Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							4.0 V8
3
REPAIR ROCKER SHAFT RENEW
Service repair no - 12.29.29
1.Remove RH or LH rocker covers.
See ENGINE
4.0 V8, Repair, rocker cover - right hand
or.
See ENGINE 4.0 V8, Repair, rocker cover -
left hand
2.Loosen four rocker shaft fixings.
3.Remove rocker shaft assembly.
NOTE: Each rocker shaft is notched at
ONE end. Notch must be uppermost and
towards front of engine on right hand side,
towards rear on left hand side.
4.Clean rocker pedestal locations on cylinder
head.
5.Fit rocker shaft assembly, locating push rods to
rockers.
6.Tighten rocker shaft fixings to
38 Nm, 28 lbf ft.
7.Fit rocker covers.
8.Fit RH or LH rocker covers.
See ENGINE 4.0
V8, Repair, rocker cover - right hand
orSee
ENGINE 4.0 V8, Repair, rocker cover - left
hand
OIL SUMP
Service repair no - 12.60.44
Remove
1.Drain engine oil
See SECTION 10,
Maintenance, Under vehicle maintenance
2.Fit and tighten drain plug to40 Nm, 30 lbf ft.
3.Remove bolt securing dipstick tube to rocker
cover.
4.Working from the centre outwards, progressively
loosen and remove 3 screws and 14 bolts
securing sump. Remove sump.
5.Remove all traces of sealant from mating
surfaces of sump, cylinder block and timing
cover, using a suitable solvent or plastic scraper.
6.Degrease mating surfaces of sump, cylinder
block and front cover.
Refit
7.Apply RTV Hylosil White sealant to mating
surface of sump.
8.Position sump, tighten bolts finger tight.
9.Tighten nuts and bolts progressively in
sequence shown to
23 Nm, 17 lbf ft.
10.Fit bolt securing dipstick tube to rocker cover. 
						

							12ENGINE
4
REPAIR ROCKER COVER GASKET - LEFT HAND
Service repair no - 12.29.40
Remove
1.Disconnect battery negative lead.
2.Remove plenum chamber.
See FUEL SYSTEM,
Repair, plenum chamber
3.Remove screw securing dipstick tube to rocker
cover.
4.Release 4 spark plug leads from guide clips and
disconnect leads from spark plugs.
5.Remove 4 bolts securing rocker cover to cylinder
head.
6.Remove rocker cover.
7.Remove and discard rocker cover gasket.
Refit
8.Clean mating faces of rocker cover and cylinder
head using Bostick 6001 or equivalent. Allow to
dry.
9.Apply a thin coating of impact adhesive (Bostick
1775 or equivalent) to mating faces of rocker
cover and gasket . Use a brush to ensure an
even film. Allow adhesive to become touch dry.
CAUTION: Gasket fits one way round only.
It must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
10.Place one end of gasket into cover recess with
edge firmly against recess wall, holding
remainder of gasket clear. Work around cover
pressing gasket into place ensuring edge firmly
contacts recess wall.
CAUTION: Allow cover to stand for 30
minutes before fitting.
11.Fit rocker cover to cylinder head, ensuring short
bolts are fitted inboard, tighten bolts to
9 Nm, 7
lbf ft.
12.Connect plug leads and secure to guide clips.
13.Align dipstick tube to rocker cover and tighten
screw.
14.Fit plenum chamber.
See FUEL SYSTEM,
Repair, plenum chamber
15.Reconnect battery negative lead. 
						

							4.0 V8
5
REPAIR ROCKER COVER GASKET - RIGHT HAND
Service repair no - 12.29.41
Remove
1.Disconnect battery negative lead.
2.Disconnect breather hose from plenum chamber
and remove hose from rocker cover.
3.Position container to collect coolant spillage.
4.Remove bolt securing coolant pipe brackets
together and nut securing bracket to manifold.
5.Loosen clip and disconnect coolant return hose
from manifold.
6.Depressurise fuel system.
See FUEL SYSTEM,
Adjustment, fuel system depressurise
7.Position cloth to absorb fuel spillage.
8.Disconnect fuel feed hose union.
CAUTION: Plug the connections.
9.Loosen clip and disconnect fuel return hose.
CAUTION: Plug the connections.
10.Remove 2 bolts securing engine harness
bracket to manifold.
11.Release 4 spark plug leads from guide clips and
disconnect leads from spark plugs.
12.Remove 4 bolts securing rocker cover to cylinder
head.
13.Remove rocker cover.
14.Remove and discard rocker cover gasket. 
						

