Land Rover Defender Workshop Rover Manual

							12ENGINE
14 REPAIR
ENGINE
OILSUMP
Service repairno-12.60.44
Remove 1. Disconnect battery.
2. Drain engine oil.
NOTE: Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
remove andrefit procedures arerequired, itmay
be necessary toremove theundertray and/or
integral accesspanels.
SeeCHASSIS ANDBODY, Repair, Front
undertray
orSee CHASSIS ANDBODY, Repair,
Rear undertray
3.Slacken sumpsecuring bolts.
4. Break sealant aroundsumpflange, usinga
sharp knife.
5. Remove 22bolts andwithdraw sump.
Refit 6. Clean mating facesofsump, timinggearhousing
and cylinder block.
7. Apply a2,0 mm bead ofHylosil RTV102 tothe
sump flange, ensuring beadisapplied inboard of
the bolt holes.
8. Secure sumptoblock with22bolts. Tightento
25
Nm (18lbf/ft).
9.Refill engine oil.SeeLUBRICANTS, FLUIDS
AND CAPACITIES, Information,Capacities
10.Reconnect battery. OIL
PICK-UP STRAINER
Service repairno-12.60.20
Remove 1. Disconnect battery.
2. Drain engine oil.
3. Remove engineoilsump.
See Engine oil
sump
4. Remove 2bolts securing pipesupport bracketto
main bearing capfixings.
5. Remove boltsfrompipeflanges.
6. Withdraw pick-upstrainer assembly.
Refit 7. Postion pick-upstrainer assembly, fittinganew
O ring seal atoil pump connection.
8. Apply Loctite 242Etothreads ofbolts atmain
bearing cap.Fitbolts, tighten to
9Nm (7 lbf/ft).
9. Fitbolts topipe flanges. Tightento25Nm (18
lbf/ft).
10. Fitsump.See Engine oilsump
11. Reconnect battery.   
						

							ENGINE15
REPAIR
FLYWHEEL Service
repairno-12.53.07
Remove 1. Disconnect battery.
2. Remove gearbox.
SeeMANUAL GEARBOX,
Repair, R380gearbox
3.Remove clutch.SeeCLUTCH, Repair,Clutch
assembly
4. Fit2,long, 8m m bolts intotheclutch boltholes,
as shown, touse ashandles whenliftingthe
flywheel offthe crankshaft.
5. Remove fancowl.
See COOLING SYSTEM,
Repair, Fancowl
6.Fitcrankshaft pulleyretainer LRT-12-080 and
secure with4bolts, torestrain crankshaft while
removing flywheelretaining bolts.
7. Remove boltsandliftoff flywheel.
Refit
NOTE: Toprevent excessive flywheel
run-out, ensurethatmating facesof
flywheel andcrankshaft areclean.
8. Locate flywheel oncrankshaft, removelifting
bolts, andsecure flywheel withnew patched
retaining bolts,progressively tightento
147Nm
(108 lbf/ft).
9.Check theflywheel forpossible run-outby
mounting adial test indicator withthestylus ina
loaded condition restingonthe flywheel faceata
radius of114 mm(4.50 in)from thecentre.
10. Turn flywheel andcheck thatrun-out doesnot
exceed 0,07mm(0.003 in).
11. Should run-out beexcessive, removeflywheel
and check againforirregularities oncrankshaft
and flywheel matingfacesandlocation dowel.
12. Remove crankshaft pulleyretainer.
13. Fitfan cowl.
See COOLING SYSTEM,Repair,
Fan cowl
14.Fitclutch.See CLUTCH, Repair,Clutch
assembly
15. Fitgearbox.See MANUAL GEARBOX, Repair,
R380 gearbox
16.Reconnect battery.    
						

