Land Rover Defender Workshop 1993 Rover Manual

							ENGINE 
RR3524M 
34. Cylinder  heads (2) 46. Plenum  chamber  upper 
35.  Rocker  covers 
(2) 47, Air filter 
36.  Oil separator 
48. Oil filler 
37.  Rocker  shafts 
(2) 49. Thermostat 
38.  Hydraulic  tappets (8)  50. Thermostat  cover 
39.  Pushrods  (8) 
51. Inlet valve  spring,  cap, seal 
and collets (8) 
40.  Rocker  brackets  (8) 52. Exhaust valve spring,  cap, collets (8) 
41.  Rocker  arms (4) left  and (4) right  53. Inlet valve  and seat  (8) 
42.  Rocker  shaft springs  (6) 
54. Exhaust  valve and seat  (8) 
43.  Inlet manifold 
55. Tappet  cover gasket  and seals 
44. Plenum  chamber  lower 
56. Cylinder  head gaskets  (2) 
45.  Ram pipes  (8) 
57. Valve  guides  (16)  
						

							ENGINE 
Lubrication system 
The V8 full flow  lubrication  system uses an external  gear pump  which is driven  from the front  of the  camshaft 
via  the  distributor  drive shaft.  The oil pump  gears  are housed  in the  timing  cover and the pressure  relief valve, 
warning  light switch  and filter  are 
fitted to the  gear  cover. 
Oil  drawn  through  the centrally  located steel gauze  strainer  in the  sump,  is pumped  under pressure  through oil 
cooler  located 
in the lower  half of the  main  coolant  radiator.  The cooled  oil then  passes  through  the filter, 
before  being distributed  from the main  gallery  via drillings,  to the  various  components  in the  engine. 
Lubrication  to 
the thrust side of the  cylinders is by oil grooves  machined  in each  connecting  rod big end  joint 
face,  which  are timed  to align  with holes  in the  big end  journals  on the  Dower  and exhaust  strokes. 
Lubrication  system 
1 Oil to cooler 
2 Oil  from  cooler  
						

							ENGINE 
RR3528M 
Distributor/oil pump drive and timing  chain 
lubrication 
The distributor/oil  pump drive, and timing  chain 
lubricated  from the camshaft  front bearing.  The feed 
to the timing  chain is channelled  along the camshaft 
sprocket,  key and  spacer  where 
it sprays  onto the 
chain. 
Unfiltered  oil 
Any blockage of the filter  element  will open  the 
by
-pass  valve  and maintain  an un-filtered oil supply 
RR3526M to the  bearings. 
1 Bearing 
2 Camshaft 
3 Key 
4 Cam gear 
5 Spacer 
6 Distributor  oil pump  drive gear 
Filtered  oil 
Lubrication  pressure is controlled  by the  pressure 
relief  valve 
E which  allows  excess  pressure to 
escape into the pump  suction  gallery D. The  oil is 
then  pumped  through the cooler  via connections 
A 
and B before  passing  through the anti-siphon  valve 
and  into the filter.  Filtered  oil 
is supplied  to the 
engine  bearings  by port 
C. 
F 
RR3529M  
						

							ENGINE 
Hydraulic tappets As the  tappet  assembly  moves off the peak  of the 
cam 
to the  closing  side, the ball  valve 2 opens to 
The  purpose of the hydraulic  tappet is to provide  equalize the pressure  in both  chambers  which 
maintenance 
free and  quiet  operation of the inlet  and  ensures  that the cylinder  valve fully closes  when the 
exhaust  valves. It achieves  its designed  purpose by tappet 
is on the  back of the cam. 
utilizing  engine oil pressures 
to eliminate  the 
mechanical  clearance between the rockers  and the 
valve  stems. 
Operation 
During  normal  operation,  engine oil pressure present 
in  the  upper  chamber 1, passes  through  the 
non
-return  ball valve 2 and  into the lower  (high 
pressure)  chamber 3. 
When  the cam  begins 
to lift the outer  sleeve 4, the 
resistance 
of the  cylinder  valve spring  felt through 
the  push  rod and  seat 
5, causes  the inner  sleeve 6, 
to move  downwards  inside the outer.  This slight 
downward  movement 
of the inner  sleeve 6, closes 
the  ball  valve 
2 and  increases  the hydraulic  pressure 
in  the  high  pressure  chamber 3 
, sufficient to ensure 
that  the push  rod opens  the  cylinder valve fully. RR3531M 
1 Upperchamber 
2 Non-return  ball valve 
3 Lower  chamber  (high pressure) 
4 Outer  sleeve 
5 Pushrod  seat 
6 Inner sleeve 
7 Spring 
8 Clip 
6  
						

