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 towards 
front 
of engine  on right  hand  bank of cylinders 
and  towards  rear  on left  hand  bank.  When 
both  connecting  rods are fitted,  bosses  will 
face  inwards  towards  each other. 
5. Position  oil control  piston rings with ring gaps 
all  at one  side,  between  piston pin and  piston 
thrust  face. Space  gaps in ring  rails 
approximately 
25 mm each  side of expander 
ring  joint. 
6. Position  compression  rings with ring gaps  on 
opposite  sides of piston  between  piston pin 
and  piston  thrust face. 
9. Place  bearing  lower shell in connecting  rod 
cap. 
10. Locate  cap and  shell  onto connecting  rod, 
noting  that rib on edge 
of cap  must  be 
towards  front of engine  on right  hand  bank of 
cylinders  and towards  rear on left  hand  bank. 
11. Check  that connecting  rods move  freely 
sideways  on the  crankshaft.  Tightness 
ST835M indicates insufficient  bearing clearance  or 
misaligned  connecting  rod. 
I 
ST836M 
8. Pull connecting  rods on to crankpins  using the 
guide  bolts. Use extreme  care 
to prevent 
scratching  crank pins.  
						

							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 shaft  axis to ensure 
adequate  lubrication 
of distributor  drive gear. 
insert  camshaft  into cylinder  block. 
2. Turn crankshaft to bring  number  one piston to 
TDC . 
3. Temporarily  fit camshaft  sprocket with  marking 
F or FRONT outward. 
4. Turn camshaft  until mark  on camshaft 
sprocket  is at  six  oclock  position,  remove 
sprocket  without disturbing  camshaft. 
RR1801E  
						

							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, fit spacer  with 
flange 
to front. 
8. Fit  the  distributor  drive gear.  Ensure  that 
annular  grooved  side is 
fitted to rear,  towards 
spacer. 
9.  Fit bolt  and  washer,  tighten to correct  torque, 
60 Nm. 
RR755M 
4. Locate  the cylinder  head bolts in position 
illustrated  and 
fit dipstick tube. 
Long  bolts 
- 1, 3 and 5. 
Medium bolts - 2,4,6,7,8,9  and 10. 
Short  bolts 
- 11,12,13  and 14. 
RR1799E 
ENGINE  
						

							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. Fit rocker  shaft assemblies.  Ensure pushrods 
ASSEMBLIES engage  rocker cups. Tighten  bolts to correct 
torque,  38 Nm. 
NOTE:  Immerse  tappets 
in clean engine  oil. 
Before  fitting, pump inner sleeve 
of tappet 
several  times using a pushrod,  to reduce  tappet 
noise  when engine  is started. 
1. Fit tappets  and push  rods in original  positions. 
Ensure  tappets  move freely 
in bores. 
NOTE: Tappet  noise can be expected  on 
initial  starting  after overhaul  or if vehicle 
has  been  standing  a very  long  period.  Run 
engine  at 
2,500 rev/min  for a few minutes 
(subject  to following  caution), when noise 
should 
be eliminated. 
2. Rocker  shafts are handed  and must  be fitted 
correctly to align  oilways. CAUTION: Do not exceed 1,000 engine 
rev/min  for 
15 seconds  when first starting 
engine,  otherwise  crankshaft  rear oil seal 
will 
be damaged.  
						

							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 cylinder 
head,  manifold  gasket and manifold,  around 
water  passage  joints. 
4. Fit manifold  gasket with word  FRONT  to front 
and  open  bolt hole  at front 
R.H. side. 
5. Fit  gasket  clamps,  do not  fully  tighten  bolts. 
1. Position a new timing  cover joint washer,  fit 
timing  cover, locating 
it on two dowels. 
2. Clean  threads  of timing  cover securing  bolts, 
coat  them  with Loctite 
572. 
3. Fit and  evenly  tighten  timing cover bolts to 
correct  torque, 
28 Nm. 
4. Fit crankshaft  pulley. Tighten  retaining  bolt to 
correct torque, 270 Nm. 
5. Fit timing  pointer. 
6. Locate  manifold  on to cylinder  head. 
7. Clean threads  of manifold  securing bolts. 
ENGINE 
ST849M  
						

							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 housing  bolts evenly 
to 
correct  torque 28 Nm.  housing 
to intake 
manifold. 
RR1791E 4. Note  fully open  temperature  stamped on 
thermostat, 
88°C. 
FIT SUMP 
1. Remove  old sealant  from sump  and cylinder 
block  joint faces. 
face  of sump  as 
shown in illustration  below. 
2. Apply 2 mm wide  bead of Hylosil 102 to joint RR799M 
5. Place  thermostat  and a thermometer  in a 
suitable  container  half 
full of water. 
RR1867E 
3. Place sump  in position, fit sump  bolts, evenly 
tighten  bolts 
to correct  torque, 10 Nm, rear 
bolts 
19 Nm. 
4. Tighten  sump plug to correct  torque, 44Nm. 
5. Allow thirty minutes  sealant curing time before 
starting  engine. 
4 
ST858M  
						