							12ENGINE
6
REPAIR Refit
15.Clean mating faces of rocker cover and cylinder
head using Bostick 6001 or equivalent. Allow to
dry.
16.Apply a thin coating of impact adhesive (Bostick
1775 or equivalent) to mating faces of rocker
cover and gasket. Use a brush to ensure an
even film. Allow adhesive to become touch dry.
NOTE: Gasket only fits one way round. It
must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
17.Place one end of gasket into cover recess with
edge firmly against recess wall, holding
remainder of gasket clear. Work around cover
pressing gasket into place ensuring edge firmly
contacts recess wall.
CAUTION: Allow cover to stand for 30
minutes before fitting.
18.Fit rocker cover to cylinder head ensuring short
bolts are fitted inboard, tighten bolts to
9 Nm.
19.Connect plug leads and secure to guide clips.
20.Position harness bracket to inlet manifold and
tighten bolts.
21.Connect fuel feed and return hoses.
22.Connect coolant hose to inlet manifold and
tighten clip.
23.Secure coolant pipe brackets
24.Fit breather hose.
25.Refill cooling system.
26.Reconnect battery negative lead.ENGINE ASSEMBLY
Service repair no - 12.41.01
Remove
1.Position vehicle on 4-post ramp [hoist].
2.Drain engine oil.
See SECTION 10,
Maintenance, under vehicle maintenance
3.Remove bonnet.See CHASSIS AND BODY,
Repair, bonnet
4.Remove radiator.See COOLING SYSTEM,
Repair, radiator
5.Loosen 3 PAS pump pulley bolts.
6.Using a 15 mm ring spanner, release auxillary
drive belt tension and release belt from
alternator pulley.
7.Remove drive belt.
8.Disconnect A/C compressor multiplug.
9.Remove 4 bolts securing compressor to
mounting bracket.
10.Collect compressor heat shield.
11.Tie compressor aside with string. 
						

							4.0 V8
7
REPAIR
12.Loosen clip screws securing heater return and
feed hoses to pipes and disconnect.
13.Position cloth to collect fuel spillage.
14.Loosen fuel feed hose to rail union, allow fuel to
spill and disconnect union.
15.Loosen clip screw securing fuel return hose to
fuel rail and disconnect hose.
CAUTION: Plug the connections.
16.Remove cloth.
17.Remove plenum.
See FUEL SYSTEM, Repair,
plenum chamber
18.Remove bolt securing 2 breather pipe P clip to
rear of RH cylinder head.
19.Loosen clip screw securing intake hose to MAF
sensor housing and remove hose.
20.Remove nut securing kick-down cable clip to
rear of LH cylinder head.
21.Remove 3 cable ties securing purge pipe to
coolant hose and harness, position pipe aside.
22.Disconnect brake servo pipe from inlet manifold
and position aside. 
						

							12ENGINE
8
REPAIR
23.Remove 3 bolts securing PAS pulley and
remove pulley.
24.Release knock sensor harness clip from PAS
return hose.
25.Remove 3 bolts securing PAS pump and
position aside.
26.Collect engine lifting bracket.
27.Position engine lifting bracket and secure with 3
(3/8 UNC x 1 MAX) bolts.
28.Raise vehicle on ramp.
29.Remove 6 nuts securing exhaust front pipe to
manifolds.
30.Remove front bolt securing RH catalyst heat
shield to chassis.
31.Remove bolt securing starter motor heat shield
to RH engine mounting bracket.
32.Release starter motor heat shield clip from
solenoid.
33.Release exhaust front pipe from manifold studs
and remove and discard gaskets.
34.Remove starter motor heat shield. 
						

							4.0 V8
9
REPAIR
35.Remove starter motor solenoid terminal nut.
36.Release 2 battery leads from terminal.
37.Disconnect solenoid Lucar.
38.Disconnect multiplug from RH Knock sensor.
39.Remove 2 cable ties securing engine harness to
RH engine mounting bracket.
40.Disconnect multiplug from LH knock sensor.
41.Remove cable tie securing engine harness to LH
engine mounting bracket.
42.Remove screw securing crankshaft position
sensor heat shield and remove heat shield.
43.Disconnect multiplug from crankshaft position
sensor.
44.Remove bolt securing gearbox cooler pipes to
engine sump bracket.
45.Remove 7 bolts securing bell housing closing
plate and remove plate.
46.Remove 3 bolts securing bell housing access
plate and remove plate. 
						