							4 
ENGINE 
ENGINE FAULT DIAGNOSIS 
ENGINE  OIL PRESSURE  TEST 
Service tools: 
LRT
-12-052:  Pressure  test equipment 
WARNING: Use  suitable  exhaust extraction 
equipment, 
if test is being  carried  out in 
NOTE: Excessive lubrication  pressure  can  effect 
engine  performance  by  over
-pressurising  the 
hydraulic  tappets causing  the  valves  to be  held 
open,  see Lubrication  system. 
workshop. 
CYLINDER  COMPRESSION - TEST 
WARNING: 
If vehicle  has  been  running, engine 
oil will be hot, care must be taken  when  fitting 
equipment 
to prevent  personal  injury due to 
scalding. 
Test 
Test 
1. Start  and run engine  until normal  engine 
operating  temperature  is achieved  (thermostat 
Equipment: 
Compression  pressure gauge 
1. Check lubricant  is to  correct level.  open). 
2. Place vehicle  on a ramp. 2. Remove  all spark  plugs. 
3.  Disconnect  battery  negative  terminal  and 3. Disconnect both  coil negative 
(WB) leads 
4. Insert  compression  gauge,  crank engine  until 
4. Fit  the  test  gauge.  reading stabilises. 
5. Connect  battery terminal. 5. Expected  readings,  throttle fully open,  battery 
6. Start and run engine  to  normal  operating fully charged 170 - 180 psi 
temperature. 
6. If compression  is appreciably  less than  correct 7. At a steady  engine  speed of 2400 rev/min - figure, or varies  by more  than 10%, piston 
minimum  engine  oil  pressure  reading  should  rings  or valves  may 
be faulty. 
be - 1.76 kg/cm². 7. Low pressure  in adjoining  cylinders  may 8. If there is no oil  pressure  check  for  air lock in indicate a  faulty head gasket. 
system.  See  Service schedule. 
9. If the  pressure  is low, see Remove  and 
overhaul  oil pump. 
remove 
oil pressure switch. 
RR2354E  
						

							ENGINE 
ENGINE NOISES 
Excessive or obtrusive  noise from the engine 
compartment  originates from three  main sources: 
A. The  exhaust  system, which makes  an  YES - Continue. 
unmistakable  and easy 
to diagnose  noise. 
B.  External  components  emit the greatest  variety 
2. Is the lubricating  pressure correct? 
of noises, but are  also  easy  to diagnose  by 
simply  disconnecting  the appropriate  drive  YES 
- Drain engine  oil and  filter,  and 
belt.  examine for metallic 
Engine  internal  mechanical  noises which can 
vary  in volume  and pitch  and may  be a  3. 
Is the oil contaminated with metal  particles? 
combination  of, tapping 
- knocking  or  YES - Suspect faulty big end 
rumbling,  are the most  difficult 
to diagnose.  bearings. To confirm 
The  following  is therefore  a guide  to diagnosis  diagnosis, short out the 
of engine  internal  mechanical  noises only.  ignition to each 
spark  plug in 
turn.  The noise 
will disappear 
Engine  internal  mechanical  noises. or be  reduced  when the 
cylinder 
with the  faulty  big end 
Single or multiple,  light tapping  noise, is shorted  out. 
particularly  when engine is cold. See Lubrication 
system. 
4. If noise  is not  conclusively  diagnosed, check 
the  security 
of the flywheel  and crankshaft 
1. Is engine  oil level  correct?  front pulley.  Temporarily  release the drive 
belts  to reduce  general  noise level and use 
a 
Heavy  knocking  noise (particularly  on load  and 
when  engine  is hot).  See Lubrication  system. 
1. Is engine oil level  correct? 
NO - Top up to correct  level. 
NO 
- See  Engine  oil pressure  test. 
contamination. 
C. 
NO - 
YES - Continue.  stethoscope to locate source  of noise. 
2. Is the  lubricating  pressure correct? 
NO - 
YES - Suspect  valve operating 
Top 
up 
to correct  level. 
Heavy  rumbling noise (particularly  during hard 
acceleration).  See Lubrication  system. 
See Engine  oil pressure  test. 
mechanism.  1. 
Is engine oil level  correct? 
NO 
- Top  up to correct  level. 
3. To confirm  diagnosis,  remove the rocker YES - Continue. 
covers  and with  the engine  idling, insert 
a 
feeler  gauge  of 0,015mm  between each 2. Is the lubricating  pressure correct? 
rocker  and valve  stem. 
A faulty  valve NO - See Engine  oil pressure  test. 
operating  mechanism 
will emit a different YES - Drain  engine  oil and  filter,  and 
noise  when  the feeler  gauge 
is inserted.  See  examine for metallic 
Rocker  shafts and valve  gear.  contamination. 
3. Is the 
oil contaminated  with metal  particles? 
YES 
- Suspect  faulty main bearings. 
If noise  is not  conclusively 
diagnosed,  check the security 
of  the  flywheel  and crankshaft 
front  pulley.  Temporarily 
release  the drive  belts 
to 
reduce  general  noise level and 
use  a stethoscope 
to locate 
source  of noise.  
						

