Land Rover Defender Workshop 1993 Rover Manual

RR1797E 
ENGINE 
ST813M 
REMOVE TIMING CHAIN SPROCKET  AND 
CAMSHAFT 
1. Remove  retaining  bolt and  washer.  Withdraw 
distributor  drive gear and spacer. 
Examine components 
4.  Visually  examine  all parts  for wear.  Fit a new 
camshaft 
if bearing  journals  and cams  show 
signs  of wear,  pits, scores  and overheating. 
2. Withdraw  sprocket complete  with timing  chain. 5. Examine  links and pins of timing  chain for 
wear.  Compare  its condition  with a new  chain. 
Inspect  teeth 
of...

ENGINE 
ST816M 
REMOVE  AND  OVERHAUL CONNECTING RODS Overhaul 
AND  PISTONS 
NOTE: Retain connecting  rods, caps and bearing 
1. Withdraw  retaining bolts and remove  sump. shells in sets, in correct  sequence.  Remove 
2. Remove  sump oil strainer. piston  rings over crown of piston. If same  piston 
3. Remove  connecting  rod caps,  retain  in is to be refitted,  mark it relative  to its  connecting 
sequence  for reassembly. rod  to ensure  that original  assembly  is 
4. Screw guide bolts LRT-12-041...

ST777M 
Original pistons 9. Check cylinder  bore dimension  at right  angles 
to  piston  pin 
40 to 50 mm from top. 
8. Remove  carbon deposits,  particularly  from ring 
grooves.  Examine  pistons for  signs 
of damage 
or  excessive  wear, refer to new  pistons  for 
method 
of checking  running clearance. Fit 
new pistons if necessary. 
New  pistons 
NOTE:  Pistons  are available 
in service  standard 
size  pistons  supplied  0.0254 mm oversize. 
Oversize  pistons are 
0.25 mm and  0.50  mm...

ENGINE 
10. Check piston dimension  at right  angles  to 14. Temporarily  fit compression  rings to piston. 
piston  pin, at bottom 
of skirt. 15. The  ring marked ‘TOP’ must  be fitted  with 
marking  uppermost  into second  groove.  The 
chrome  ring 
fits top groove  and can  be fitted 
16. Check  compression  ring clearance  in piston 
groove.  Clearance  limits: 
0.05 to 0.10 mm. 
either 
way round. 
ST818M 
11. The piston  dimension  must be 0.018  to 0.033 
mm  smaller  than cylinder. 
12. 
If new...

ENGINE 
Examine connecting  rods 
20. Check  alignment  of connecting  rod. 
21.  Check  connecting rod small  end, piston  pin 
must  be a press fit. 
Check  crankshaft  bearings 
22.  Locate  bearing upper shell into the  connecting 
rod. 
23. Locate  connecting  rod and  bearing onto its 
NOTE:  Domed  shape boss on connecting 
rod  must  face towards  front of engine 
on 
right  hand  bank of cylinders  and towards 
rear 
on left  hand  bank. 
24. When  both connecting  rods  are fitted,  bosses  30....

ENGINE 
k 
d. Lubricate piston pin and  bores of j. Set a torque  spanner to 16 Nm. This 
connecting  rod and  piston  with  represents minimum load for an 
graphited  oil (Molykote  2). 
Also acceptable  interference fit of piston 
lubricate  ball race  and centre  screw 
pin 
in connecting rod. 
of LRT-12-013. k. Using torque  spanner  and socket on 
Fit connecting  rod and  piston  together 
large nut, and  holding  lock screw,  pull 
onto  tool, with markings  aligned 
if piston pin in until  flange...

REMOVE AND OVERHAUL  CRANKSHAFT 
1. Remove  main bearing  caps  and  lower  bearing 
shells. 
Retain in  pairs  and  mark with number 
of journal 
until it is  decided if bearing  shells 
2. Lift out crankshaft  and rear  oil seal. 
ST824M 
are to be refitted.  

ENGINE 
Inspect and overhaul  crankshaft 9. The centre  main bearing  shell, which  controls 
crankshaft  thrust, 
has thrust  faces increased 
3. To check  for straightness,  place crankshaft  on in thickness  when more than 0.25 mm 
vee
-blocks  at numbers  one and five main  undersize, as shown  in following  chart. 
bearing  journals.  10. 
When  a crankshaft  is to  be  reground,  thrust 
4. Using a dial  indicator,  check run-out at centre  faces on either  side of centre  main journal 
main...

ST828M 
ENGINE 
Crankshaft dimensions-millimetre 
Cranks 
haft Diameter 12 Width 13 Diameter 1 4 
Grade 
Standard  58.400
-58.412 
26.975-27.026  50.800-50.812 
0.254 U/S 58.146-58.158 
26.975-27.026  50.546-50.558 
0.508  U/S  57.892
-57.904 
27.229-27.280 50.292-50.304 
Check  main bearing  clearance  26. Graduation  most closely  corresponding 
to 
width of Plastigauge  indicates bearing 
16.  Remove  oil seals  from cylinder  block and rear  clearance. 
main  bearing  cap.  27. Correct  bearing...

4. Lubricate lower main bearing  shells and fit NOTE: Lubricant  coating must cover  seal 
numbers  one 
to four main  bearing  caps and  guide outer surface  completely  to ensure 
shells  only, leave  the fixing  bolts finger
-tight.  that oil seal lip is not  turned  back during 5. Fit cross  shaped  side seals to grooves  each  assembly. 
side  of rear  main  bearing  cap. 
Do not cut  side  Position oil seal, lipped side  towards  the 
seals,  they must  protrude 1.5 mm  engine, on to seal  guide....