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  each manifold,  and withdraw 
1. Release  hose clamp  at water  pump  manifolds and gaskets. 2. Detach  retaining  clips from  top of injectors. 
3. Remove  four bolts  securing  fuel rail to 
manifold. 
4. Withdraw  fuel rail and  injectors. 
5. Evenly  loosen  and remove  twelve bolts 
securing  intake manifold  to cylinder  heads. 
Remove  water pump 
1. Remove  fifteen bolts, pump  and joint  washer. 
NOTE:  The water  pump  is not  serviceable.  II n 
event of failure, fit a new  water  pump  assembly. 
RR1794E  
						

							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. 
12.  Examine  each component  for wear,  in 
particular  rockers and shafts.  Discard  weak or 
broken  springs. 
3.  Withdraw  pushrods and retain  in sequence 
removed. 
4.  Remove  hydraulic  tappets. Retain with their 
respective  pushrods. 
If a tappet  cannot  be 
removed  leave in position  until camshaft  is 
removed. 
Inspect tappets and pushrods 
13.  Hydraulic  tappet: inspect  inner and outer 
surfaces  of body  for blow  holes  and scoring. 
Fit  a new  hydraulic  tappet 
if body is roughly 
scored  or grooved, 
or has  a blow  hole 
extending  through wall in a position  to permit 
oil  leakage  from lower  chamber. 
14.  The prominent  wear pattern 
just above  lower 
end  of body  should  not 
be considered  a 
defect  unless  it is  definitely  grooved or scored. 
It  is  caused  by side  thrust 
of cam  against 
body  while  tappet 
IS moving  vertically  in its 
bore. 
15.  Inspect  cam contact  surface  of tappets.  Fit 
new  tappets 
if surface is excessively  worn or 
damaged. 
16. 
A hydraulic  tappet body that has been  rotating 
will  have  a round  wear pattern. 
A non-rotatlng 
tappet  body 
will have a square  wear pattern 
with  a very  slight  depression  near centre. 
5 
ST787M  
						

							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. 
RR2937M 
25. Early  type rocker  arms are angled.  They must 
be  fitted 
so that  valve  end of rocker  arms 
angle  away from each  other  as shown. 
26. On later  type rocker  arms the valve  end IS 
offset and must  be fitted  as shown. 
27. Early  and late rocker  arms are 
interchangeable  provided complete  set 
is 
changed. 19. Fit a new  hydraulic  tappet if area of pushrod 
contact  is rough  or damaged. 
20. Fit  a new  pushrod if it is  bent  or has  a rough 
or  damaged  ball end 
or seat. 
Assemble  rocker shafts 
21. Assemble  rocker shafts with identification 
groove  at one  oclock  position  with push  rod 
end  of rockers  to the  right. 
RR2899M 
28. Assemble  rocker arms, brackets  and springs 
to  rocker  shaft. 
29. Compress  the springs,  fit wave  washer,  plain 
washer  and split  pin 
to end of rocker  shaft. 
30. Fit locating  bolts through  brackets.  Place 
assemblies 
to one  side. 
RR2900M 
CAUTION: If incorrectly  assembled shafts 
and rockers  are fitted to engine,  oil supply 
to rocker shafts will be restricted.  
						

							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  face 
is 45° ± 
1/4. 
4. Remove  spark plugs.  12. Correct  angle for seat  is 46° ± 1/4  and  seat 
5. Using  valve spring  compressor  18G 106A or a  witness towards  outer edge. 
suitable  alternative,  remove valves, springs, 
retain 
in sequence  for refitting.  Discard inlet 
valve  stem seals. 
Dismantle  cylinder heads 
13. Check  valve guides  and fit replacements  as 
necessary.  Using valve guide  remover 
274401,  drive out old guides 
from valve  spring 
seat  face  of cylinder  head. 
ST793M  
						

							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. Using  service tool MS621 if necessary,  cut 
valve  seats 
to 46° ±1/4, 
20. Nominal  seat width  is 1,5 mm. If seat  exceeds 
2,O mm it should  be reduced to the  specified 
width  by the  use 
of 20°  and 70° cutters. 
21.  The inlet  valve  seat diameter: 
A is 37,03 mm 
and  exhaust  valve seat is 
31,510 mm. 
Fit  new  valve guides 
NOTE: Service  valve  guides  are 0,025 mm larger 
on  outside  diameter  than  original equipment 
to 
ensure interference  fit. 
14. Lubricate new valve  guide  and place  in 
position. 
A. Using  guide drift LRT-12-038 partially  drive 
guide  into cylinder  head. 
B. Remove  drift LRT-12-038 and  place  distance 
piece  LRT
-12-515 over  valve  guide.  Drift 
guide  into head  until distance  piece contacts 
spring  seat. 
C. Alternatively  drift guide  into cylinder  head until 
it protrudes  19 mm above valve spring  recess 
in head. 
ST797M  
						

