seat correctly in front cover, oil pump drive is not engaged. Engage by lightly pressing down distributor while turning engine. 6. Fit clamp and bolt leaving both loose at this stage. 7. Rotate distributor anti-clockwise until contact points just start to open. 8. Secure distributor in this position by tightening clamp bolt. 9. Fit the distributor cap and spark plugs and connect the H.T. leads in accordancc with the illustration below. NOTE: The above distributor setting is to enable the engine to be run so that the correct setting given in ‘Engine Tuning data’ can be achieved once the engine is refitted to the vehicle. FIT ROCKER COVERS 1. Remove all traces of old gasket on the covers and cylinder heads. 2. Clean and dry the gasket mounting surface, using Bostik cleaner 6001. 3. Apply Bostik 1775 impact adhesive to the seal face and the gasket, using a brush to ensure an even film. Allow the adhesive to bccome touch-dry, approximately fifteen minutes. NOTE: The gasket fits one way round only and must be fitted accurately first time; any subsequent movement would destroy the bond. 4. Place one end of the gasket into the cover recess with the edge firmly against the recess wall; at the same time hold thc remainder of thc gasket clear; then work around the covcr, pressing the gaskct into place ensuring that the outer edgc firmly abuts the recess wall. 5. Allow the cover to stand for thirty minutes before fitting it to the engine. 6. Secure the rocker covers to the enginc with the four screws. Short screws - in board, long screws -out board. 120
V8 CYLINDER ENGINE FIT ENGINE OIL FILTER .,: 2 .;$., I. . .;:$ :U, 1. Clean oil pump mating face with filter. 2. Smear clean engine oil on the rubber washer of the new filter. 3. Fill the filter with new oil as far as possible, noting the angle at which the filter is to be fitted. 4. Screw on the filter until the sealing ring touches the oil pump cover face, then tighten it a further half turn by hand only. Do not overtighten. - *... ,: I.. I -:..: .,. ... ,., .. .. . ...,,. .. . .... .... ., FIT THE CLUTCH 1. Clean the flywheel and clutch assembly pressure plate. 2. Fit the centre plate and the clutch assembly and loosely secure to thc flywheel with the retaining bolts. 3. Insert centralising tool 18G 79 or a slave primary shaft and finally tighten the clutch assembly retaining bolts in a diagonal sequence, to the correct torque. 4. Smear the centre plate splines with Rocol MV3 or Rocol MTS 1000 grease. I . .. .. :;:. .. :, : . ..., . ., FIT THE FAN PULLEY, VISCOUS COUPLING AND FAN 1. Secure the fan to the viscous coupling with the four bolts and tighten evenly. 2. If removed, fit the pulley to hub assembly adaptor and secure with the four nuts. 3. Screw the viscous coupling onto the adaptor thread by inserting a tommy bar in the hole in the pulley to restrain it while tightening the coupling. 4. Fit the fan and any other drive belts. FIT THE ALTERNATOR 1. Offer up the alternator to the mounting bracket and locate the pivot nuts and bolts noting that the fan guard is attached to the front nut and bolts. 2. Slacken the alternator adjustment bracket and attach alternator bracket. Note that the fan guard is attached to the adjustment bracket bolt. 3. Fit and tension the fan belt as follows: Pivot the alternator away from the engine but in doing so, do not apply any pressure to the slip-ring end bracket. Tighten the pivot nuts and bolts and adjustment bolt. The tension is correct when, with thumb pressure, the belt deflection is approximately 8 mm (A in) for non-air condition engines, 4 mm (& in) for air condition engines, Finally, tighten the fixings and connect the wiring plug to the alternator. hPt..,nP.. CIIWLCIII (IILbIILILVL oitP-..n+n- all --A the crankshaft pu!!ey. continued 3 ST854M 121
