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 clipsonfront
timing coverplate.
22.Remove splitpinsecuring innerthrottle cableto
injector pumplever.
23. Depress tagsonouter cable adjusting nut,
remove cablefrommounting bracketandmove
aside.
24. Iffitted, release handthrottle cablefrom
mounting bracketandinjector pumpleverand
move aside.
25. Disconnect feedpipeandspill return pipefrom
injector pump.      
						

							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. Ensure allrelevant connections toengine have
been removed.
36. Remove engine.
Refit 37. Clean bellhousing.
38. Apply Hylomar sealanttomating facesofbell
housing andflywheel housing.
39. Lubricate splinesofgearbox primarypinionwith
Rocol MV3.
40. Carefully lowerengine intoposition andlocate
primary pinionintoclutch andengage bell
housing dowels.
41. Fitengine tobell housing fixings.Tighten to
40
Nm (30lbf/ft).       
						

							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, reconnect handthrottle cableto
mounting bracketandinjector pump.
52. Fitouter cable adjusting nutinto injector pump
mounting bracket.
53. Fitinner throttle cabletoinjector pumpand
secure withclevis andsplit pin.
54. Secure bleedhoseinretaining clipsonfront
timing cover.
55. Fitbleed hosetothermostat housing.
56. Connect inletandoutlet hoses topower steering
pump.
57. Fitdown pipetoexhaust manifold andsecure
with 3nuts.
58. Connect startermotorbattery andfuse box
leads.
59. Iffitted, connect EGRvalve multi-plug and
vacuum pipe.
60. Secure breather pipecliptocylinder head.
61. Connect engineharness multi-plug.
62. Fitheater plugfeed wire.
63. Connect electrical feedplugatrear ofcylinder
head.
64. Fitheater hosestocylinder headandheater
rails.
65. Fitfeed pipe/hose toturbo-charger and
intercooler.
66. Fitrocker coverinsulation.
67. Fitradiator assembly.
SeeCOOLING SYSTEM,
Repair, Radiator
Ifapplicable, fitair
conditioning condenser,compressor pipesand
heater matrixhoses.
SeeAIRCONDITIONING,
Repair, Condenser
68.Fitbonnet.
69. Reconnect battery. CRANKSHAFT
PULLEY
Service repairno-12.21.01
Remove 1. Disconnect battery.
2. Drain coolant.
SeeCOOLING SYSTEM,
Repair, Drainandrefill cooling system
3.Remove tophose fromradiator.
4. Remove intercooler toinduction manifoldhose.
5. Remove viscouscoupling andfan.
See
COOLING SYSTEM,Repair,Viscous
coupling andfan
6.Remove fancowl.See COOLING SYSTEM,
Repair, Fancowl
7.Remove drivebelt.SeeELECTRICAL, Repair,
Auxiliary drivebelt
8.Fitcrankshaft pulleyretainer LRT-12-080 and
secure with4bolts.
9. Remove crankshaft pulleyretaining bolt
anti-clockwise usingsocket andsuitable long
bar.
10. Remove pulleyretainer.
11. Remove pulley,ifnecessary usingextractor
LRT-12-049 withthrust padfrom LRT-12-031 .  
						

							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 tophose.
22. Refill cooling system.
SeeCOOLING SYSTEM,
Repair, Drainandrefill cooling system
23.Reconnect battery. FRONT
COVER PLATEANDSEAL
Service repairno-12.65.01
Remove 1. Disconnect battery.
2. Drain coolant.
SeeCOOLING SYSTEM,
Repair, Drainandrefill cooling system
3.Remove tophose fromradiator.
4. Remove intercooler toinduction manifoldhose.
5. Remove viscouscoupling andfan.
See
COOLING SYSTEM,Repair,Viscous
coupling andfan
6.Remove fancowl.See COOLING SYSTEM,
Repair, Fancowl
7.Remove drivebelt.SeeELECTRICAL, Repair,
Auxiliary drivebelt
8.Remove crankshaft pulley.SeeCrankshaft
pulley
9. Remove 14bolts securing frontcover plate.Note
that top2bolts alsoretain thermostat hoseclips.
10. Remove coverplatecomplete withgasket.
11. Remove smallgasket fromcentre boltboss.
Seal replacement
12.Remove wornsealfrom cover andclean recess.
13. Support coverandfitnew seal, open sidefitted
into recess, usingspecial toolLRT-12-077 .   
						

							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 toradiator.
22. Refill cooling system.
SeeCOOLING SYSTEM,
Repair, Drainandrefill cooling system
23.Reconnect battery. CAMSHAFT
DRIVEBELT
Service repairno-12.65.18
Remove 1. Remove frontcover plate.
SeeFront cover
plate
2. Position engineatTDC onNo. 1cylinder.
3. Remove blankingplugfrom flywheel housing
and insert timing toolLRT-12-044 .
4. Engage timingtoolpinwith slotinflywheel.
5. Check correct alignment oftiming markon
camshaft gearandthatcrankshaft keyaligns
with cast arrow onhousing.
6. Insert pinfrom special toolLRT-12-045 in
injection pumpgearandthrough intopump
flange.    
						

