Land Rover Defender 90 110 Workshop 1984 Rover Manual
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DEFENDER ENGINE CYLINDER HEAD REMOVE. 12 .. ._... . I.. .-.I .. 39
121 ENGINE a DEFENDER Rocker cover remove. 4. Having removed the rocker shaft, lift-out the push rods and insert them through holes in a piece of card marked from 1 to 8 to ensure assembly to their original locations. 5. Remove the cap from each valve stem. 1. Release the crankcase ventilation hose connections, evenly slacken and remove the three bolts then lift-off the rocker cover. See fitting rocker cover See fitting rocker shaft ST2948M Rocker shaft remove. 2. Evenly release the five rocker shaft retaining bolts but do not remove the bolts from the shaft, especialy the two end ones, to prevent the assembly from falling apart when removed from the cylinder head. ST294CM 40
. .I ., .,.. .. e DEFENDER ENGINE n 12 Removing cylinder head 8. Evenly slacken and remove the eighteen bolts retaining the cylinder head and lift the cylinder head from the cylinder block and remove the gasket. See cylinder head overhaul or see fitting cylinder head ST2951 M Note:- If..necessary, at this stage the cam followers may be removed for inspection. See Cam follower removal FRONT COVER OIL SEALS/TIMINC BE LT/CAM S HA fi See radiator removehefit Water pump remove. 1. If necessary remove the viscous coupling complete, with the fan, from the water pump spindle, using a cranked open-ended spanner, noting that it has a left-handed thread. 2. Remove the four screws, to release the pulley from the water pump hub. 3. If necessary release the two Jubilee clips and remove the by -pass hose. 4. Evenly release and remove the six bolts and one nut to remove the water pump from the front cover plate. See water pump inspection and fitting. ST2952M Front cover plate or seal remove Front pulley and damper. 5. Release the four bolts and remove the crankshaft pulley from the damper. 1. 41
12 6. To remove the crankshaft damper retaining bolt use pecial service tool FR I01 tor LST 127 o restrain the damper and a 30 socket to remove the special bolt. ENGINE a DEFENDER Removing front cover plate. 9. Unscrew the 11 bolts and one nut to release the cover plate. See fitting front cover plate ST3125M 7. Fit the pressure button 18G1464/5 to the end of the crankshaft and using service tool LST 136, extract the damper as illustrated. See fitting front damper and pulley STZ 91 8M 75 Removing timing belt 1. Use the xstraining tool LST 127 to turn the crankshaft in a clockwise direction to TDC so that the valves of number one cylinder are closed with number four cylinder valves on the rock and the crankshaft key aligned with the arrow cast into the front cover as illustrated. If the crankshaft is turned inadvertently beyond TDC do not turn it back but continue on round until the above conditions are achieved. e. Q, .. J/ A3
DEFENDER ENGINE 11 2 1 2. Now screw the body of the timing pin tool LST 128 into the flywheel housing and check that the pin can be inserted in to the appropriate slot in the flywheel periphery. Note that there are two slots in the flywheel one being wider than the othe. The narrowest slot determines TDC for this engine and it is therefore important that the correct slot is used. 4. To lock the pump, Slacken the locking screw anticlockwise and remove the inhibiting plate. Turn the screw clockwise to lock the pump shaft. Remove the timing pin from the flywheel housing. I .:!. c. *. a* 0 ST2954M 3. Remove the three screws to release the injection pump access cover from the front cover plate and insert the locking pin LST129/2 through the U shaped cut-out in the pump hub and into the hole in the pump body. This will confirm that the injection pump is correctly timed in relation to the valves and crankshaft and can be locked ready for removing. Leave the pin in position in the pump. CAUTION: It is important to ensure that once the injection pump has been locked no attempt must be made to rotate it. Therefore take care not to allow the crankshaft to be turned until the pump has been removed. NOTE:- If renewing the timing belt,oil seals or gears (with the cylinder head fitted) and there is any possibility that the crankshaft will need to be rotated after removal of the timing belt, it would be advisable to remove the rocker shaft. This will prevent the pistons contacting the valves as the crankshaft is turned. If necessary, See rocker shaft removal. .. ...I .: .. .. - . .,... 43