							12ENGINE
16 REPAIR
CRANKSHAFT
REAROILSEAL
Service repairno-12.21.20
Remove
NOTE: Thecrankshaft rearoilseal is
retained inits own housing, ifthe seal
requires replacing, thecomplete housing
assembly (1)must berenewed. Housingandseal
assemblies aresupplied withtheir own
former/seal guide(2)already fitted.Thisformer
must notberemoved beforefittingtheassembly
to the engine. Ifaseal andhousing assembly is
received withoutaformer/guide fitteditmust be
returned tothe supplier. Usedformers/guides
must bediscarded immediately afteruse,under
no circumstances shouldtheybereused onother
assemblies.
NOTE: Adifferent rearoilseal housing,
with integral Oring seal andgasket, was
fitted onearlier engines. Theymust be
replaced withthecurrent housing andgasket (3)
shown below.
1.Disconnect battery.
2. Remove gearbox.
SeeMANUAL GEARBOX,
Repair, R380gearbox
3.Remove clutch.SeeCLUTCH, Repair,Clutch
assembly
4. Remove flywheel.SeeFlywheel
5.Remove 5bolts andwithdraw sealhousing,
complete withgasket.
Refit
NOTE: Theraised sideofgroove atthe
bottom ofseal housing gasketmustbe
fitted tocylinder blockface.
6.Insert slavestuds tolocate sealhousing gasket.
7. Position newgasket overslave studs and
crankshaft flangeontocylinder block.
8. Fitnew sealhousing assembly, with
former/guide in-situ,overcrankshaft flange.This
action willeject former/guide.
9. Secure assembly tocylinder block,removing
slave studs individually andinserting bolts.
Tighten to
25Nm (18lbf/ft).
10. Refit flywheel.See Flywheel    
						

							ENGINE17
REPAIR
11.
Refit clutch.
SeeCLUTCH, Repair,Clutch
assembly
12. Refit gearbox.SeeMANUAL GEARBOX,
Repair, R380gearbox
13.Reconnect battery.
CRANKSHAFT BEARINGBUSH
Service repairno-12.21.45
Remove 1. Disconnect battery.
2. Remove gearbox.
SeeMANUAL GEARBOX,
Repair, R380gearbox
3.Remove clutch.SeeCLUTCH, Repair,Clutch
assembly
4. Remove flywheel.SeeFlywheel
5.Remove bearingbush.
NOTE:Thebearing bushcanberemoved
by using oneofthe following methods.
Method 1.
Obtain ashort length ofsteel rodofadiameter having
a good slidefitin the bore ofthe bush. Packthebore
with grease andinsert thesteel rodinto theend ofthe
bore, giveasharp blowwithahammer andthe
grease shoulddriveoutthebush. Itis recommended
that thebush androdbecovered byasuitable cloth
or rag toprevent greasefromsplashing. Method
2.
Thread thebore ofthe existing bushandusing a
suitable boltextract thebush. Thoroughly cleanbush
location ensuring allswarf isremoved.
Refit 1. Fitnew bush using asuitable shouldered drift,
inserting bushflushwithendofcrankshaft.
2. Refit flywheel.
See Flywheel
3.Refit clutch.SeeCLUTCH, Repair,Clutch
assembly
4. Refit gearbox.SeeMANUAL GEARBOX,
Repair, R380gearbox
5.Reconnect battery.   
						

							12ENGINE
18 REPAIR
FLYWHEEL
HOUSING
Service repairno-12.53.01
Remove 1. Disconnect battery.
2. Remove gearbox.
SeeMANUAL GEARBOX,
Repair, R380gearbox
3.Remove clutch.SeeCLUTCH, Repair,Clutch
assembly
4. Remove flywheel.SeeFlywheel
5.Remove 3fixings andwithdraw startermotor.
6.Remove 2bolts fromtopofflywheel housing.
7. Remove 4bolts securing bottomofflywheel
housing toengine mounting brackets.
8. Remove innerboltsandliftoff flywheel housing. Refit
9. Clean rearface ofhousing andmating faceon
block, ensuring allold sealant isremoved.
10. Apply sealant toflywheel housingmatingfaceon
cylinder block.
11. Fithousing tocylinder block.Tighten retaining
bolts to
45Nm (33lbf/ft).
12. Remove surplussealantfromblock.
13. Fitstarter motor.
14. Fitflywheel.
See Flywheel
15.Fitclutch.See CLUTCH, Repair,Clutch
assembly
16. Fitgearbox.See MANUAL GEARBOX, Repair,
R380 gearbox
17.Reconnect battery.   
						