							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 - These  three holes  may be drilled 0.3906 in 
dia. 
x 0.937 + 0.040 in deep.  Tapped  with Helicoil 
Tap  No. 6 CPB  or 6CS 
x 0.875 in  (min)  deep (3/8 ST1024M 
23. Coat  valve  seat with a small  quantity of UNC 1.5D insert). 
engineers  blue, revolve  a properly  ground 
valve  against  seat. 
A continuous  fine line  Holes B - These  eight holes  may be drilled 0.3906 in 
should  appear  round valve. 
If there is a gap of dia. x 0.812 + 0.040 in deep.  Tapped  with Helicoil 
not  more  than 12 mm  it can 
be corrected  by Tap No. 6 CBB 0.749 in (min)  deep (3/8 UNC 1.5D 
lapping.  insert) . 
24. Alternatively,  insert a strip  of cellophane 
between  valve and seat,  hold valve  down  by 
stem, 
slowly pull  out cellophane. If there  is a 
drag,  seal 
is satisfactory  in that  spot.  Repeat 
in  at  least  eight  places.  Lapping
-in will correct 
a small  open spot.  Holes 
C 
- These  four holes  may be drilled 0.3906 in 
dia 
x 0.937 + 0.040 in deep.  Tapped  with Helicoil 
Tap  No. 6 CPB  or 6CS 
x 0.875 in (min)  deep (3/8 
UNC 1.5D insert). 
Holes  D 
- These  four holes  may be drilled  0.261 in 
Re-Assemble  valves to cylinder head dia x 0.675 + 0.040 in deep. Tapped  with Helicoil 
Tap  No. 
4 CPB  or 4CS x 0.625  in (min)  deep (1/4 
UNC 1.5D insert). 
Holes 
E - These  six holes  may be drilled 0.3906 in 
dia 
x 0.937 + 0.040 in deep.  Tapped  with Helicoil 
Tap  No. 6 CPB  or 6CS 
x 0.875 in  (min)  deep (3/8 
UNC 1.5D insert). 
25. Before  fitting valves  and springs,  check height 
of each valve  above  head. Measure  height of 
stem  above  valve spring  seat surface,  holding 
head  firmly  against  seat. This dimension  must 
not  exceed 
47.63 mm. If necessary fit a new 
valve  or grind  end 
of valve  stem. 
26.  Lubricate  valve stems.  Fit new  inlet valve 
stem  seals  and springs.  Fit caps,  compress 
springs  using LRT
-12-034 and fit collets.  
						

							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  line to enable  re
-assembly in not go below  39.93 mm (1.572 in). Remove 
original 
position. 3. Examine  ring gear  for  worn,  chipped and 
three 
dowels  before machining. 
1. Remove  four retaining  bolts.  broken teeth. Renew  as follows: 
2. Withdraw  clamp ring, flexible  drive plate,  hub 
aligner  and ring gear  assembly. 
3.  Remove  six socket  head bolts securing 
crankshaft  adaptor plate and shim  to 
crankshaft  flange. 
4. Withdraw crankshaft  adaptor plate and shim. 
5. Inspect  ring gear  assembly  for distortion, 
cracks,  chipped  or badly 
worn teeth. If ring 
gear 
is in poor condition fit a  new  assembly. 
4. Drill  a 10 mm diameter  hole axially  between 
roots  of any  tooth  and inner  diameter 
of 
starter  ring sufficiently  deep to weaken ring. 
DO 
NOT allow  drill to enter  flywheel. 
RR1806E 
ENGINE 
3 
ST803M  
						

							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. 
7.  Heat  new ring gear  uniformly  to between 
170
°C  and  175°C, DO NOT EXCEED  higher 
temperature. 
8. Place  flywheel,  clutch side down,  on flat 3. Remove two bolts  securing  sump to bottom of 
surface.  timing cover. 
9. Locate  heated  starter ring gear in position  on 4. Remove  timing cover bolts and withdraw 
flywheel, 
with chamfered  inner diameter  cover complete  with oil pump. 
towards  flywheel  flange. 
If starter ring gear  is 
chamfered  both sides,  it can 
be fitted either 
way  round. 
10.  Press  starter  ring gear 
firmly against  flange 
until  ring contracts  sufficiently  to grip  flywheel. 
11. Allow  flywheel  to cool gradually. DO NOT 
HASTEN  cooling in any way,  distortion  may 
occur. 
12. Fit  new  clutch  assembly  location dowels to 
flywheel. 
ST804M  
						

							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 pump  cover. 
2. Withdraw  oil pump  cover. 
3. Lift off cover and remove  gasket. 
4. Withdraw  oil pump  gears. 
DISTRIBUTOR REMOVE 
1. Release  single nut securing  distributor  clamp. 
2. Remove clamp, withdraw  distributor. 
3. If necessary  overhaul distributor. 
REMOVE  ENGINE OIL COOLER ADAPTOR 
PLATE 
1. Remove  both oil cooler  pipes. 
2. Mark position of adaptor plateloil pump  cover. 
3. Remove  centre fixing and withdraw  adaptor 
plate. 
Dismantle  pump 
Refit 
5. Unscrew  plug from  pressure  relief valve. 
4. Reverse  the removal  procedure,  lining up the 6. Remove sealing washer  from plug. 
location  marks to ensure  pipe runs  are 
7. Withdraw  spnng from relief  valve. 
correct.  Ensure the pipes  and centre  fixing are 
tightened  to the  specified  torque. 
8. Withdraw  pressure relief valve.  
						

							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. 
22.  Place  new gasket  on oil pump  cover. 
23.  Locate  oil pump  cover 
in position. 
24.  Fit special  fixing bolts and tighten  to 13  Nm. 
Examine  pump 
9. Check oil pump gears for wear/scoring. 
10.  Fit oil  pump  gears and shaft  into front  cover. 
11.  Place  a straight  edge across  gears. 
12.  Check  clearance  between straight edge and 
front  cover. 
lf less than 0.05 mm,  check  front 
cover  gear recess  for wear. 
13. Check  oil pressure  relief valve  for 
wear/scoring. 
14.  Check  sides of relief  valve 
spring for wear  or 
signs  of collapse. 
15. Clean  wire screen  filter for relief  valve. 
16. Check  relief valve  is an  easy  slide fit with no 
perceptible  side movement  in its  bore. 
ST810M