E[ ENGINE e DEFENDER 5. To verify any timing error, check that the timing marks inside the front cover line-up with the gear wheels. 6. If necessary temporarily fit the damper and restrain the crankshaft with service tool FR 101 while the three screws securing the pump timing gear to the pump hub and the camshaft gear wheel retaining bolt is being slackened. 7. Remove the single bolt, special washer and remove the tensioner. 8. If the original belt is to be re-fitted, mark its direction of rotation with soft chalk before removing it. ST2959M/ 1 NOTE:- A used drive belt develops a wear pattern relative to the driving loads and its direction of rotation. If the belt is to be re -used it must be refitted so that it continues to operate in the original direction. S ee fitting Timing gears and belt. Removing timing belt gears 9. If the crankshaft gear wheel cannot be removed by hand, use special service tool 18C 1462-2 and pressure button 18G 1464-5. Assemble the tool and withdraw the gear wheel as illustrated. 18G 1464-2 \\ ST2960M 10. Remove the camshaft gear wheel retaining bolt assembly to enable the gear to be removed. Use special service tool 18G 1462-2 and button 18G 1464-6. Assemble as shown and withdraw the the gear. ST2960M 18G 1464-2 \\?--. The camshaft and crankshaft oil seals may be renewed at this stage with the engine in the vehicle without removing the front cover. See fitting front cover seals 44
DEFENDER ENGINE n 12 Removing injection pump Removing front cover I * .I 11. Release the injection pump from the rear 13. To remove the front cover,release the three support bracket. bolts securing it to the cylinder block front face and the three bolts that pass up through the sump and ladder frame into lower face of the cover. See fitting front cover timing belt and gears 12. Remove the three nuts securing the pump flange to the front cover and withdraw the pump and gasket complete with hub and timing pin. Removing vacuum pump 14. Mark the position of the brake servo vacuum pump with relation to the cylinder block. Using a 6mm Allen key remove the three screws and lift -out the pump. See fitting vacuum pump 45
112) ENGINE DEFENDER Removing skew gear During normal operation of the engine the camshaft and skew gear teeth develop a mated a wear pattern. It is therefore important that if the skew gear is to be re-used it should be fitted so that the teeth on the gear and camshaft engage in the original running position. 15. To ensure orininal re-engagement of the gears turn the camshaft so that the camshaft key is aligned with the oil groove in the thrust plate and mark the position of the skew gear in relation to the one of the three bolt holes for securing the vacuum pump. Also mark the skew gear housing flange to the same bolt hole. 16. To remove the skew gear assembly, tap the flange round so that the edge overlaps the cylinder block, then tap the flange upwards to enable the skew gear assembly to be lifted out. If necessary the oil pump drive shaft may be removed at this stage Removing skew gear bush 17. Unscrew the oil filter cartridge, anti-clockwise, using a strap wrench. Dispose of the oil safely, 18. Release the two bolts and remove the oil filter adaptor and gasket from the engine. 19. Using a 6 mm alien key remove the retaining screw and bush. 46
ENGINE a DEFENDER Removing fuel pump and side cover 12 20. Use a 6 mm allen key to release the fuel lift pump to gain access to the side cover retaining bolts. 21. Release the six bolts and remove the cover plate. See fitting lift pump. Remove front side cover plate 22. Release the six bolts and remove the front side cover plate complete with the crankcase ventilation pipe. I 111 ST3003 M Remove camfollowers See cylinder head remove CAUTION: The camfollers are solid rollers held in position against the cam by a slide inside a fixed guide. If the guide is removed before the roller, it is possible that the roller can fall behind the camshaft and become jammed. Furthermore the roller could slip past the cam and fall into the crankcase. It is therefore important to adopt the following procedure for removal. 1. Slacken back the guide locating screw so that the end is below the bore of the guide. x n i 2. Using a length of thin wire with a hooked end 3. With the same piece of wire remove the roller 4. Remove the guide locating screw and lift-out 6. As each assembly is removed number it, from lift-out the slide. the guide. one to eight, for refitting to its original location. See fitting cam followers 47
12 Removing the camshaft. ENGINE e DEFENDER 1. Release the two screws and remove the camshaft thrust plate. 2. Carefully Withdraw the camshaft taking care not to allow the end of the shaft to drop on to the bearings as it is removed. See fitting camshaft ST2552M Removing Clutch and Flywheel housing See 1. 2. See engine unit removal Mark the relationship of the cover to the flywheel to ensure original balance is maintained. Evenly slacken and remove the six retaining bolts and washers and remove the assembly complete with the friction plate. fitting clutch Removing flywheel 1. In the intrests of safety, fit two long 8mm bolts into the clutch bolt holes, diametrically opposite, to use as handles for lifting the flywheel off the crankshaft. 2. temporarily fit the the crankshaft damper and use special service tool FR 101 to restrain the crankshaft while slackening the flywheel eight retaining bolts. Remove the bolts and reinforcing plate and lift -off the flywheel. See overhaul and fitting flywheel Removing flywheel housing. 1. Remove the eight internal and two external and five ladder frame securing bolts, then ease the flywheel housing from the two locating dowels and crankshaft. See fitting rear main oil seal to flywheel housing. ST2972M i A8