							ENGINE19
REPAIR
OIL
FILTER
Service repairno-12.60.01
Remove 1. Place draintrayunder oilfilter.
2. Unscrew filteranti-clockwise, usingastrap
wrench, ifnecessary.
Refit
3. Clean mating faceofoil filter adaptor.
4. Coat rubber sealing ringofnew filter withclean
engine oil.
5. Screw onfilter untilsealing ringtouches
machined face,thentighten afurther halfturn by
hand only.DONOT overtighten. OIL
TEMPERATURE CONTROLVALVE
Service repairno-12.60.69
Remove 1. Clean adaptor housing.
2. Disconnect oilcooler feedpipefrom thermostat
extension housingandplug toprevent ingressof
dirt.
3. Remove 2bolts andcarefully withdraw
thermostat extensionhousing(1)complete with
O ring seal (2),thermostat (3),2washers (4)
and spring (5).
4. Inspect allparts andrenew asnecessary.
Refit 5. Fitthermostat toextension housingensuring pin
locates inhole.
6. Fittwo washers andspring tothermostat.
7. Fitanew Oring toextension housing.
8. Insert spring intoadaptor andsecure extension
housing toadaptor. Tightenboltsto
9Nm(7
lbf/ft).    
						

							12ENGINE
20 REPAIR
OIL
FILTER HEADGASKET
Service repairno-12.60.03
Remove 1. Clean filterhead adaptor.
2. Disconnect oilcooler pipesandplug toprevent
ingress ofdirt.
3. Disconnect oilpressure switchlead.
4.Remove 4bolts andwithdraw filterhead,
complete withgasket.
5. Clean mating facesoffilter head andcylinder
block.
6. Fithead withnew gasket.
7. Tighten boltsto
45Nm (33lbf/ft).
8.Reconnect oilpressure switchlead.
9. Reconnect oilcooler pipes. CYLINDER
HEADGASKET
Service repairno-12.29.02
Remove 1. Disconnect battery
2. Remove bonnet.
3. Drain coolant.
SeeCOOLING SYSTEM,
Repair, Drainandrefill cooling system
4.Remove aircleaner.See FUEL SYSTEM,
Repair, Aircleaner
5.Detach crankcase ventilationvalveandside
breather hosefromrocker coverandmove to
one side.
6. Remove fuelinjectors andpipes.
See FUEL
SYSTEM, Repair,Fuelinjectors
7.Remove heaterplugs.SeeFUEL SYSTEM,
Repair, Heaterplugs
8.Disconnect radiatortophose fromthermostat.
9. Disconnect bleedhoseatthermostat.
10. Disconnect waterpump hoseatthermostat.
11. Disconnect watertemperature sensorlead.    
						

							ENGINE21
REPAIR
12.
Remove induction manifold.
SeeMANIFOLD
AND EXHAUST SYSTEM,Repair,Induction
manifold
13. Remove exhaustmanifold andturbocharger
assembly.
See MANIFOLD ANDEXHAUST SYSTEM,
Repair, Exhaust manifold
14.Disconnect heaterhosefromwater pump and
move heater railaside.
15. Disconnect heaterhosefromrearofcylinder
head.
16. Remove boltsecuring aircleaner mounting
bracket tosupport strut.
17. Remove boltsecuring harnessbracketto
cylinder head.
18.Remove rearengine liftingbracket. Thiswillalso
release clipssecuring transmission andengine
breather pipesandmulti-plug. Noteloose spacer
beneath innerclip.
19. Unscrew 3bolts, withsealing washers and
remove rockercover.
20.Remove 3nuts and2bolts andliftrocker shaft
assembly fromcylinder head.
21.Remove pushrodsandstore asan identified set
to allow refitment tosame location.
22. Remove valvestemcaps.
23.Evenly slacken andthen remove cylinder head
to block retaining boltsinthe sequence shownin
J6157. Twoofthe bolts alsosecure theair
cleaner mounting bracket.
24. Liftoffcylinder headandremove gasket.
Refit 25. Thoroughly cleanmating facesofcylinder block
and head.
26. Select newgasket ofcorrect thickness.
CAUTION: Threegaskets, ofdifferent
thicknesses, areavailable andcanbe
identified bythe number ofsmall holes
punched inthe RHside ofthe gasket. Onehole
identifies thethinnest gasket,twoholes the
middle thickness andthree holes thethickest.
When renewing agasket itmust beofthe same
thickness asthe one removed.
27. Position gasketoncylinder blockwith
identification holesonRH side andTOP
identification markuppermost.      
						