V8 CYLINDER ENGINE 3 ST855M FIT EXHAUST MANIFOLD AND AIR RAILS 1. Ensure that the mating surfaces of the cylinder head and exhaust manifold are clean and smooth and coat the faces with ‘Foliac J 166’ or ‘Moly Paul’ anti -seize compound. ‘Foiiac J 166’ is manufactured by Rocol Ltd., Rocol House, Swillington, Leeds, England. ‘Moly Paul’ is manufactured by K.S. Paul Products Ltd., Nobel Road, London N18. 2. Place the manifold in position on the cylinder head and fit the securing bolts, lockplates and plain washers. The plain washers are fitted between the manifold and lockplates. Evenly tighten the manifold bolts to the correct torque figure and bend over the lock tabs. 3. Fit pulse-air rails to cylinder heads. FIT THE CARBURETTERS If removed, fit the carburetters to the induction manifold, using new joint washers in the correct sequence as illustrated according to the engine serial number. See Section 19 for S.U. Carburetters. Illustration A from serial number 1400001A Non- detoxed. 1. Fit the liner. 2. Fit the two joint washers. 3. In between the washers fit the insulator. Illustration B from serial number 15G00001A detoxed. 4. Fit the three joint washers. 5. Fit the saw toothed deflector. 6. Fit the insulator. MISCELLANEOUS AND NON-STANDARD ITEMS Fit any other items of equipment and miscellaneous hoses, pipes, filters, clips and brackets to the positions noted during dismantling. @-:“ ‘K .,/ 122
12 I FAULT DIAGNOSIS SYMPTOM BURNED VALVES NOISY VALVE MECHANISM NOISE FROM HYDRAULIC TAPPETS 1. Rapping noise only when engine is started 2. Intermittent rapping noise 3. Noise on idle and low speed 4. General noise at all speeds - V8 ENGINE ONLY 5. Loud noise at normal operating MAIN BEARING RATTLE temperature only LOW 011. PRESSURE WARNING LIGHT REMAINS ON, ENGINE RUNNING RATTLE IN LUBRICATION SYSTEM ~ ENGINE OVERHEATING ~~ ~ MECHANICAL NOISES Medium low pitch knock Low pitch thud High pitch tap Intermittent thuds Continual tapping Continual slapping POSSIBLE CAUSE ~~ 1. Sticking valves 2. Weak valve springs 3. Excessive deposit on valve seats 4. Distorted valves 5. Excessive mileage between overhauls I. Excessive oil in sump, causing air bubbles in hydraulic tappets - V8 engine 2. Worn or scored parts in valve operating mechanism 3. Valves and seats cut down excessively, raising end of valve stem, 1,27 mm (0.050 in) above normal position 4. Sticking valves 5. Weak valve springs 6. Worn timing chain or chain wheels I. 2. 3. 4. Oil too heavy for prevailing temperature Excessive varnish in tappet Leakage at check ball Excessive leakdown High oil level in sump Leakage at check ball Worn tappet body Worn camshaft 5. Excessive leak-down rate or scored lifter plunger I. Low oil level in sump 2. Low oil pressure 3. Excessive bearing clearance 4. Burnt -out bearings 5. Loose bearing caps 1. Thin or diluted oil 2. Low oil level 3. Choked pump strainer 4. Faulty release valve 5. Excessive bearing clearance 6. Oil pressure switch unserviceable 7. Electrical fault 8. Relief valve plunger sticking 9. Weak relief valve spring 10. Pump rotors excessively worn I I. Excessively wom bearings: main, connecting rod, big end, camshaft. etc 12. Faulty skcw gear asscmbly, 4-cylinder engines 1. Oil pressure rclief valve plunger sticking I. Low coolant level 2. Faulty cooling system 3. Faulty thcrmostat d. Tncorrcct timing 5. Defcctive lubrication system 3ig-end bearing slack or run dain bearing slack or run Worn gudgeon pins aose tly wheel or excessive crankshaft end-float Zxcessive valve clearance .- NOT V8 iston clearance excessive. -more apparent vhen sngine cold may disappear when engine 101 Overhaul cylinder head 1 Drain and refill to correct level on dipstick Replace faulty parts Grind off end of valve stem or replace parts V8 engine only ] Overhaul cylinder head Renew worn parts Drain and refill with correct grade Replace tappet Replace tappet Replace tappet Drain and refill to correct level on dipstick Replace tappet Replace tappet Replacc camshaft Replace tappet ~~ Replenish as ncccssary to high mark on dipstick Worn bearings. Faulty skew, gear asscmbly. 