							ENGINE 
ENGINE STARTING  PROBLEMS 
NOTE:  References  to the  Electrical  Trouble  Engine  runs at high  speed 
but will not idle 
Shooting  Manual  (ETM)  in  the  following  (stops) 
paragraphs  are  to the  Range  Rover ETM.  Engine  idle  speed erratic  Engine  starts 
but stops 
However,  only the specific  circuits referred  to in 
the  following  paragraphs  are applicable  to  the 
Defender. 
Engine  fails 
to crank Check  brake vacuum  connections. See 
ENGINE RUNNING  PROBLEMS 
immediately 
Engine  stalls  Engine  misfires/hesitation 
1. Multiport fuel injection.  See ETM  A1. 
Brakes. 
If problem  is not  diagnosed  continue. 
1. Is battery  in good  state of charge? 
NO - Charge  the battery. 
YES 
- See  ETM  B1 2. Are HT leads  correctly  routed and clipped? 
If problem  is not  diagnosed  repeat tests, NO - See Electrical. 
starting  at 
1. YES - Continue. 
Engine  cranks but fails  to  start 3. Is fuel supply,  tank, pump,  ventilation  and 
emission  control systems  in correct  working 
order  or the  fuel  contaminated? 
1. 
Is the  cranking  speed fast enough (120 rpm)? 
NO - Charge  the battery. NO - See  Fuel  System. 
If necessary  also see ETM B1 If problem is not  diagnosed  repeat tests, 
YES 
- Continue.  starting at 1. 
2. Is there  combustion  in any  cylinder? 
NO - 
YES - Continue.  incorrectly adjusted? 
and  emission  control systems  in correct 
NO - Continue. 
working  order or the  fuel  contaminated? 
NO - See  Fuel  System  or Emission 2.  Is the  Ignition  and Multiport  Fuel Injection 
If problem  is not  diagnosed  repeat tests, NO - See ETM A1 
starting  at 
2. YES - Continue. 
Engine  lacks power/poor  performance 
See Ignition  system tests. See 
ETM  A1  1. 
Is accelerator pedal travel  restricted  or cable 
YES 
- Check  thickness  of carpets. 
3. Are  the fuel  supply,  tank, pump,  ventilation  See Fuel  System. 
Control.  systems in order? 
3. Is fuel  supply, tank, pump,  ventilation  and 
emission  control systems  in correct  working 
order  or the  fuel  contaminated? 
NO 
- See  Fuel  System  or Emission 
Control. 
YES 
- Suspect  valves held open  by 
hydraulic  tappets due 
to high 
oil  pressure.  See Engine  oil 
pressure  test. 
4. Is oil pressure  high? 
YES 
- Remove  oil filter  and cooler 
adaptor  and check  pressure 
relief  valve  strainer  gauze for 
blockage  and that the relief 
valve  is not  stuck  closed.  See 
Lubrication  system. 
Carry  out cylinder  compression 
tests 
to determine  condition of 
head  gaskets  and valves. 
See 
Cylinder  compression  test. 
NO -  
						