							12ENGINE
22 REPAIR
28.
Lower cylinder headontoblock ensuring correct
location withdowels.
NOTE: Cylinder headretaining boltscan
be used uptoamaximum offive times.
29. Lubricate threadsofbolts withlight oiland fitto
positions shownbelow.(Fitaircleaner mounting
bracket atpositions 6and 14).
Bolt sizes:
M10 x117mm locations 3,5,12, and 13.
M12 x140mm locations 1,2,7,8,9,10, 15,16,17,
and 18.
M12 x100mm locations 4,6,11, 14.
30. Tighten boltssothat underside ofheads just
make contact withcylinder head.
31. Following thesequence indicated,tightenall
bolts to
40Nm (30lbf/ft).
32. Attach anglegauge LRT-12-007 .
33. Make asuitable pointerfromwelding rodand
attach toabolt screwed intoarocker shaft
securing bolthole.
34. Tighten allbolts through 60°strictly insequence
illustrated.
35. Repeat 60°tightening procedure, againstrictly in
sequence illustrated.
36. Tighten the10longer bolts(M12 x140mm) a
further 20°, again following thesequence
illustrated.
NOTE: Repositioning ofthe pointer willbe
necessary toreach allbolts, thepointer
can befitted tothe rocker shaftsecuring
studs using2nuts.
CAUTION: Thedouble tightening
procedure MUSTbecarried out,onno
account shouldthebolt tightening be
performed inone operation, otherwisedamageto
the cylinder headmayoccur.
37. Fitvalve stemcaps.
38. Fitpush rodstolocations fromwhich theywere
removed.
39. Position rockershaftassembly overlocating
studs andfitretaining nutsandbolts, butdonot
tighten atthis stage.
40. Attach anglegauge LRT-12-007 .
41. Make asuitable pointerandattach toone ofthe
rocker shaftlocating studs.
42. Tighten allfixings inturn to
5Nm (4 lbf/ft).Then
tighten afurther 50°in same sequence.
NOTE: Repositioning ofthe pointer willbe
necessary toreach allfixings.    
						

							ENGINE23
REPAIR
43.
Check andadjust valveclearances.
SeeAdjustment, Valveclearances -check
and adjust
44.Fitrocker cover,ensuring oilseal issatisfactory
for continued use,andrenew ifnecessary.
45. Secure rockercoverwithspecial sealwashers
and nuts. Tighten to
10Nm (7lbf/ft).
46. Fitrear engine liftingbracket, securing breather
pipe andmulti-plug retainingclips.Tighten fixing
bolts to
25Nm (18lbf/ft).
47. Fitengine harness brackettocylinder head.
48. Secure aircleaner mounting brackettosupport
strut.
49. Connect heaterhosetorear ofcylinder head.
50. Position heaterrailand connect hosefromwater
pump.
51. Fitexhaust manifold andturbocharger assembly.
SeeMANIFOLD ANDEXHAUST SYSTEM,
Repair, Exhaust manifold
52.Fitinduction manifold.SeeMANIFOLD AND
EXHAUST SYSTEM,Repair,Induction
manifold
53. Connect watertemperature sensorlead.
54. Connect waterpump hoseatthermostat.
55. Fitbleed hoseatthermostat.
56. Connect radiatortophose atthermostat.
57. Fitheater plugs.
SeeFUEL SYSTEM, Repair,
Heater plugs
58.Fitfuel injectors.See FUEL SYSTEM, Repair,
Fuel injectors
59.Fitcrankcase ventilationvalveandside breather
hose.
60. Fitaircleaner.
See FUEL SYSTEM, Repair,
Air cleaner
61. Refill cooling system.SeeCOOLING SYSTEM,
Repair, Drainandrefill cooling system
62.Fitbonnet.
63. Reconnect battery. OIL
PUMP
Service repairno-12.60.26
Remove 1. Remove enginefrontcover.
See Front cover
gasket
2. Remove 7screws andrelease oilpump retaining
plate fromengine frontcover.
3. Mark oilpump innergearrotor, outergearrotor
and front cover housing forreassembly.
4. Check forrotor clearances:
Outer rotortohousing, 0,025-0,075 mm(0.010
- 0.030 in).
Inner rotortoouter rotor, 0,025 -0,075 mm
(0.010 -0.030 in).
Rotor endfloat, 0,026 -0,135 mm(0.010 -0.054
in).
5. Remove innerandouter rotors.
6. Check condition ofoil pump components.
NOTE: Ifthe oilpump seating inthe front
cover orretaining plateisbadly worn,
pitted orscored, anew front cover must
be fitted.
See Front cover gasket
Always renewoilpump rotors asapair.
7. Clean sealant frompump retaining plateand
front cover.