							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 is incorrectly reset oil pump drive tongue, repeat  operation. 
FIT DISTRIBUTOR 
1. Turn crankshaft to bring  number  one piston to 
6° BTDC  on compression  stroke (both valves 
closed  number  one cylinder). 
2. Turn  distributor  drive until rotor  arm is 
approximately 
30 anti-clockwise  from number 
one  spark  plug  lead  position on cap. 
3. Turn  oil pump  and distributor  drive shaft until 
tongue  is in  approximate  position illustrated. 
RR178E 
6. Fit clamp  and nut,  leave  loose. 
7. Rotate  distributor  until peak  on pick-up lines 
up  with  a peak  on reluctor  ring. Remove  rotor 
arm  for better  view. 
CAUTION:  On  no account  must  engine be 
started  before this operation  is carried 
out. 
8. Secure  distributor  in this  position  by tightening 
clamp  nut. 
ST859M 
7.  Disard  thermostat  if  faulty. 
mating  faces.  
						

							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  Bostik  cleaner 
6001. 
Apply Bostik 1775 to seal  face  and gasket, 
use  a brush 
to ensure  an even  film. Allow 
adhesive 
to become  touch-dry, approximately 
fifteen  minutes. 
NOTE: The gasket  fits one  way  only, it 
must be fitted  accurately  first time. 
Subsequent  movement would destroy 
bond. 
FIT  ROCKER  COVERS 
ST853M 
3. Fit pilot  studs  in rocker  cover fixing holes to 
guide  gasket  onto cover  and into recess. 
Press  gasket  into place  ensuring  that outer 
edge  firmly  contacts  recess wall. 
4. Allow covers  to stand  for thirty  minutes  before 
fitting. 
5. Secure  rocker covers  to cylinder  heads with 
short screws  inboard,  long screws  outboard. 
Tighten 
to correct  torque, 9 Nm.  
						

							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  sealing  ring touches  lockplates, securing bolts and plain  washers. 
mating  face, then tighten  a further  half turn  by 
The  plain  washers  are fitted between  manifold 
hand  only. 
DO NOT OVERTIGHTEN. 
and lockplates.  Evenly tighten  manifold  bolts 
5. Refill engine  with specified  grade and quantity 
to correct  torque.  20 Nm.  Bend  over lock tabs. 
of oil. 
MISCELLANEOUS  AND NON-STANDARD  ITEMS 
Fit remaining  items of equipment,  miscellaneous 
hoses,  pipes, filters,  clips and brackets  in position. RR2618S  
						

							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  instructions  12 
to 1. 
8.  Remove  both exhaust  manifolds. 
9. Remove  air cleaner  assembly. CYLINDER  HEADS - RENEW 
10. Remove  air flow  meter. 
11.  Remove  earth leads  from rear 
of left hand 1. Remove  cylinder heads and gaskets. 
cylinder  head  2. Remove  spark plugs. 
12.  Right  hand cylinder  head 
- remove breather  3. Using  spring  compressor  18G 106A,  remove 
pipe  from  lifting  bracket. 
13.  Loosen  cylinder  head bolts,  reversing 
tightening  sequence. 
14.  Remove  cylinder heads. 
15. Remove  cylinder head gaskets. 
16.  Clean  exhaust  mating faces. 
17.  Clean  head and block  faces. 
18.  Fit new  cylinder  head gaskets,  word TOP 
uppermost. 
DO NOT  use sealant. 
19. Oil cylinder  bores. 
20. Clean threads  of head  bolts and coat  with 
Loctite 
572. 
21.  Locate  cylinder  heads on block. 
22.  Locate  cylinder  head bolts 
in position 
illustrated. 
Long  bolts 
- 1, 3, and 5. 
Medium bolts - 2, 4, 6, 7, 8, 9 and  10 
Short bolts - 11, 12, 13, and  14  valves, 
collets, springs  and caps. RR3819M 
4. From  left hand  cylinder  head, remove  earth 
lead  studs. 
5. Remove PAS pump  pivot stud. 
6.  Right  hand cylinder  head, remove  rear lifting 
bracket. 
7. Fit  lifting  bracket  to new  right  hand  cylinder 
head. 
8. 
Fit PAS pump  pivot stud,  earth  lead studs to 
new left hand  cylinder  head. 
9. Regrind valves. 
10.  Lubricate  valve stems, 
fit valves,  springs,  and 
caps.  Fit new  seals 
to inlet  valve  stems  only. 
11.  Using  spring  compressor  18G 106A, 
compress  springs, 
fit collets. Tap valve to 
check  correct  collet seating. 
10.  Fit spark  plugs. 
11.  Fit cylinder  heads with new gaskets. NOTE:  Left hand  cylinder  head illustrated, 
arrow  points  to front  of 
vehicle.