Land Rover Defender 1990 Workshop Manual

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GED

DEFENDER

90 110 130

WORKSHOP MANUAL SUPPLEMENT

Publication Number SLR 621 E N WS 1

Published by the

Technical Publications Department of

Copyright Land Rover 1990

Land Rover

Lode Land

Sol ihul I

West Midlands, 892 8NW

England

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Section

Number

INTRODUCTION

General information

Poisonous substances

Fuel Handling

Sealants

Disposal of oil and fluids

Abbreviations and symbols

Special tools

- Vehicle identification numbers

G E

E

L

SPECIFICATION DATA

Tdi engine data

Fuel system

- Cooling system

Clutch

E

GI

E TU

NIN

G

DATA

TO

QUE

WRENCH SETTING

109

RECOMMENED LUBRICANTS, FLUIDS AND CAPACITIES

- Tdi engine lubricants

Capacities

Anti-freeze

ENGINE

Camshaft - remove and refit

- including front cover oil seals/timing belt and gears

- Power steering pump bracket - remove and refit

Cylinder head

- remove and refit

Camshaft timing belt

- renew

Tdi engine - overhaul

FUEL SYSTEM

Fuel injection pump

- remove and refit

Air cleaner

- remove and refit

~ur-bo

Intercooler

- remove and refit

Page

9 - 1 2

17 - 18

- i a

17 - 18

3 2

84 a5

Section

Number

COOLI

G

SYSTEM

Engine protection

Drain and refill

Fan cowl

- remove and refit

- Fan and coupling - remove and refit

Radiator

- remove and refit

Water pump

- remove and refit

MANIFOLDS

AND

EXHAUST

157

ELECTRICAL EQUIPMENT

Page

87 a8

INTRODUCTION 01

INTRODUCTION

This Workshop Manual Supplement is designed t o assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.

Individuals who undertake their own repairs should have s o m e skill and training, a n d limit repairs t o components which could not affect t h e safety of t h e vehicle or its passengers. Any repairs required t o safety critical items such as steering, brakes, o r suspension should b e carried o u t by a Land Rover

Dealer. Repairs t o such items should NEVER b e attempted by untrained individuals.

WARNINGS and CAUTIONS are given throughout this Supplement in the following form:

WARNING: Procedures which must be followed precisely t o avoid t h e possibility of personal injury.

CAUTION: This calls attention t o procedures which must b e followed t o avoid damage to components.

NOTE: This calls attention t o m e t h o d s which make a job easier t o perform.

REFERENCES

References t o the left or right hand side in t h e supplement are made when viewing the vehicle from the rear unless otherwise stated. With the engine and gearbox assembly removed, the water pump end of the engine is referred t o as t h e front.

To reduce repetition, some operations covered in this Manual d o not include reference t o testing the vehicle after repair. It is essential that work is inspected a n d tested after completion and if necessary a road test of t h e vehicle is carried out particularly w h e r e safety related items are concerned.

DIMENSIONS

The dimensions quoted are to design engineering specification. Alternative unit equivalents, shown in brackets following the dimensions, have been converted from the original specification.

REPAIRS AND REPLACEMENTS

When replacement parts are required it is essential that genuine Land Rover parts are used.

Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories: Safety features embodied in the vehicle may b e impaired if other than Land Rover parts are fitted. In certain territories, legislation prohibits the fitting of parts not t o the vehicle manufacturer's specification. Torque wrench values given in the Workshop Manual supplement must be strictly adhered to.

Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be replaced with a new one. Certain fasteners must not b e re-used. These fasteners are specified in the Workshop Manual Supplement.

IS 0 N 0 US SUBSTANCES

Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances b e consumed and should be kept away from open wounds. These substances among others include anti-freeze, brake fluid, fuel, windscreen washer additives, air conditioning refrigerant, lubricants and various adhesives.

AS B EST0 S

WARNING: S o m e components o n t h e vehicle, such a s gaskets a n d friction surfaces (brake linings, clutch discs) may contain asbestos. inhaling asbestos dust is dangerous t o your health and t h e following essential precautions must be observed:

1 .

Work o u t of doors or in a well ventilated area and wear a protective mask.

Dust found o n the vehicle or produced during work on the vehicle should be removed by vacuuming and not by blowing.

Dust waste should be dampened, placed in a sealed container and marked to ensure safe disposal.

If any cutting, drilling etc., is attempted o n materials containing asbestos the item should b e dampened and on1 hand tools or low speed power tools used.

101

INTRODUCTION

FUEL H A N D L I N G PRECAUTIONS

The following information provides basic precautions which must be observed if fuel is t o b e handled safely. It also outlines the other areas of risk which must not be ignored.

This information is issued for basic guidance only, and in any case of doubt, appropriate enquiries should be made of your local fire station.

Fuel vapour is highly flammable and in confined spaces is also very explosive and toxic.

When fuel evaporates it produces 150 times its own volume in vapour, which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of fuel is very dangerous.

Always have a fire extinguisher containing F O A M CO GAS, o r P O W D E R close at hand when handling fuel, or when dismantling fuel systems and in areas where fuel containers are stored.

WARNING: It is imperative that the battery is not disconnected during fuel system repairs as arcing at the battery terminal could ignite fuel vapour in the atmosphere. Always disconnect the vehicle battery

BEFORE carrying out work o n a fuel system. Whenever fuel is being handled, transferred or stored, or when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any head-lamps used must b e flameproof and kept clear of spillage.

