Land Rover Defender Workshop 1993 Rover Manual
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ROCKER COVER - RIGHT HAND - RENEW 10. Apply Bostik 1775 impact adhesive to rocker cover seal face and gasket, using a brush to 1. Disconnect battery negative lead. ensure an even film. Allow adhesive to 2. Disconnect purge pipe from charcoal canister become touch dry. at plenum. 11. Place one end of gasket into cover recess 3. Remove breather pipe from rocker cover. with edge firmly against recess wall, holding 4. Remove coolant pipes from inlet manifold. remainder of gasket clear. Work around cover, 5. Remove spark plug leads from plugs and pressing gasket into place ensuring edge retaining clips. 6. Remove four rocker cover bolts. Moving fuel 12. Allow cover to stand for thirty minutes before 13. Fit rocker cover to cylinder head with four 8. screws, short screws, inboard, tighten to 8 Nm. 9. 15. Fit breather pipe to rocker cover, tighten clip. pipes aside, remove rocker cover. fitting. Remove plug lead retaining clips from rocker cover, fit to new rocker cover. Clean and dry rocker cover and cylinder head matng faces using Bostik cleaner 6001. 16. Fit breather pipe to inlet manifold, tighten bolts. 17. Fit spark plug leads to plugs and retaining NOTE: Gasket fits one way round only. It Subsequent movement will destroy 18. Connect purge pipe from charcoal canister at must be fitted accurately, first time. clips. bonding. plenum, tighten clip. ROCKER COVER - LEFT HAND - RENEW 1. Remove air flow sensor. 2. Remove plenum chamber. 3. Remove dipstick. 4. Remove spark plug leads from plugs and retaining clips. 5. Disconnect HT lead from coil. 6. Remove alternator heat shield from rocker cover. 7. Remove air flow meter harness clip. 8. Remove dipstick tube clip. 9. Remove four rocker cover bolts, remove rocker cover. 11. Remove plug lead retaining clips from rocker cover, fit to new rocker cover. 12. Clean and dry rocker cover and cylinder head mating faces, using Bostik cleaner 6001. NOTE: Gasket fits one way round only. It must be fitted accurately, first time. Subsequent movement will destroy 13. Apply Bostik 1775 impact adhesive to rocker cover seal face and gasket, using a brush to ensure an even film. Allow adhesive to become touch dry, approximately fifteen minutes. 10. Discard gasket I bonding. RR3820M ENGINE firmly contacts recess wall. 14. Position fuel pipes.
14. Place one end of gasket into cover recess with edge firmly against recess wall, holding remainder of gasket clear. Work around cover, pressing gasket into place ensuring edge firmly contacts recess wall. 2. Loosen four rocker shaft fixings ROCKER SHAFT RENEW 1. Remove rocker covers as required, RR3821M 15. Allow cover to stand for thirty minutes before 3. Remove rocker shaft assembly. fitting. 16. Fit rocker cover to cylinder head with four NOTE: Each rocker shaft is notched at screws, short screws inboard, tighten to 8 Nm. ONE end. Notch must be uppermost and 17. Locate and tighten dipstick tube clip. towards front of engine on right hand side, 18. Fit and tighten air flow meter harness clip. towards rear on left hand side. 19. Fit alternator heat shield to rocker cover. 20. Connect HT lead to coil. 4. Clean rocker pedestal locations on cylinder 21. Connect spark plug leads to plugs and head. retaining clips. 5. Fit rocker shaft assembly, locating push rods 22. Fit dipstick. to rockers. 23. Fit plenum chamber. 6. Tighten rocker shaft fixings to 38 Nm. 24. Fit air flow meter. 7. Fit rocker covers.
