Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							4.0 V8
13
REPAIR 113.Fit nut securing LH engine mounting rubber to
chassis mounting and tighten to
30 Nm, 22 lbf
ft.
114.Fit nut securing RH engine mounting rubber to
chassis mounting and tighten to
30 Nm, 22 lbf
ft.
115.Fit bell housing to engine bolts and tighten to46
Nm, 34 lbf ft
.
116.Remove piece of wood from bell housing access
hole.
117.Align converter to drive plate.
118.Fit bolts securing converter to drive plate and
tighten to
45 Nm, 33 lbf ft.
NOTE: Rotate crankshaft during the above
procedure.
119.Fit bell housing access plate and secure with
bolts tightened to
9 Nm, 7 lbf ft.
120.Clean bell housing cover plate and mating face.
121.Fit plate and secure with bolts tightened to
9
Nm, 7 lbf ft.
122.Connect multiplug to crankshaft position sensor.
123.Fit crankshaft position sensor heat shield and
secure with screw.
124.Position engine harness to LH engine mounting
bracket and secure with cable tie.
125.Connect multiplug to LH knock sensor.
126.Position engine harness to RH engine mounting
bracket and secure with cable ties.
127.Connect multiplug to RH knock sensor.
128.Connect Lucar to starter motor solenoid.
129.Position battery leads to starter motor solenoid
terminal and secure with nut.
130.Position starter motor heat shield.
131.Clean exhaust manifold to front pipe mating
faces.
132.Fit NEW front pipe to manifold gaskets.
133.Connect front pipe to manifold studs and secure
with nuts.
134.Secure starter motor heat shield clip to solenoid.
135.Align starter motor heat shield to RH engine
mounting bracket and secure with bolt.
136.Align RH catalyst heat shield to chassis and
secure with bolt.
137.Lower vehicle.138.Remove 3 bolts securing engine front lifting
bracket, retain bracket but discard bolts.
139.Position engine lifting bracket to PAS pump,
align to cylinder head and secure with bolts
tightened to
35 Nm, 25 lbf ft.
140.Secure knock sensor harness clip to PAS return
hose.
141.Fit PAS pulley to pump, fit bolts but do not
tighten.
142.Position brake servo pipe and connect to inlet
manifold.
143.Position purge pipe and secure to coolant hose
and harness with cable ties.
144.Fit intake hose to MAF sensor housing and
secure with clip.
145.Position breather pipe P clip to RH cylinder
head and secure with bolt.
146.Fit plenum.
See FUEL SYSTEM, Repair,
plenum chamber; Refit
147.Remove plugs from fuel return and feed hose
connections.
148.Clean fuel feed pipe connections.
149.Connect feed hose to fuel rail and tighten union.
150.Connect fuel return hose to fuel rail and secure
with clip.
151.Connect heater feed and return hoses to pipes
and secure with clips.
152.Release A/C compressor and position to
mounting bracket.
153.Position heat shield to compressor fixing, fit bolts
and tighten to
25 Nm, 18 lbf ft.
154.Connect compressor multiplug.
155.Clean drive belt and pulley grooves.
156.Using a 15 mm spanner, rotate tensioner
clockwise, fit belt to pulleys and release
tensioner.
157.Tighten PAS pump pulley bolts to
10 Nm, 7 lbf
ft.
158.Fit radiator.See COOLING SYSTEM, Repair,
radiator
159.Fit bonnet.See CHASSIS AND BODY, Repair,
bonnet
160.Refill engine oil.See SECTION 10,
Maintenance, under vehicle maintenance
161.Adjust kick-down cable.See AUTOMATIC
GEARBOX, Adjustment, kickdown cable
adjustment 
						

							4.0 V8
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Engine V8i Nm lbf ft
Crankshaft pully bolt 270......................................................... 200
Camshaft gear bolt 58........................................................... 43
Timing cover / coolant pump bolts*** 22............................... 16
Rocker cover to cylinder head 9.......................................... 7
Rocker shaft bracket to cylinder head 38.............................. 28
Spark plug 15........................................................................ 11
Cylinder head bolts:*
Stage 1: 20................................................................... 15
Stage 2: then 90° ................................................................... then 90°
Stage 3: further 90° ................................................................... further 90°
Generator / steering pump bracket to cylinder head 30........ 22
Lifting bracket to cylinder heads 40....................................... 30
Power steering hose unions:
14 mm 15..................................................................... 11
16 mm 20..................................................................... 15
Power steering pump heat shield 25..................................... 18
Drive belt tensioner 50.......................................................... 39
Drive plate to converter 40.................................................... 30
Drive plate to crankshaft 45.................................................. 33
Drive plate hub aligner to crankshaft socket head screws 85 65
Bell housing bolts 40............................................................. 30
Access plate 9..................................................................... 7
Bell housing cover plate 9................................................... 7
Main bearing cap rear bolts:
Stage 1: 13................................................................... 10
Stage 2: 72................................................................... 53
Oil sump drain plug 40.......................................................... 30
Oil sump to cylinder block 23................................................ 17
Starter motor bolts 45............................................................ 33
Starter motor shield 9.......................................................... 7
Oil cooler pipe unions to transmission 30............................. 22
Tie bar to transmission 45..................................................... 33
Gearbox breather pipe bracket 9........................................ 7
Engine harness bracket 9................................................... 7
Engine mountings to engine and chassis 55......................... 40
Engine mounting rubbers to brackets 30.............................. 22
Compressor heat shield 25................................................... 18
* Lightly oil threads prior to assembly
** Apply Loctite 222 to threads before assembly
*** Apply Loctite 577 to threads before assembly 
						