							12ENGINE
10
REPAIR
47.Mark relationship between converter and drive
plate.
48.Rotate crankshaft to access drive plate to
converter retaining bolts.
49.Remove 4 bolts securing drive plate to
converter.
50.Fit suitable piece of wood through bell housing
access hole to retain converter.
51.Remove 2 bell housing lower retaining bolts.
52.Remove nut securing RH engine mounting to
chassis bracket.
53.Remove nut securing LH engine mounting to
chassis bracket.
54.Lower vehicle.
55.Loosen clip screw and disconnect radiator
bottom hose from heater pipe.
56.Disconnect multiplug from camshaft position
sensor.
57.Disconnect Lucar from oil pressure switch.
58.Release harness from front of engine. 
						

							4.0 V8
11
REPAIR
59.Remove 2 alternator terminal nuts and
disconnect Lucar.
60.Remove screw securing heater pipe to bracket.
61.Loosen clip screw and remove heater hose/pipe
assembly from inlet manifold.
62.Remove 2 screws securing engine harness to
RH side of inlet manifold.
63.Disconnect 4 RH injector multiplugs.
64.Disconnect RH rocker cover breather pipe from
ram housing.
65.Release RH bank HT leads from clips and
disconnect from spark plugs.
66.Remove 2 screws securing engine harness to
LH side of inlet manifold.
67.Disconnect multiplug from ECT sensor.
68.Disconnect multiplug from fuel temperature
sensor.
69.Disconnect temperature sensor thermistor.
70.Disconnect 4 LH injector multiplugs.
71.Release ignition coil multiplug from mounting
bracket and disconnect multiplug.
72.Position engine harness aside. 
						

							12ENGINE
12
REPAIR
73.Fit engine lifting toolLRT-12-514to hoist.
74.Lower hoist and connect lifting chains to engine
brackets.
75.Raise hoist until lifting chains become taught and
use a jact to support gearbox.
76.Remove 6 bell housing to engine bolts.
77.With assistance, raise engine on hoist from
engine compartment.
CAUTION: During the engine removal
procedure ensure that the engine does not
damage any surrounding components.
78.Move engine clear of vehicle and lower onto
work bench.
79.Disconnect lifting chains from engine.
80.Raise hoist and position aside.
Refit
81.Clean engine and gearbox mating faces.
82.Clean dowel and dowel holes.
83.Position hoist above engine.
84.Connect lifting chains to engine.
85.Raise engine from work bench and position
above engine compartment.86.Position jack beneath gearbox fluid pan and
raise transmission to ease alignment of bell
housing to engine.
CAUTION: Use a block of wood or hard
rubber pad to protect fluid pan.
87.With assistance, lower engine into engine
compartment.
CAUTION: During the engine fitment
procedure ensure that the engine does not
damage any surrounding components.
88.With assistance, align engine to bell housing
dowels.
89.Fit bolts securing bell housing to engine and
tighten to
46 Nm, 34 lbf ft.
NOTE: Align harness brackets to 2
uppermost bell housing retaining bolts.
90.Remove jack supporting gearbox fluid pan.
91.Lower engine hoist ensuring mountings are
aligned with chassis brackets.
92.Disconnect lifting chains from engine eyes.
93.Remove lifting toolLRT-12-514from hoist.
94.Remove hoist from above vehicle.
95.Position engine harness around engine.
96.Connect ignition coil multiplug and secure to
bracket.
97.Connect LH injector multiplugs.
98.Connect gauge temperature thermistor.
99.Connect multiplug to fuel temperature sensor.
100.Connect multiplug to ECT sensor.
101.Connect RH bank HT leads to spark plugs and
secure to guides.
102.Connect RH rocker cover breather pipe to ram
housing.
103.Connect RH injector multiplugs.
104.Align engine harness to RH side of inlet manifold
and secure with screws.
105.Fit heater hose/pipe assembly to inlet manifold
and secure with clip.
106.Align heater pipe to bracket and secure with
screw.
107.Position alternator terminal leads and secure.
108.Route harness down front of engine.
109.Connect Lucar to oil pressure switch.
110.Connect multiplug to camshaft position sensor.
111.Connect radiator bottom hose to heater pipe and
secure with clip.
112.Raise vehicle.