							ENGINE 
5. Are cylinder  compressions  satisfactory?  Engine backfires  into inlet system 
NO - 
YES - Check  brake vacuum  correct? 
For 
overhaul,  see Remove  and 
overhaul  cylinder heads. 
connections, 
see Brakes. NO - See  Electrical. 
1. 
Is the  Distributor,  HT connections  and routing 
If  problem  is not  diagnosed:  Continue.  YES 
- Continue. 
6. Are 
the brakes  binding? 2. Is air fuel  ratio  correct? 
YES - Investigate  cause of binding. NO - Check  multiport  fuel injection, 
NO - Continue.  Check brake vacuum 
connections, 
see Brakes. 
Check  the crank  case and fuel 
tank  ventilation  system. See 
See 
Brakes.  see 
ETM A1. 
Engine backfires  into exhaust  system 
1. Are there  any leaking  joints/connections  or  Emission control. 
holes  in the  exhaust  system?  YES 
- Continue. 
YES - See Exhaust  system. 
NO 
- Continue.  3. Are cylinder  compressions  satisfactory? 
NO - Carry out compression  test to 
2. Is distributor fitted correctly, HT leads in  check for leaking  gaskets 
correct  firing order  and routed  correctly?  valves etc. See  Cylinder 
NO - See Electrical.  compression test. 
YES 
- Continue.  For overhaul,  see Remove  and overhaul 
3. Is air fuel  ratio correct? If problem  is not  diagnosed:  repeat tests 
cylinder 
heads. 
NO 
- Check  multiport  fuel injection,  starting at 1. 
see ETM  A1. 
Check  brake vacuum 
connections, 
see Brakes. 
Check  the crank  case and fuel 
tank  ventilation  system. See 
Emission  control. 
YES - Continue. 
4. Are cylinder  compressions  satisfactory? 
NO - Carry out compression  test to 
check  for leaking  gaskets 
valves  etc. See  Cylinder 
compression  test. 
For  overhaul, 
see Remove  and 
overhaul  cylinder heads. 
If problem  is not diagnosed:  repeat tests 
starting  at 
1.  
						

							ENGINE 
ENGINE REMOVAL NOTE: Release  bolts securing  compressor 
mounting  bracket to engine  and remove  bracket 
Remove  to 
enable  temporary  lifting eye ETC 
5964 to be 
fitted. Secure  lifting eye to mounting  bracket 
1. Park vehicle  on level  ground  and apply  park fixing  points  with suitable  bolts of equivalent 
brake. size,  pitch  and thread.  Leave lifting eye attached 
2. Depressurize  fuel system,  see Depressurise until  engine  is reinstalled  in vehicle. 
fuel  system. 
3. Remove  bonnet, see CHASSIS  AND BODY. 15. Place  drain tray underneath  vehicle. 
4.  Disconnect  battery.  16. Disconnect  hose from reservoir 
to power 
5. Remove  radiator/oil  coolers.  steering 
pump. Secure  hose end above  level 
6. Place an absorbent  cloth around  fuel feed  of fluid  reservoir to avoid  unnecessary loss of 
hose  at fuel  rail and  release  compression  nut.  fluid. 
Remove  feed hose  from rail, seal  end of pipes 
17. Disconnect  power steering  pump to power 
with  masking  tape 
to prevent ingress of dirt.  steering box hose.  Seal hose  and pump 
7. Release  fuel return  hose clamp  and remove  openings with masking  tape to prevent ingress 
hose  from pressure  regulator,  seal both 
of dirt. Wipe  away  any fluid  spillage  from 
openings with  masking tape 
to prevent ingress  chassis or steering  box. 
of  dirt. 
18. Disconnect  fuel temperature  and coolant 
8. Remove  vacuum hose from rear of regulator. 
9. Disconnect  throttle cable from bracket.  Disconnect leads from coil. 
temperature 
sensor multi
-plugs. 
10.  Remove  ram housing.  Identify 
each injector 
multi-plug for 
11. Remove  air flow  sensor.  re-assembly and disconnect  plugs from 
12. Remove  air cleaner  assembly.  injectors. 
13. Remove 
alternator,  See alternator. 21. Manoeuvre  harness from behind  fuel rails  and 
14. Release  air conditioning  compressor from its  PIace to  one  side clear  of engine  assembly. 
mounting  and lay 
to one side.  DO NOT 22. Remove two clamps  securing  gearbox oil 
discharge  air conditioning  system. 
23. Remove engine mounting  fixings on both 
24.  Fit lifting  chains 
to engine  lifting eyes as 
cooler 
pipes 
to engine  block. 
sides  of cylinder  block. 
shown  in illustration 
RR1780E. 
RRl780E 
1. L/H Front  chain  356mm  total overall  length. 
2. R/H Front  chain  330mm total overall  length. 
3. R/H Rear chain  457mm  total overall  length  
						