							12ENGINE
2
SPECIFICATIONS, TORQUE
NOTE: The following torque values are for screws and bolts not specified in the previous table.
METRIC Nm lbf ft
M5 6........................................................................... 5
M6 9........................................................................... 7
M8 25........................................................................... 18
M10 45......................................................................... 33
M12 90......................................................................... 65
M14 105......................................................................... 75
M16 180......................................................................... 130
UNC / UNF
1/4 9........................................................................... 7
5/16 25......................................................................... 18
3/8 40........................................................................... 30
7/16 80......................................................................... 60
1/2 90........................................................................... 65
5/8 135........................................................................... 100 
						

							EMISSION CONTROL
1
DESCRIPTION AND OPERATION EMISSION CONTROL
Three systems are used to control the vehicle
atmospheric emissions, these are:
- Engine crankcase fume emissions.
- Fuel tank Evaporative emissions
- Engine exhaust gas emissions.
Crankcase ventilation system
The crankcase ventilation system, which is an integral
part of the air supply to the engine combustion
chambers, is often overlooked when diagnosing
problems associated with engine performance. A
blocked ventilation pipe or excessive air leak into the
inlet system through a damaged pipe or leaking
gasket can effect the mixture, performance and
economy of the engine.The purpose of the crankcase ventilation system is to
ensure that any noxious gas generated in the engine
crankcase is rendered harmless by burning in the
combustion chambers as follows:
Oil laden noxious gas in the engine crankcase is
drawn through an oil separator located in the RH
cylinder head rocker cover, where the oil is separated
and returned to the sump. The gas flows through a
restrictor and via a hose into the inlet plenum chamber
where it is drawn into the combustion chambers and
burned. The volume of fresh air which is drawn from
the atmospheric side of the throttle butterfly, via a
hose into the LH rocker cover to mix with the gas,
depends on the position of the throttle and the engine
speed.
As the throttle opening increases, manifold depression
increases, and at a given point, the crankcase gases
are drawn into the throttle housing. This reversal helps
to prevent excessive crankcase pressure or
depression developing. 
						

							17EMISSION CONTROL
2
DESCRIPTION AND OPERATION EXHAUST SYSTEM
1.Manifold to front pipe connection.
2.Front oxygen sensor.
3.Front silencer support bracket.
4.Rear oxygen sensor.
5.Front pipe to silencer joint.
6.Silencer rear support bracket.
7.Rear silencer support bracket. 
						

							EMISSION CONTROL
3
DESCRIPTION AND OPERATION Exhaust emission control.
The multiport Sequential Fuel injection (SFi) system
provides accurately metered quantities of fuel to the
combustion chambers to ensure the most efficient air
to fuel ratio under all conditions of operation. A further
improvement to combustion is made by measuring the
oxygen content of the exhaust gases to enable the
quantity of fuel injected to be varied, according to
conditions, to correct any unsatisfactory composition
of the exhaust.
The main components of the exhaust emission
system are two catalytic converters which are an
integral part of the front exhaust pipe assembly. The
catalytic converters are included in the system to
reduce the emission, to atmosphere, of carbon
monoxide, oxides of nitrogen, and hydrocarbons. The
active constituents of the converters are platinum and
rhodium. The correct functioning of the converters is
dependent upon close control of the oxygen
concentration in the exhaust gas entering the catalyst.
The oxygen content of the exhaust gas is signalled to
the Engine Control Module (ECM) by Heated Oxygen
Sensors (HO2S) located in the exhaust front pipes
each side of the catalytic converters. The ECM can
then make an appropriate adjustment to the fuel
supply to correct the composition of the exhaust
gases.
CAUTION: Unleaded fuel only must be
used on vehicles fitted with catalytic
converters. As a reminder a label to
indicate this is adhered to the inside of the fuel
filler flap. As a further safeguard, the filler neck is
designed to accommodate only unleaded fuel
pump nozzles. 
						