4-cylinder enginc Renew bearings; grind crankshaft - NOT diesel Renew and investigate reason for failure Tighten to correct torque Drain and refill with correct oil and renew filter Replcnish to high mark on dipstick Clean Rectify Rectify Renew Check circuit Remove and ascertain cause Renew Overhaul oil pump Ascertain which bearings and rectify Check skew gear bearing. Chcck plug not leaking or seals in 2.5 diesel engine. See Zngine overhaul Remove and clean Chcck for leaks. Check expansion tank level Check fan and belt, pump, radiator fins ?ot blocked rest and renew, if necessary Check and adjust using electronic equipmcnt Renew filter. Check pump. Clean strainer. :heck oil circulation 124
FAULT DIAGNOSIS POSSIIILE CAUSE 1. Lack of fucl 2. Stop solenoid faulty 3. Wrong starting procedure 4. Air in fucl system 5. Fucl inlct restriction 6. Fuel contamination 7. Low cranking spccd 8. Starting aid ineffective 9. Injcction timing incorrect 10. Timing bclt slipped 1 I. Bxk Icakagc restricted 12. Fucl circuit incorrect I SYMPTOM CHECK Fuel level in tank Audible opcration when switched - Check electrical supply, replace solenoid Starting procedure correct -Throttle c!osed and heater plugs in operation All joints and unions arc tight Filter not chocked and feed pipes clear Diesel fucl being used. not pctrol, free of water. dirt, ice. wax. Battery, startcr, cable connections. Correct engine lubricating oil Correct functioning of heater plugs Punip to engine timing using timing tool Belt condillon and tcnsion. Pump rotor not seized Tank return clear, flow from cam box valve when cranking. Replace pump if blocked Inlet and back leak pipes correct way round. Banjo bolts of correct type for pump injector DIESEL ENGINE MECHANICAL FAULTS MAIN BEARING RATTLE ENGINE OVERHEATING LOW OIL PRESSURE WARNING LIGHT REMAINS ON, ENGINE RUNNING ___ ~ XATTLE IN LUBRICATION SYSIEM JOISY VALVE MECHANISM vlECHANICAL NOISES: ,ow pitch knock ,ow pitch thud ntermittent thuds 4igh pitch tap .ight tapping ;lapping POSSIBLE CAUSE 34. Low oil level in sump 35. Low oil pressure 36. Exccssive bearing clearance 37. Burnt-out bearings 38. Loose bearing caps 39. Low coolant level 40. Faulty cooling system 41. Faulty thermostat 42. Cracked cylinder head 43. Defcctive lubrication system 44. Thin or diluted oil 45. Low oil level 46. Choked pump strainer 47. Faulty release valve 48. Excessive bearing clearancc 49. Oil pressure switch unserviceable 50. Electrical Iault 51. Relicf valvc plunger sticking S2. Weak rclicfvalvc sprin: 53. Pump rotors excessively worn 54. Excessively worn bearings) main, connecting rod. big end, camshaft, ctc 55. Faulty skew gear assembly, 4-cylinder engines 56. Oil pressure relief valve plunger sticking 57. Sticking valves 5X. Weak valve springs 59. Tappet clearance too wide 60. Worn timing chain or chain wheels Big -end bearing slack or run Main bearing slack 01 run Loose flywhecl or excessive crankshaft end-float Worn gudgeon pins Excessive valve clearance Excessive piston clearance - more apparent whcn cold DIESEL ENGINE CURE Replenish as necessary to high mark on dipstick Worn bearings. Faulty skew, gear assembly. 