Land Rover Defender Workshop Rover Manual

12ENGINE
4 REPAIR
14.
Disconnect engineharness multi-plug.
15. Remove singleboltsecuring transmission
breather pipecliptocylinder headandmove
breather pipesaside.
16.Disconnect multi-plugandvacuum pipefrom
EGR valve, iffitted.
17. Remove startermotorcoveranddisconnect
battery andfuse boxleads.
18. Remove 3retaining nutsanddisconnect exhaust
down pipe.
19. Disconnect inletandoutlet hoses frompower
steering pump.
20. Disconnect bleedhosefromthermostat housing.
21. Release bleedhosefromretaining...

ENGINE5
REPAIR
26.
Disconnect bothpipes fromfuelliftpump.
27. Release fuelfeed pipefrom retaining cliponair
cleaner bracket.
28.Disconnect vacuumhosefrombrake servo.
29.Remove oilpipes fromoilfilter adaptor. 30.
Using suitable hoist,fitchains tolifting brackets
and support engine.
31.Remove nutsandplain washers securing front
engine mountings tochassis.
32. Support gearbox.
33. Remove enginetobell housing fixings,leaving
starter motorattached toengine.
34. Carefully raiseengine torelease fromgearbox.
35....

12ENGINE
6 REPAIR
42.
Raise engine, andlocate frontengine mountings
to chassis.
43. Remove gearboxsupportandlower engine.
44. Tighten frontengine mounting tochassis fixings
to
45 Nm (33lbf/ft).
45. Release chainsfromengine liftingbrackets and
remove hoist.
46. Connect oilcooler pipestooil filter adaptor.
47. Fitvacuum hosetobrake servoadaptor.
48. Secure fuelfeed pipeinretaining cliponair
cleaner bracket.
49. Fitfuel liftpump pipes.
50. Connect feedandspill return pipestoinjector
pump.
51. Iffitted,...

ENGINE7
REPAIR
Refit
12. Lightly grease pulleyspigot andlocate pulley
onto cranshaft.
13. Fitpulley retaining bolt.
14. Fitpulley retainer LRT-12-080 andsecure with4
bolts.
15. Tighten pulleynutto
80Nm (59lbf/ft)+90°.
16. Remove pulleyretainer.
17. Fitdrive belt.
SeeELECTRICAL, Repair,
Auxiliary drivebelt;Refit
18.Fitfan cowl.See COOLING SYSTEM,Repair,
Fan cowl
19.Fitviscous coupling andfan.See COOLING
SYSTEM, Repair,Viscous coupling andfan
20.Fitintercooler toinduction manifoldhose.
21. Fitradiator...

12ENGINE
8 REPAIR
Refit
14. Fitgasket tocentre boltboss.
15. Locate newgasket andfitfront cover plateusing
fixing boltsasshown. Tighten boltsto
25Nm (18
lbf/ft).
1 -25 mm, 2-35 mm, 3-50 mm, 4-100 mm, 5-110
mm
16. Fitcrankshaft pulley.
SeeCrankshaft pulley
17.Fitdrive belt.SeeELECTRICAL, Repair,
Auxiliary drivebelt
18.Fitfan cowl.See COOLING SYSTEM,Repair,
Fan cowl
19.Fitviscous coupling andfan.See COOLING
SYSTEM, Repair,Viscous coupling andfan
20.Fitintercooler toinduction manifoldhose.
21. Fittop hose...

ENGINE9
REPAIR
NOTE:
Ifthe camshaft gearisto be
removed duringtheseoperations its
retaining boltshould beslackened before
the timing beltisremoved.
7. Slacken belttensioner bolt.
8. Remove idlerpulley.
9. Remove timingbelt.
NOTE: Ifexcessive timingbeltdebris is
evident inthe front cover, thisisprobably
due tothe misalignment ofthe front timing
cover caused byincorrect assembly ofthe fuel
injection pumpbracket.
SeeFUEL SYSTEM,
Repair, FuelInjection pump
NOTE:During use,abelt develops awear
pattern...

12ENGINE
10 REPAIR
17.
Slacken belttensioner securingbolttofinger
tight.
18. Insert 13mm square driveextension barin
tensioner plate.
NOTE:Belttensioning shouldbecarried
out using adial type torque meterhaving a
range notexceeding
60Nm (44lbf/ft).The
torque metershould beused inthe almost vertical
position.
19. Apply atension of
15Nm (11lbf/ft)foranew
belt or
12Nm (9lbf/ft)for anoriginal belt.When
tension iscorrect, tightenclampbolt.
20. Tighten injection pumpgearbolts.
21. Remove pinfrom injection...

ENGINE11
REPAIR
CRANKSHAFT
OILSEAL
Service repairno-12.21.14
Remove 1. Remove crankshaft gear.
SeeCrankshaft gear
2.Prise outoilseal from frontcover.
Refit
3. Lubricate anew crankshaft oilseal withclean
engine oil.
4. With lipside leading, driveinseal squarely using
special toolLRT-12-079 .
5. Fitcrankshaft gear.
SeeCrankshaft gear
CAMSHAFT GEAR
Service repairno-12.65.24
Remove 1. Remove camshaft drivebelt.
SeeCamshaft
drive belt
2.Remove centreboltand withdraw camshaft
gear, complete withhubandretaining...

12ENGINE
12 REPAIR
CAMSHAFT
OILSEAL
Service repairno-12.13.05
Remove 1. Remove camshaft gear.
SeeCamshaft gear
2.Remove camshaft oilseal from frontcover using
special toolLRT-12-083 .
Refit
3. Lubricate anew camshaft oilseal withclean
engine oil.
4. With lipside leading, driveinseal squarely using
special toolLRT-12-082 .
5. Fitcamshaft gear.
SeeCamshaft gear
INJECTION PUMPGEAR
Service repairno-19.30.06
Remove 1. Remove camshaft drivebelt.
SeeCamshaft
drive belt
2.Slacken 3bolts onfront ofinjector...

ENGINE13
REPAIR
FRONT
COVER GASKET
Service repairno-12.65.10
Remove 1. Remove camshaft drivebelt.
SeeCamshaft
drive belt
2.Remove crankshaft gear.SeeCrankshaft gear
3.Remove camshaft gear.SeeCamshaft gear
4.Remove injectionpumpgear.SeeInjection
pump gear
5.Remove fuelinjection pump.SeeFUEL
SYSTEM, Repair,Fuelinjection pump
6.Remove engineoilsump.See Engine oil
sump
7. Remove oilpick upstrainer.See Oilpick-up
strainer
8. Remove 10bolts securing timinggearhousing to
block.
9. Withdraw timinggearhousing...