ENGINE HYDRAULIC TAPPETS RENEW CRANKSHAFT PULLEY ASSEMBLY 1. Remove rocker shafts. 1. Remove viscous coupling, see viscous 2. Remove inlet manifold. 3. Remove push rods, retain in removal 2. Remove water pump drive belt. coupling, fan blades, pulley and fan cowl. 3. Remove alternator drive belt. Remove power steering pump drive belt. 5. Raise vehicle on ramp. 6. Remove bell housing bottom cover. 7. With assistance to stop flywheel rotation, remove crankshaft pulley assembly retaining bolt. 4 sequence. 8. Remove crankshaft pulley assembly. 9. If required: Place assembly in vice and remove pulleys. 10. Fit pulleys to torsional vibration damper. 11. Lubricate seal face of assembly. 13. With assistance to stop flywheel rotation, fit retaining bolt, tighten to 280 Nm. 14. Reverse instructions 1 to 6. 12. Fit pulley assembly. I 4. Remove hydraulic tappets 5. Fit tappets, push rods and rocker assemblies. 6. Fit inlet manifold. 7. Reverse remaining removal procedure. FRONT COVER OIL SEAL - RENEW 1. Remove crankshaft pulley, 2. Remove eight screws and remove mud excluder. 3. Fit button of 18G1328 to crankshaft, fit extractor to seal. 4. Turn centre bolt of extractor to remove seal. 5. Remove seal from extractor. 6. Clean seal seating. 7. Lubricate outside diameter of seal. 8. Locate seal in front cover. 9. Fit adaptor 18G1291/5 to 18G1291/4. 10. Fit tool to seal. 11. Fit and tighten centre bolt to crankshaft, tighten centre locknut to seat seal. 12. Slacken locknut and remove tool. 13. Lubricate seal lip. 14. Fit mud excluder and tighten screws. 15. Fit crankshaft pulley assembly.
ENGINE FRONT COVER GASKET 29. Clean threads of cover fixing bolts, apply 1. Remove crankshaft pulley. 30. Fit timing cover, fit fixing bolts, tighten to 28 2. Remove water pump pulley. Nm. 3. Release distributor cap clips. 31. Fit alternator support strut to front cover. 4. Release plug leads from plugs and clips. 5. Place cap and leads to one side. Nm. 6. Turn engine until No. 1 piston is at T.D.C. 7. Check position of rotor arm. 34. Lubricate distributor O ring. 8. Remove fixings securing power steering pump 35. Fit distributor in position marked. bracket to water pump bracket. 36. Align oil pump drive, if distributor does not 9. Remove power steering pump bracket from seat correctly. water pump. 37. Fit distributor clamp, tighten to 20 Nm. tensioner. bracket. Loctite 372 to threads. 32. Tighten sump to timing cover fixings to 10 33. Tighten sump fixings to 10 Nm. 10. Remove clips securing wiring to alternator 38. Locate alternator tensioner on water pump 11. Disconnect distributor feed wire. 39. Connect heater hose, tighten clip. 12. Pivot power steering pump away from front 40. Connect oil pressure switch. 41. Connect bottom hose, tighten clip. 13. Disconnect vacuum pipe from distributor. 42. Connect vacuum pipe to distributor. 14. Remove water pump bottom hose. 43. Loosen power steering pump pivot, lower 15. Disconnect oil pressure switch. pump. 16. Disconnect heater hose at water pump. 44. Connect distributor feed wire. 17. Remove alternator tensioner from water pump, 45. Connect wire ties to alternator tensioner. move tensioner aside. 46. Fit power steering pump bracket to water 18. Mark distributor position to front cover. pump, tighten to 28 Nm. 19. Remove distributor clamp, remove distributor. 47. Fit power steering pump to bracket. 20. Remove fixings sump to front cover. 48. Position distributor cap. Fit plug leads to plugs 21. Loosen four adjacent sump fixings. and clips. 22. Remove alternator support strut from front 49. Clip distributor cap in position. 23. Loosen remaining front cover fixings and 51. Fit crankshaft pulley. 24. Remove front cover gasket. 53. Check ignition timing. 54. Refill cooling system. cover, tighten pivot to retain in position. cover, move strut aside. remove front cover. 52. Tension drive belts correctly. 50. Fit water pump pulley, tighten to 10 Nm. Refit 25. Clean timing cover, clean block face. 26. Lightly grease gasket faces. 27. Fit new gasket to block face. 28. Apply hylosil to sump gasket.
