Land Rover Defender Workshop 1993 Rover Manual

ST834M 
ENGINE 
FIT CONNECTING RODS AND PISTONS 7. Using  a piston  ring compressor,  locate piston 
into  cylinder  bore, until piston  crown 
IS just 
below  cylinder  block top face. 
1. Locate  applicable  crankshaft  journal at B.D.C. 
2, Place bearing  upper shell in connecting  rod. 
3. Retain upper shell by screwing  guide bolts 
605351 onto connecting  rods. 
4. Insert connecting  rod and  piston  assembly  into 
respective  bore, noting  that domed  shape 
boss  on connecting  rod must  face...

ENGINE 
RR1800E 
12. Check end-float between  connecting-rods on 5. Encircle  sprockets  with chain  keeping  timing 
each  crankshaft  journal. Clearance  limits: 
0.15 
to 0.37 mm. 
13. Tighten connecting  rod nuts to the correct 
torque, 
50 Nm. Fit oil  strainer  and joint 
washer.  marks 
aligned. 
FIT CAMSHAFT  TIMING CHAIN AND SPROCKET 6. Fit sprocket  assembly  to camshaft  and 
crankshaft  key locations.  Check that camshaft 
1. Lubricate  camshaft journals and carefully  key is parallel  to...

ST841M 
CAUTION: The space  between  key and  FIT CYLINDER  HEADS 
keyway acts as an  oilway for lubrication of 
drive  gear.  Ensure  that key is seated  to full 
depth  of keyway.  Overall dimension of uppermost. Do NOT use sealant. 
shaft  and key must 
not exceed 30.15 mm, 
dimension 
A below. 
1. Fit  new  cylinder  head gaskets  with word TOP 
ST843M 
2. Locate  cylinder  heads on dowels. 
3. Clean  threads of cylinder  head bolts and 
lubricate  with engine 
oil. 7. Check  timing marks line up,...

ENGINE 
5. Tighten head bolts progressively  in sequence 
shown.  Finally tighten 
to correct  torque,  outer 
row 
60 Nm  centre  and inner  row 90 Nm. 
tightened. 
3. Ensure  each rocker  shaft IS fitted with notch 
uppermost  and towards  front of engine  on 
right  hand  side, towards  rear on left  hand 
6. Re-check  torques  when all bolts  have  been  side. 
ST845M 
NOTE: Left-hand cylinder  head illustrated. 
Arrow  points  to front  of vehicle. RR2241E 
FIT  TAPPETS,  PUSH RODS  AND ROCKER 4....

8. Fit all manifold  bolts, evenly  tighten a little at 
a time,  alternate  sides working from centre to 
each end. Finally  tighten  to correct  torque, 40 
9. Tighten  gasket clamp bolts to correct  torque, 
FIT INTAKE  MANIFOLD 
1. Apply globule  of Hylomar  SQ32M sealing  Nm. 
compound  to notches  between  cylinder head 
and  block. 
18 Nm. 
2. Locate NEW seals in position  with ends 
engaged  in notches. 
RR2268E 
FIT TIMING  COVER AND CRANKSHAFT  PULLEY 
3. Apply Hylomar SQ32M on corners  of...

ENGINE 
RR1795E 
FIT WATER PUMP 
TEST 
AND FIT THERMOSTAT 
1. Lightly grease  a new  joint  washer  and place it 
in position  on timing  cover. 1. Remove two bolts  securing  thermostat 
2. Clean threads  of four  long  bolts  and coat  with 
Loctite 
572 thread  lubricant  sealant. 2. Remove housing gasket. 
Locate  water pump in position. 
3. Withdraw  thermostat. 
3. Locate alternator  adjusting link on water 
pump. 
4. Leaving  alternator  adjusting link loose,  tighten 
remaining  water pump...

ENGINE 
6. Heat water  and observe  temperature  at which 
thermostat  opens. 4. Fit distributor to engine,  check that centre  line 
of rotor arm is now  in line  with  number  one 
8.  Clean 
intake and manifold  and thermostat  housing 
9.  Fit  thermostat with jiggle  pin uppermost. 
NOTE: Airlocks may develop in  cooling 
positioned, 
with consequent  loss of 
coolant and  possible  overheating. 
10. Fit housing  with  new gasket,  tighten two bolts 
to correct torque,  28 Nm. 
system if thermostat...

ENGINE 
RR1876E 
9. Fit distributor cap and  spark  plugs.  Connect 
H.T. leads as shown  in illustration  RR1876E. 
NOTE: This distributor  setting is to  enable 1. An  oil baffle  is fitted inside  each rocker  cover, 
engine  to 
be started.  When engine  is  Remove two screws to remove  baffle for 
refitted  the ignition  timing must 
be set  cleaning. 
using  electronic  equipment. 
2. Remove old gasket  and sealant  from covers 
and  cylinder  heads. Clean and 
dry gasket 
mounting  face, using...

ENGINE 
FIT ENGINE OIL FILTER  FIT EXHAUST  MANIFOLD 
1. Clean oil cooler  adaptor  mating face. 1. Ensure  mating surfaces  of head  and exhaust 
2. Coat  sealing  ring of new  filter  with clean  manifold are clean.  Fit new  gaskets to 
engine  oil. 
exhaust manifold.  Coat threads  of bolts  with 
3. Fill filter  with new  oil as far  as possible,  noting  anti-seize compound. 
angle  at which  filter is 
to be fitted. 2. Position  manifold  on cylinder  head and fit new 
4. Screw  on filter  until...

ENGINE 
CYLINDER HEAD GASKETS - RENEW 23. Tighten  bolts progressively  in sequence,  see 
illustration  number ST845M.  Finally tighten 
to 
1. Drain  cooling  system.  torque: 
2.  Remove  inlet manifold.  Outer row 60 Nm 
3.  Remove  alternator.  Centre row 
90 Nm 
4.  Remove  rocker shafts.  Inner row 
90 Nm. 
5. Remove  push rods.  24. When  all bolts  have  been  tightened,  re-check 
6.  Remove  power steering  pump belt.  for correct  torque. 
7.  Remove  alternator  bracket.  25. Reverse...