							17EMISSION CONTROL
4
DESCRIPTION AND OPERATION EVAPORATIVE EMISSION CONTROL SYSTEM
The system is designed to prevent harmful fuel vapour
from escaping to the atmosphere. The system
consists of a vapour separator tank, connected to the
fuel tank and located between the body inner and
outer panels on the right hand side of the vehicle near
the rear wheel arch. An Evaporative Emissions
(EVAP) canister, containing activated charcoal, is
positioned in the engine compartment attached to the
front right valance. The two components are
connected by a pipe running the length of the chassis.
A Pressure relief to atmosphere.
B From fuel tank to separator.
C To evaporative emmissions canister.
D Pressure relief valve.
E Pressure relief valve.
F Shut-off valve.
G Speed Fit connectors.A pressure relief valve is fitted in the hose which is
open to atmosphere. This valve acts as a safety valve
should a build-up of pressure occur in the system, for
example if a hose became blocked or kinked. The
volume of vapour emitted, in such an instance, would
be limited.
A pressure relief valve is also fitted in the hose
connected to the adsorption canister and releases
vapor to the canister when the pressure in the
separator reaches between 5 and 7 Kpa, 0.7 and 1.0
lbf/in
2.
In the top of the separator a shut-off valve is
incorporated in the vapour exit port to prevent the
possible presence of any liquid fuel being transmitted
to the EVAP canister should the vehicle roll over.
The EVAP canister, which is connected by a hose to
the plenum chamber, absorbs and stores the fuel
vapour from the fuel tank while the engine is not
running. When the engine is started, the vapour is
purged from the canister by air drawn through an
orifice in the base of the canister and by the influence
of vacuum at the top. The vapour drawn into the
plenum chamber through a solenoid operated purge
valve is finally burnt in the combustion chambers.
The purge valve, which is attached to the evap
canister support bracket, is controlled by the Engine
Control Module ECM which determines the optimum
time at which purging should take place. This will
normally be at engine speeds above idle and when
the vehicle is in motion. A signal from the ECM to the
purge valve operates the solenoid and opens the
valve to purge the canister of fuel vapour. 
						

							EMISSION CONTROL
5
DESCRIPTION AND OPERATION
1. Vapour separator and pipes
2. Non-return valve to atmosphere
3. Pipe from fuel tank
4. Pipe to EVAP canister
5. EVAP canister and purge valve
6. Fuel tank 
						

							EMISSION CONTROL
1
FAULT DIAGNOSIS TESTING EVAPORATIVE EMISSION CONTROL
Equipment required.
Nitrogen cylinder (compressed air may be used to
pressure the system when there has NEVER been
fuel present in the fuel or evaporative control
systems).
The following pressure test procedure is intended to
provide a method for ensuring that the system does
not leak excessively and will effectively control
evaporative emissions.
Water manometer (0 - 30 H2O or more).
Pipework and a T piece.
Method.
1.Ensure that there is at least two gallons of fuel in
the petrol tank unless there has never been any
fuel in the system.
2.Disconnect, at the EVAP canister, the pipe to the
vapour separator.
3.Connect this pipe to the nitrogen cylinder and
the water manometer using the T piece.
4.Pressurize the system to between 26.5 and 27.5
inches of water, allow the reading to stabilize,
then turn off the nitrogen supply.
5.Measure the pressure drop within a period of 2
minutes 30 seconds. If the drop is greater than
2.5 inches of water the system has failed the
test. Note that a fully sealed system will show a
slight increase in pressure.
6.Should the system fail the test, maintain the
pressure in the system and apply a soap
solution round all the joints and connections until
bubbles appear to reveal the source of the leak.
7.Repeat the test and if successful, dismantle the
test equipment and reconnect the pipe to the
EVAP canister. 
						

							EMISSION CONTROL
1
REPAIR EVAP CANISTER AND PURGE CONTROL VALVE
Service repair no - 17.15.13
Remove
1.Remove 3 clips securing purge pipe to coolant
hose.
2.Depress tags and disconnect purge pipe from
plenum chamber.
3.Remove PAS reservoir clamp bracket bolt.
4.Open clamp and release reservoir from bracket.
5.Remove 2 nuts securing bracket to wing.
6.Release bracket from wing and disconnect
multiplug from purge valve.
7.Release clip and disconnect fuel tank vapour
separator pipe from canister pipe.
8.Move PAS reservoir aside, release and remove
charcoal canister, purge valve and bracket
assembly.
Do not carry out further dismantling if component
is removed for access only.
9.Remove bracket from purge valve.
Refit
10.Fit bracket to purge valve.
11.Position assembly, connect vapour separator
pipe to canister pipe and secure with clip.
12.Locate purge valve bracket and expansion hose
clip to studs and locate assembly to wing.
13.Fit and tighten nuts.
14.Locate PAS reservoir to bracket clip, compress
clip, fit bolt and tighten to
8 Nm, 6 lb ft.
15.Connect purge pipe to plenum chamber.
16.Secure purge pipe to coolant hose with clips.