							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 relative toits running direction, if
the original beltisto be re-used itmust be
refitted sothat itrotates inthe original direction.
Mark beltdirection ofrotation, usingsoftchalk, to
ensure correct refitment.
CAUTION: Thebeltmust bestored onits
edge onaclean surface andinsuch a
manner thatbends arenot less than 50
mm (2.0in.) radius. Donot bend beltsatan acute
angle, otherwise premature failurecouldresult. Belt
tensioner
NOTE: Thebelttensioner needonlybe
removed ifitis being replaced orfor
access purposes toremove frontcover.
10. Remove securing boltand withdraw tensioner
complete withspacer.
Refit 11. Ifnecessary, fitbelt tensioner andspacer.
Tighten fixingboltto
45Nm (33lbf/ft).
Timing beltfitting andtensioning
NOTE: Itis important thatbelttensioning
is carried outcarefully andaccurately. The
following procedure involvestensioning
the belt twice toensure thatitis equally tensioned
between eachgear. Newandoriginal beltsare
tensioned todifferent figures.
12.Ensure timingmarks arecorrectly aligned,pin
from special toolLRT-12-045 iscorrectly
inserted ininjection pumpgearandtiming tool
LRT-12-044 isfitted toflywheel housingwithpin
located inflywheel slot.
13. Fitbelt, observing rotationalmarksmadeduring
removal. Feedbeltover gears keeping ittight on
drive side.
14. Fitidler pulley.
15. Slacken injection pumpgearretaining bolts.
16. Adjust belttocorrectly sitingears.    
						

							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 pumpgear.
22. Disengage timingpinfrom timing slotinflywheel
or ring gear.
23. Rotate crankshaft oneandthree quarter turnsin
a clockwise direction;thencontinue rotationuntil
timing pinintiming toolcan beengaged withslot
in flywheel.
24. Disengage timingpin.
25. Insert pinfrom special toolLRT-12-045 in
injection pumpgearandthrough intopump
flange.
26. Slacken injection pumpgearretaining bolts.
27. Slacken tensioner andretension belt.
28. Tighten injection pumpgearretaining bolts.
29. Remove pinfrom injection pumpgear.
30. Remove timingtooland refitplug.
31. Fitfront cover plateusing newgaskets.
See Front cover plateandseal
CRANKSHAFT GEAR
Service repairno-12.65.25
Remove 1. Remove camshaft drivebelt.
SeeCamshaft
drive belt
2.Ifthe crankshaft gearcannot beremoved by
hand, usespecial toolLRT-12-078 withmain
body andthrust button fromspecial tool
LRT-12-031 ,a s illustrated .Withdraw gear
complete withOring seal.
Refit 3. Lubricate newOring seal withpetroleum jelly
and slide ontocrankshaft, takingcarenotto
damage sealonwoodruff keys.
4. Fitcrankshaft gearandtapfully home ensuring
O ring seal isproperly seated.
5. Fitcamshaft drivebelt.
SeeCamshaft drive
belt   
						

							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 plate.
Refit 3. Fitcamshaft gear.Tighten boltto
80Nm (59
lbf/ft).
4. Fitcamshaft drivebelt.SeeCamshaft drive
belt    
						

							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 pumpgear.
3. Remove specialtoolpinfrom gear.
4. Remove 3bolts andwithdraw gearandretaining
plate.
Refit
CAUTION: Itis important toensure that
when theinjection pumpislocked no
attempt mustbemade torotate it.Take
care nottoallow thecrankshaft tobe turned.
5. Fitgear andretaining plate.Tighten boltsto
25
Nm (18lbf/ft).
6.Insert pinfrom special toolLRT-12-045 in
injection pumpgearandthrough intopump
flange.
7. Fitcamshaft drivebelt.
SeeCamshaft drive
belt    
						

							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 complete with
gasket.
10. Clean allgasket material frommating faces.
Refit
11. Fitslave guide studstolocate gasket.
12. Fitnew gasket tocylinder block.
13. Align flatsonoilpump withflats oncrankshaft.
14. Fitfront cover toblock taking carenottodamage
oil seal. 15.
Secure withbolts ofcorrect lengthinlocations
where slavestuds arenotfitted, seeJ6149.
16. Remove slavestuds andfitcorrect lengthbolts.
17. Tighten allbolts to
25Nm (18lbf/ft).
1-25 mm, 2-35 mm, 3-80 mm.
18. Fitoilpick-up strainer.
SeeOilpick-up
strainer
19. Fitoilsump.See Engine oilsump
20. Fitfuel injection pump.SeeFUEL SYSTEM,
Repair, Fuelinjection pump
21.Fitinjection pumpgear.SeeInjection pump
gear
22. Fitcamshaft gear.SeeCamshaft gear
23.Fitcrankshaft gear.SeeCrankshaft gear
24.Fitcamshaft drivebelt.SeeCamshaft drive
belt