Land Rover Defender Workshop 1993 Rover Manual

ENGINE 
ENGINE - DISMANTLE AND OVERHAUL 
Remove  engine from vehicle,  see engine  removal 
and  clean  exterior.  For safe  and efficient  working 
secure  engine to an  approved  engine stand. Drain 
engine  oil into  a suitable  container. 
Remove  intake manifold 
6. Lift intake  manifold  from cylinder  heads. 
7. Remove  surplus coolant,  remove gasket 
clamp  bolts, remove  clamps. 
8. Lift off gasket and seals. 
Remove  exhaust manifolds 
1. Bend back lock tabs,  remove  eight bolts 
securing...

ENGINE 
REMOVE AND OVERHAUL ROCKER SHAFTS  Dismantle rocker shafts 
AND  VALVE  GEAR 
5. Remove  split pin from  one end of rocker  shaft. 
1.  Remove  spark plug leads 
from spark  plugs  6. Withdraw  following components  and retain  in 
and  retaining  clips. Release  four screws  and  correct 
sequence  for re
-assembly: 
lift off rocker  covers. 7. A plain washer. 
2. Remove  four rocker  shaft retaining bolts and 8. A wave washer. 
lift off assembly. 9. Rocker  arms. 
10.  Brackets. 
11.  Springs....

RR750M 
ENGINE 
17. Tappets MUST rotate, a circular  wear 22. Fit new  split pin to one  end of rocker  shaft. 
condition 
is normal.  Tappets  with this wear 
pattern  can be refitted  provided  there are no 
other  defects. 
18. If a tappet  is not  rotating  check camshaft 
lobes  for wear.  Fit new  tappet  ensuring  it 
rotates  freely in cylinder  block. 
23. Slide a plain washer  over the long  end of the 
shaft  to contact  the split  pin. 
24. Fit a wave  washer  to contact  plain washer....

ENGINE 
REMOVE AND OVERHAUL  CYLINDER HEADS 6. Clean combustion  chambers using a soft wire 
brush. 
1.  Evenly  loosen fourteen  cylinder head bolts,  7. Clean  valves. 
reversing  tightening  order.  8. Clean  valve guide  bores. 
2. Mark heads LH and RH for reassembly. 
3. Lift off cylinder  heads, discard  gaskets. 
9. Regrind or fit new  valves  as necessary. 
10.  If a valve  has to be  ground  to a knife
-edge  to 
obtain  a true  seat,  fit a new  valve. 
11.  Correct  angle for valve  seating...

RR2355M 
ENGINE 
Examine and fit new  valve  seats 
15. Check  valve seats for wear,  pits and  burning. 
Fit  new  inserts 
if necessary. 
16.  Remove 
old seat  inserts  by grinding  them until 
thin  enough 
to be cracked  and pried out. 
17. Heat  cylinder  head evenly to approximately 
65°C. 
18. Press 
new insert  into recess  in cylinder  head. 
NOTE:  Service  valve seat inserts  are 
available  in 
two over-sizes 0.25 and 0.50 
mm larger  on outside  diameter  to ensure 
interference  fit. 
19....

ENGINE 
22. Ensure cutter blades  are correctly  fitted to 
cutter head with angled  end of blade 
downwards,  facing work, as illustrated. 
Check  that cutter  blades  are adjusted 
so that 
middle 
of blade  contacts  area of material to 
be cut. Use  key provided  in hand  set MS76. 
Use  light  pressure  and remove  only minimum 
material  necessary. 
Reclaiming  cylinder head threads 
Damaged  or stripped  threads in cylinder  head can 
be  salvaged  by fitting  Helicoils  as follows: 
Holes 
A -...

RR751M 
REMOVE AND OVERHAUL  FLYWHEEL 
1. Remove  retaining  bolts and withdraw  flywheel 
from  crankshaft. 
NOTE: Right-hand  cylinder  head illustrated. 
F  Exhaust  manifold  face 
G  Intake manifold  face 
H  Front face 
I  Rear face 
J  Front of engine 
REMOVE  FLEXIBLE  DRIVE  PLATE AND RING 
GEAR  ASSEMBLY 2. Examine  flywheel clutch face for cracks, 
scores  and overheating.  The flywheel  can be 
NOTE: Scribe  each component with an  refaced provided  minimum  thickness does 
identification...

ENGINE 
5. Secure flywheel  in a vice  using soft jaws  and 
place  a cloth  over flywheel 
to protect  operator REMOVE  TIMING GEAR COVER AND WATER 
from flying  fragments. PUMP 
WARNING: Take  adequate  precautions 1. Place an oil drip-tray  beneath  timing  cover, 
against  flying fragments  when splitting remove  oil filter  element. 
ring gear. 2. Remove  crankshaft  pulley bolt and  special 
washer,  withdraw  pulley. 
6. Place a chisel  as shown,  strike it sharply to 
split  starter  ring gear....

ENGINE 
Fit new  timing  cover oil seal 
5. Remove  seven drive screws  and withdraw 
mud  shield  and oil seal. 
6. Position  gear cover  with front  face uppermost 
and  underside  supported  across oil seal 
housing  bore on a suitable  wooden  block. 
7. Enter oil seal, lip side  leading,  into housing 
bore. 
8. Press  in oil seal until plain  face is 
approximately 1,5 mm below  gear cover  face. 
9. Fit mud  shield  and securing  screws. 
REMOVE  AND OVERHAUL  OIL PUMP 
1. Remove  bolts from oil...

ENGINE 
ST809M 
11 
Assemble pump 
17. Insert  relief valve  spring. 
18. Locate  sealing  washer  on relief  valve  plug. 
19. Fit relief  valve  plug, tighten to 40 - 47 Nm. 
20.  Fully  pack oil pump  gear housing  with 
Petroleum  Jelly. 
No other grease  is suitable. 
21.  Fit oil  pump  gears ensuring  that Petroleum 
Jelly 
is forced  into every  cavity  between  teeth 
of  gears. 
IMPORTANT:  Unless pump is fully  packed 
with  Petroleum  Jelly 
it may not prime  itself 
when  engine  is started....