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 sprockets, if necessary fit a 
new  sprocket. 
6. Measure  camshaft  journals for overall  wear, 
ovality  and taper.  Diameters  of journals  are as 
follows, from  front of shaft: 
Number  1 journal  45,4 to 45,3  mm 
Number  2 journal  44,6 to 44,5  mm 
Number  3 journal  43,84 to 43,81  mm 
Number  4 journal  43,07 to 43,05  mm 
Number  5 journal  42.31 to 42,29  mm 
7. To check  camshaft  for straightness  rest two 
end  journals  i.e. numbers 
1 and 5 on V 
blocks  and mount  a dial  gauge  on centre 
journal.  Rotate shatt and note  reading. 
If run 
out 
is more  than 0.05  mm fit a new  camshaft. 
3. Withdraw  camshaft,  taking particular  care not 
to damage  bearings  in cylinder  block.  
						

							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 onto maintained. 
connecting  rods. 
7. Withdraw piston pin, using  tool LRT-12-013: 
a.  Clamp hexagon  body 
of LRT-12-013 
in  vice. 
b.  Position  large nut flush  with end of 
centre  screw. 
C. Push screw  forward  until nut contacts 
thrust  race. 
d.  Locate  piston adaptor  LRT
-12-013 
with  its long  spigot  inside bore 
of 
hexagon  body. 
e. Fit remover/replacer  bush of 
LRT
-12-013  on centre  screw with 
flanged  end away  from piston  pin. 
f. Screw  stopnut  about half-way onto 
smaller  threaded  end of centre  screw, 
leaving  a gap 
A of 3 mm (1/8 in) 
between  nut and  remover/replacer 
bush. 
5. Push  connecting  rod and  piston  assembly  up  g. Lock stop-nut securely  with lock 
cylinder bore, withdraw it from top. Retain  screw. 
connecting  rod and  piston  assemblies  in  h. 
Check that remover/replacer  bush is 
sequence  with respective  caps. 
correctly positioned in bore of piston. 
6. Remove  guide bolts LRT-12-041 from i. Push  connecting-rod to right to 
connecting  rod.  expose 
end of piston pin, which  must 
be  located  in end  of adaptor  d. 
Screw  large nut up to thrust  race. 
Hold lock screw  and turn  large  nut 
until  piston  pin has  been  withdrawn 
from piston.  Dismantle tool. 
j. 
k.  
						

							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 
oversize.  When fitting  new service  standard  size 
pistons  to a cylinder  block, check for correct 
piston  to bore  clearance,  honing bore 
if 
necessary.  Bottom of piston  skirt/bore  clearance 
should 
be 0.018 to  0.033  mm. 
NOTE: Piston  and cylinder  block temperature 
must 
be same  to ensure  accurate  measurement. 
When  reboring  cylinder block, crankshaft  main 
bearing  caps must 
be fitted  and tightened  to 70 
Nm. ST817M  
						

							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  piston  rings are to be fitted  without 
reboring,  deglaze cylinder  walls with a hone 
without  increasing  bore diameter,  to provide  a 
cross
-hatch  finish.  After honing,  thoroughly 
clean  piston  bores 
to remove  all traces of 
foreign matter. 
held  square  to bore  with piston.  Gap limits: 
0.44 to 0.56 mm.  Use a fine-cut  flat file to 
increase  gap 
if required.  Select a new  piston 
ring 
if gap  exceeds  limit. 
NOTE: Gapping does not apply to oil control 
rings.  Fit 
piston  rings 
13. Check  compression  ring in applicable  cylinder,  17. Fit expander  ring into bottom  groove  making 
sure  that ends  butt and  do not  overlap. 
18. Fit two ring  rails  to bottom  groove,  one above 
and  one  below  expander  ring. 
19.  Fit second  compression  ring 
with marking 
’TOP’ uppermost. Fit chrome  ring into top 
groove,  either way round. 
ST821M 
ST819M 
19  
						

							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. Remove  connecting rod  cap and shell. 
will face  inwards  towards  each other. 31. Using  scale printed  on Plastigauge  packet, 
measure  flattened  Plastigauge  at its  widest 
point. 
32. The  graduation  most closely  corresponding to 
width of Plastigauge  indicates  bearing 
clearance. 
33.  Correct  bearing clearance  with new  or 
overhauled  components  is 0.015 
to 0.055 mm. 
34. If a  bearing  has  been in service, fit a new 
bearing 
if clearance  exceeds 0.08 mm. 
35. If a new  bearing  is being  fitted,  use selective 
assembly 
to obtain correct clearance. 
36.  Wipe 
off Plastigauge  with  an oily  rag. DO 
NOT  scrape it off. 
NOTE:  It is  important  that connecting  rods, 
caps  and bearing  shells 
be retained in 
sets, and in correct  sequence. 
ST822M 
Assembling  pistons to connecting  rods 
25. Place a  piece  of Plastigauge  (P61) across 
centre  of lower  half  of crankshaft journal.  37.  Using tool  LRT
-12-013 refit 
each piston to its 
26. Locate  bearing  lower  shell  into connecting  rod  connecting rod 
as follows: 
cap. 
27.  Locate  cap and shell  onto connecting  rod. 
a. Clamp hexagon  body of  LRT-12-013 
in  a vice,  with adaptor  LRT
-12-014 
NOTE: Note that rib on edge of cap must positioned  as instruction 7d. 
be  on  same  side as domed  shape boss on Remove  large nut of LRT-12-013  and 
connecting  rod. push  the centre screw approximately 
50 mm into body  until shoulder  is 
28.  Secure connecting  rod cap.  Tighten 
to 50 Nm. exposed. 
29. 
Do not  rotate  crankshaft  while  Plastigauge is C. Slide parallel  guide  sleeve,  grooved 
end  last,  onto  centre  screw  and  up 
to 
shoulder. 
b. 
in  use. 
crankshaft  journal.  
						