4 -cylinder engine Renew hearings; and or crankshaft Renew and investigate rcason for failure Tighten to correct torque Check for Icaks, check expansion tank level Check fan and belt, pump, radiator fins not blocked Test and renew, if necessary Renew Renew Filter, Check pump. Clean strainer. Check oil circulation Drain and refill with correct oil and renew filter Replenish to high mark on dipstick Clean Rectify Rectify Renew Check circuit Remove and ascertain cause Renew Overhaul oil pump Ascertain which bearings and rectify Check skew gear hcaring. Check plug not leaking or seals in 2.5 diesel engine. See engine overhaul Remove and clean ~~ ~ ~ Ovcrhaul cyliiidcr head I FAULT DIAGNOSIS DPA AND DIS PUMPS - 2.25 and 2.5 litre diesel engines SYMPTOM DIFFICULT STARTING 13. Engine condition 14. Fuel atomisation 15. Fucl tank blockage 16. HP pipe lcakirig 17. Injection pump defective intcrnally scating Cylinder compression, valve timing and clearances. Air filter not choked Injectors; correct type, opening pressure. spray condition Tank vent and outlet unrestricted HP pipe joint tightncss If all other relevant checks salisfiictory, replace pump 125 continued
1211 FAULT DIAGNOSIS SYMPTOM IRREGULAR IDLE INSUFFICIENT MAXIMUM SPEED ERRATIC RUNNING OR SURGING EXCESSIVE SMOKE EXCESSIVE NOISE LACK OF POWF,R EXCESSIVE FUEL CONSUMPTlON 3TALLING ~~ 3LOW ENGINE DIE DOWN ZNGINE WILL NOTSHUTOFF ~ SXCESSNE KNOCKING (DETONATION) , POSSIBLE CAUSE Any of the following items: 4,5,6,9,11, 12,13, 14, 16, 17. Plus: 18. HP pipe restriction 19. Idlingspeed incorrect 20. Anti-stall setting incorrect 21. Manual idle advance faulty 22. Accelerator linkage faulty 23. Engine vibration 24. Injection pump loose Any of items 4,5, 17,22. Plus the following: 25. Max. speed setting incorrect 26. Vehicle brakes binding Any of items I, 2,4,5,9,12,13, 14,155, 16, 17, 18.27.23.24. Anv of items 6.9. 13. 14 and 17 Any of items 9,14,24,23. Plus the following: 27. Cambox pressure IOW Anyofitcms4,5,6,9, 11, 12, 13, 14.IS.16, 18,22,24,25,26. Plus the following: 28. Exhaust system defective 29. L.P. leakage ~~ Anyofitems9,13, 14, 16.17, 19,26. Any of the following items; 4,5, 6,9, 11, 13, 17,19,20.21. Any of the following items; 17,20,22 Either of the following two items: 2 and 17. Plus: 30. Stop solenoid valve leaking Items 8,9, 13 or any of the following: 31, Injectors sticking 32. Lack coolant in radiator 33. Lack of oil in engine CHECK HP pipes not kinked or bore reduced at nipples Idling speed given in ‘engine tuning data’ Recovery from acceleration, engine warm (Reset idling and anti-stall) Cable and lever operation satisfactory Lever tight on pump reaches stop screws, linkage wear, adjustment Engine mountings tight and effective Tightness of pump drive mounting bolts and rear support bracket nut and bolt ~ Seal intact. Engine maximum speed in ‘Engine tuning data’ - adjust Brake freedom, all wheels in turn and transmission brake Pressure with gauge at control cover vent screw. Replace pump if pressure too low System is unrestricted Feed and return pipes, filter and tank for leak Engine stops when supply lead removed. Replace solenoid if faulty Injectors individually - see ‘Injector overhaul’ Cooling system and expansion tank level. Radiator fins not blocked Oil level on dipstick 126
PETROL FUEL SYSTEM 119 c OVERHAUL FUEL LIFT PUMP DISMANTLE 5. Turn, whilst pressing down the metal part of the diaphragm through 90 in either direction and withdraw the diaphragm and spring. 6. Unstake the oil seal housing and lever-out the oil scal and retainer. ~ x2 1. Remove the sediment bowl, where fitted, and collect the filter gauze and sealing washer. 2. Mark the upper and lower halves of pump casing to ensure correct alignment on reassembly. 3. Remove top cover fixing screws, and while pressing diaphragm tab against pump body, lift top cover clear. 3 ST1096M 7. Using a small chisel, rcmovc thc staking from the rocker arm retainers. 8. Withdraw the retainers. 9. Withdraw the rocker arm. 10. Withdraw the rocker arm pin and washers. 11. Dctach the operating link. 12. Withdraw thc rocker arm spring. 4. If necessary remove the valves by cutting away the retaining stakes with a scraper. Warm the top cover, note the position of the valves and withdraw them from the cover. . ..* . ... , ,. . . ,. .... , . .2. .- ., .. .I . 13. It is unlikely that the hand priming mechanism will ever require replacement, but it can be removed by filing the hexagon each side of the operating lever and springing the hand lever clear, withdraw the cork washers and hand rocker. 1