							ENGINE 
NOTE: All chain  dimensions  are measured  from 
end  of lifting  hook to end  of last  link  in chain.  Refit 
43. 
Fit lifting  chains to engine.  Raise engine  using 
25.  Fit chain  lifting eye to a suitable  engine hoist.  hoist. 
Raise  hoist high enough  to enable  engine  44. Lower  engine  into engine  compartment. 
mountings  to be  removed,  and withdraw  Ensure all components  are clear  of engine 
rubber  mountings.  assembly. 
26.  Lower  hoist until engine  rests securely  on 45. Lower  engine  into position.  Locate primary 
engine  mounting  brackets. Remove lifting  pinion into clutch.  Engage  bell housing 
chains  and hoist.  dowels. 
27.  Disconnect  two heater  hoses located  on top  of 
right  hand  rocker  cover.  47. Remove  jack and lower  hoist until engine 
28.  Remove  ground strap from rear of left  hand 
cylinder  head. DO NOT  remove  from retaining  48. Fit top  two  bell  housing  securing  bolts. 
clip.  Tighten to 40  Nm. 
29.  Remove  all electrical  harnesses  from retaining 
clips  at rear  of engine.  49. 
Fit remaining  bell housing  to cylinder  block 
30.  Remove  transmission  breather pipes from  bolts, and tighten  to 40  Nm. 
retaining  clip on rear  lifting  eye.  50. 
Fit new  gasket  and refit bottom  cover, tighten 
31.  Remove 
top two bolts  securing  bell housing  to  bolts to 9 Nm. 
cylinder  block.  51. 
Fit new  exhaust  flange gaskets,  fit exhaust  to 
32.  Raise 
front of vehicle,  lower vehicle  on to axle  manifold. 
stands.  52. Refit  all harnesses,  ground straps breather 
33.  Remove 
bell housing  bottom cover. Remove  pipes and hoses  at rear  of engine. 
gasket  from bell housing  face.  53. Raise  engine  and refit engine  mounting 
34.  Remove 
nuts securing  exhaust downpipes  to  rubbers, tighten nuts to 20  Nm. 
manifolds,  remove heat shield  from right hand  54. 
Remove  temporary  lifting eye ETC  5964  and 
side  downpipe.  reverse 
instructions  1 to  23,  ensuring  that all 
35.  Remove  electrical  leads from starter  motor  electrical plugs and harnesses  are fitted  in 
solenoid.  Disconnect  multi
-plug from  oil level  correct locations. 
sensor  on side  of sump,  if fitted. 
36.  Remove  remaining  bell housing  to cylinder 
block  bolts. 
37.  Remove  starter motor ground  strap from 
chassis. 
38.  Remove  stands and lower  vehicle. 
39.  Position  hydraulic  trolley jack under  bell 
housing  to support  gearbox  when engine  and 
gearbox  are separated. 
40.  Fit lifting  chains  to engine.  Carefully  raise 
hoist  a little,  ease  engine  and gearbox  apart, 
steady  engine  on hoist. 
41.  Ensure  no components  remain that will 
Prevent  engine being removed. 
42.  Slowly 
raise engine  clear of engine 
compartment.  Move engine  away from vehicle 
and  place  on a suitable  engine stand.  46. 
Fit two  bolts  and partially  tighten. 
rests  securely 
on engine  mounting  brackets.