							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 of 
fitting original  pair, with connecting  remover/replacer bush is 4mm B 
rod  around  sleeve up to groove. 
from face of piston.  This flange  must 
f. Fit piston  pin into  piston  bore, up to not be allowed to contact  piston. 
connecting  rod. 
g.  Fit remover/replacer  bush LRT
-12-015 CAUTION:  If torque  spanner  has 
with its flanged  end towards  piston not reached at least 16 Nm. 
pin. throughout  pull, fit of piston  pin to 
h.  Screw stop nut onto  centre  screw and connecting  rod is not acceptable 
adjust  nut to obtain an 0.8 mm end and  necessitates  fitting new 
float A on whole  assembly,  and lock components.  The large  nut and 
nut securely  with screw. centre  screw of tool must  be kept 
body  and screw  large nut up to thrust 
race. 
e. 
I. Slide 
assembly  back into hexagon well oiled. 
38. Remove  tool and  check  that piston  moves 
freely  on piston  pin and  that  no damage  has 
occurred  during pressing. 
k h 
ST778M  
						

							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  bearing  journal.  must be machined in  accordance with 
dimensions  in charts 
that follow. 
Main  bearing  journal size  Thrust  face width 
Standard  Standard 
0.25  mm undersize  Standard 
0.50 mm undersize 0.25 mm oversize 
11. 
For example: If fitting  a 0.50 mm undersize 
bearing,  0.125 mm must  be machined 
off 
each  thrust  face of centre  journal,  maintaining 
correct  radius. 
Crankshaft  dimensions 
12.  Radius  for all journals  except rear main 
bearing 
is 1.90 to 2.28 mm. 
13.  Radius  for rear  main  bearing  journal is 
3.04 
mm. 
5. Total run-out at each  journal  should not  14. Main  bearing  journal diameter,  see following 
chart. 
exceed 
0.08 mm. 
6. If crankshaft  is bent  it is  not  suitable  for  15. 
Thrust  face width,  and connecting  rod journal 
regrinding  and should 
be renewed.  diameter, see following 
chart. 
7. Check each crankshaft  journal for ovality. If 
ovality  exceeds 0.040 mm around  crankshaft 
journal,  regrind or 
fit a new crankshaft. 
8. Crankshaft  main and connecting  rod bearings 
are  available  in following  undersizes: 
0.25mm 
0.50mm 
ST826M 
RR1793E 13  
						

							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 clearance  with new 
or 
17. Locate  upper main bearing  shells (with oil  overhauled components is 0.023 to 0.065 mm. 
hole  and oil grooves)  into cylinder  block.  28. If correct clearance  is not  obtained  initially, 
18.  Locate  flanged  upper centre  main bearing  select a suitable  bearing to give  required 
shell.  clearance. 
19.  Place  crankshaft  in position  on bearings.  29. Wipe 
off Plastigauge  with an oily  rag. Do NOT 
20.  Place  a piece of Plastigauge  across centre of 
crankshaft  main bearing  journals. 
21.  Locate  lower shells  into main  bearing  caps.  scrape 
it off. 
30. 
Maintain  bearing shells and caps  in sets, in 
the  correct  sequence. 
ASSEMBLING  ENGINE 
FIT  CRANKSHAFT  AND MAIN  BEARINGS 
1. Locate  upper main bearing  shells (with oil 
holes  and grooves) 
in cylinder  block. 
2.  Locate  the flanged  upper centre  main bearing 
shell. 
3. Lubricate  crankshaft  main bearing  journals 
and  bearing  shells with clean  engine 
oil and 
lower  crankshaft  into position. 
ST830M 
22.  Fit numbers  one to four  main  bearing  caps 
and  shells,  tighten 
to 70 Nm. 
23.  Fit rear  main  bearing  cap and shell  and 
tighten 
to 90  Nm. Do not  allow  crankshaft to 
rotate  while Plastigauge  is in  use. 
24.  Remove  main bearing  caps and shells. 
25.  Using  scale printed  on Plastigauge  packet, 
measure  flattened  Plastigauge  at widest  point.  
						

							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.  Seal outside 
approximately  above bearing  cap parting  face.  diameter must 
be clean and dry. 
6. Apply  Hylomar  SQ32M jointing compound to 
rearmost  half of rear  main  bearing  cap parting  12. 
Push  oil seal  fully and squarely  by hand  into 
face 
or, if preferred,  to equivalent  area on  recess formed  in cap  and  block  until it 
cylinder  block as illustrated.  contacts 
machined  step in recess. 
7. Lubricate bearing half and  bearing  cap side  Withdraw seal guide. 
seals  with clean  engine  oil. 
8. Carefully  fit bearing  cap assembly. 
9. Do not tighten  fixings,  but ensure  that cap  is 
fully  home  and squarely  seated on cylinder 
block. 
CAUTION: Do  not  handle  oil seal  lip, check 
it  is  not  damaged  and ensure  that outside 
diameter  remains clean and dry. 
10. Position  seal guide  LRT-12-010 on crankshaft 
flange. 
11.  Ensure  that oil seal  guide  and crankshaft 
guide  and oil seal  journal  with clean  engine 
oil. 
journal 
are scrupulously  clean. Coat seal 
CAUTION: Do not  exceed  1,000 engine 
rev/min  for 15 seconds  when first starting 
engine,  otherwise  crankshaft  rear oil seal 
will  be damaged. 
13. 
Tighten  cap bolts 
to correct  torque,  numbers 
one 
to four  bearings 70 Nm, rear  main 
bearing 
90 Nm. 
14.  Check  crankshaft  end
-float, 0.10 to 0.20 mm.