PETROL FUEL SYSTEM 14. 15. 16. 17. 18. 19. 20. ~~ ~~ Inspect 29. Fit the filter gauze and sealing ring on pumps with a sediment bowl and fit the bowl and secure with the retaining clip. Ensure that the bowl and seal are located squarely. Do not overtighten securing nut to prevent cracking the bowl. Clean all parts in paraffin (Kerosene) and examine for wear and renew as necessary including all gaskets . Sediment bowl filter disc must be free of damage and fit tightly around inlet neck of upper casing. Renew diaphragm assembly if any sign of hardening, cracking or porosity is present. Only very slight wear should be tolerated at the rocker arm contact face, pivot pin, operating link and diaphragm pull rod slots. Springs should be renewed ensuring that the correct type are used. Test valves for air tightness, by suction. Check upper and lower casing flanges for distortion, using a straight edge. Test fuel pump 30. Immerse pump in a bath of paraffin and operate rocker arm several times to flush. 31. Hold the pump clear of the bath and continue to operate the rocker arm until the pump is empty, then place a finger over the inlet port and operate rocker arm several times. A distinct suction should be heard when the finger is removed from the inlet port, denoting that a reasonable degree of suction has been developed. 32. Place a finger over the outlet port and again Assemble 21. Fit the rocker arm spring. 22. Fit the operating link. 23. Fit the rocker arm pin and washers. 24. Fit the rocker arm assembly to the pump body and secure with the retainers and stake. 25. Fit the oil seal and retainer and secure by staking. operate the rocker arm. Air pressure should be felt for two to three seconds after rocker movement has &:>. ceased. Build up the air pressure in the pump c-. again, and with the finger held firmly over the outlet, submcrge the pump completely in the paraffin bath, then observe thc joint face edges for signs of air leakage. 26. To refit the diaphragm assembly, hold the pump body with the diaphragm rcturn spring in position, and the rocker arm held outwards. Position the diaphragm over the spring with the flattened end of the pull rod in line with the slot in the opcrating link. Push the diaphragm inwards and turn to lock. 27. Fit the inlet and outlet valves and secure by staking. 28. Place top cover assembly in position, aligning the marks made before dismantling. Fit securing screws, but do not tighten at this stage; using hand priming lever, fully depress diaphragm and fully tighten securing screws. The diaphragm 01 r edges should be approximately flush 1. the outer edge of the pump joint faces when 2 OVERHAUL ELECTRICAL FUEL PUMP NOTE: The electrical components of the pump are sealed and cannot be repaired. DISMANTLE 1. Remove pump from the vehicle, and clean outside of pump before dismantling. 2. Release the end -cover from the bayonet fixing. 3. Remove the following items: --. p : _ _- ._ a) filter and seal b) magnet c) gasket Pump piston assembly 4. Carefully prise out the retaining clip. 5. The following parts will then bc released: a) plain washer b) rubber seal c) one -way valve 6. Withdraw the piston return spring with the piston. If the piston remains in the pump tube, hold the pump body vertically (in the fitted position) and tap the closed end until the piston is released from its magnetic hold and drops out. NOTE: The piston is fitted with a one-way valve which should not be disturbed. 4 . 3 0 -J con t I n ued