ENGINE TIMING CHAIN AND CHAINWHEELS Remove 1. Remove engine. 2. Remove flywheel. 1. Remove front cover. 3. Remove dipstick. 2. Remove retaining bolt and washer, remove 4. With assistance, invert engine, support on distributor drive gear and spacer. 3. Ensure number one piston is at TDC. 4. Remove chainwheels and chain as an 6. Remove rear main bearing cap. assembly. 7. Remove cross seals from cap. 8. Remove crankshaft rear oil seal. 9. Clean main bearing cap and oil seal area of CRANKSHAFT REAR OIL SEAL blocks. 5. Remove sump. Refit 5. Clean chainwheels and chain. 6. Fit chainwheels to chain, aligning timing 11. Apply Hylomar SQ32M to block as illustrated. marks. 7. Ensure camshaft key is fitted parallel to shaft axis to ensure adequate lubrication to distributor drive gear. 8. Engage chainwheel assembly on camshaft and crankshaft keys, ensure chain wheels are fully located. 9. Check alignment of timing marks with straight edge. 10. Fit spacer with flange to front, 11. Fit distributor drive gear with groove towards spacer. 12. Fit retaining bolt and washer, tighten to 58 Nm. 13. Fit front cover. 10. Fit new cross seals to bearing cap. FLYWHEEL Remove 1. Remove gearbox and clutch. 2. Slacken starter motor bolts. 3. Lock flywheel, remove flywheel bolts and RR3827M flywheel. 12. Lubricate bearing shell and cross seals using 13. Fit bearing cap, do not tighten bolts. on the block. Refit clean engine oil. 4. Clean components for reassembly. 14. Ensure cap is fully home and seated squarely 5. Fit flywheel. 6. Lock flywheel, fit flywheel bolts, tighten to 80 Nm. block.
RR3828M ENGINE 15. Ensure oil seal guide RO1014 and crank journal are scrupulously clean. Coat seal guide and oil seal journal with clean engine oil. CAUTION: Do not handle oil seal lip, check it is not damaged. Ensure outside diameter remains clean and dry. 16. Position oil seal guide RO1014 on crankshaft flange. NOTE: lubricant coating must cover seal guide outer surface completely to ensure that oil seal lip is not turned back during assembly. Position oil seal, lipped side towards engine, on seal guide. Seal outside diameter MUST be clean and dry. 17. Push oil seal fully and squarely by hand into recess in cap and block until it contacts machined step in recess. Remove seal guide. 18. Tighten rear main bearing cap to 90 Nm. 19. Fit sump. 20. Reposition engine, fit dipstick. 21 . Fit flywheel. 22. Fit engine to vehicle.
RO605351 18G1150 18G1150E 18G79 ENGINE LRT-12-041 Guide bolts RO605351 LRT -12-013 18G1150 Piston pin remover/replacer - Basic tool LRT-12-014 18G1150E Adaptor remover/replacer - piston pin LRT -12-001 Clutch centralising tool. 18G79
ENGINE MS1519A RO.600959 LRT-12-034 Spring compressor MS1519A LRT -12-038 RO600959 exhaust Drift - Valve guide replacement - intake and LRT -12-515 RO605774A Distance piece for valve guide LRT-12-504 Valve seat cutter MS621 MS.621
RO.1014 RO274401 ENGINE LRT-12-010 Crankshaft rear seal sleeve RO1014 LRT-12-037 Drift for valve guide removal - intake and RO274401A exhaust LRT-12-047 Torque adaptor lambda sensor LST134 LST134
EMISSION CONTROL The purpose of the crankcase ventilation system is to ensure that any noxious gas generated in the Three systems are used to control the vehicle engine crankcase is rendered harmless by burning in atmospheric emissions these are: the combustion chambers as follows: Oil laden noxious gas in the engine crankcase is Engine crankcase fume emissions. drawn through an oil separator 3 located on the right Fuel tank Evaporative emissions cylinder head rocker cover, where the oil is Engine exhaust gas emissions. separated and returned to the stump. The gas flows through a restrictor in the three way connection 1 Crankcase ventilation system and into the inlet plenum chamber where it drawn into the combustion chambers and burned. The The crankcase ventilation system which is an volume of fresh air which is drawn from the integral part of the air supply to the engine atmospheric side of the throttle butterfly to mix with combustion chambers, is often overlooked when the gas, depends on the position of the throttle and diagnosing problems associated with engine the engine speed. performance. A blocked ventilation pipe or filter or excessive air leak into the inlet system through a The air filter 2 fitted to the left cylinder head rocker damaged pipe or leaking gasket can effect the cover, must be maintained in clean condition to mixture, performance and economy of the engine. ensure sufficient air enters the crankcase under varying throttle openings and manifold depression, to prevent excessive crankcase pressure or depression developing. 1 Three way connector 2 Air filter 3 Oil separator REISSUED: FEB 1993 1 RR3534M