NO ONE S H O U L D BE P E R M W r E D TO REPAIR C O M P O N E N T S ASSOCIATED WITH FUEL WITHOUT FIRST

H A V I N G H A D SPECIALIST TRAINING.

HOT FUEL H A N D L I N G

Before commencing any operation requiring fuel drainage from fuel tanks, the following procedures should be adhered to. i

1. Allow sufficient time for the fuel t o cool, thus avoiding contact with hot fuels.

2. Vent system by removing the fuel cap in a well ventilated area. Replace cap until commencement of tank drainage.

FUEL TRANSFER

WARNING: Fuel must not b e extracted or drained from any vehicle while it is standing over a pit.

The transfer of fuel from t h e vehicle fuel tank must b e carried o u t in a well ventilated area. An approved transfer tank must be used according t o the transfer tank manufacturef s instructions and local regulations, including attention to grounding of tanks.

FUEL TANK R E M O V A L

A fuel vapour label should b e attached t o the fuel tank upon removal from the vehicle.

FUEL TANK REPAIR

U n d e r no circumstances should a repair t o any tank b e attempted. i. p

:’”

INTRODUCTION

101

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RECOMMENDED SEALANTS

A number of branded products are recommended in this Supplement for use during maintenance and repair work. These items include: HYLOMAR GASKET AND JOINTING COMPOUND and HYLOSIL R N

COMPOUND. They should b e available locally from garage equipment suppliers. If there is any problem obtaining supplies, contact o n e of the following companies for advice and the address of the nearest stockist.

Marston Lubricants Limited

Hylo House

Cale Lane, New Springs

Wigan, WN2 IJR

Northern Adhesives Limited

Prudhoe

Northumberland

NE42 6NP

Tel: 0942 824242

Fax: 0942 826653

Telex: 67230

Tel: 0661 32014

Fax: 0661 35839

USED ENGINE OIL HANDLING PRECAUTIONS

Prolonged and repeated contact with engine or motor oil will result in the removal of natural fats from the

-skin, leading t o dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should b e provided.

Health Protection Precautions

1. Avoid prolonged and repeated contact with oils, particularly used engine oils.

2. Wear protective clothing, including impervious gloves where applicable.

3. Do not put oily rags in pockets.

4. Avoid contaminating clothes, particularly underwear, with oil.

5. Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear.

6 . First aid treatment must be obtained immediately for open cuts and wounds.

Use barrier creams, before each work period, t o help the removal of oil from the skin.

Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help).

Preparations containing lanolin replace the natural skin oils which have been removed.

9. D

O not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing the skin.

10. If skin disorders develop, obtain medical advice.

11. Where practicable, degrease components prior t o handling.

12. Where there is a risk of eye contact, eye protection should be worn, for example, goggles or face shields; in addition an eye wash facility should b e provided.

DISPOSING OF USED OILS AND FLUIDS

Environmental protection precaution

It is illegal t o pour used oil and other fluids o n t o the ground, down sewers o r drains, or into waterways.

Dispose of used oil through authorised waste disposal contractors.

S

E CI FICATIO N

Purchasers are advised that the specification details set out in this Supplement apply t o a range of vehicles and not to any one. For the specification of a particular vehicle, purchasers should contact their Dealer.

The Manufacturers resetve the right t o vary their specifications with or without notice, and at such times and in such manner as they think fit. Major as well as minor changes may b e involved in accordance with the

Manufacturer's policy of constant product improvement.

While every effort is made t o ensure the accuracy of the particulars contained in this Supplement, neither the

Manufacturer or Dealer, by whom this Supplement is supplied, shall in any circumstances b e held liable for any inaccuracy or the consequences thereof.

INTRODUCTION

COPYRIGHT

Rover Group Ltd 1990

All rights reserved. N o part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, photocopying, recording or other means without prior written permission of

Rover Group Ltd.

SPECIAL SERVICE TOOLS

The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently, and safely. Where the use of special service tools i specified, only these tools should be used to avoid the possibility of personal injury or damage to components.

ACCESSORIES AND CONVERSIONS

Land Rover vehicles are designed and constructed for a variety of uses but no alterations or conversions should be carried out to any vehicle produced by Land Rover which could affect the safety of the vehicle or its passengers.

Land Rover has tested and approved a large number of accessories and conversions, suitable for this vehicle.

Before fitting any accessory o r commencing any conversion work to any Land Rover vehicle, CHECK that t h e accessory o r conversion is approved by Land Rover.

WARNING: DO NOT FIT unapproved accessories o r conversions, as they could affect the safety of the vehicle. Land Rover will not accept any liability for death, personal injury o r damage t o property which may occur as a direct result of fitment of non-approved accessories or the carrying out of non-approved conversions t o Land Rover vehicles.

DEFENDER

INTRODUCTION

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ABBREVIATIONS A N D SYMBOLS

Across flats (bolt size) .......................................... AF Low tension .......................................................... 1.t.

After bottom dead centre

After top dead centre

.............................. ABDC

..................................... ATDC

Alternating current .............................................. a.c.

Maximum

Metre ..................................................................... m

Millilitre

......................................................... m a .

................................................................ mi

Millimetre ........................................................... mm

Ampere

..............................................................

Ampere hour amp

................................................. amp hr

Before bottom dead centre ............................ BBDC

Before top dead centre ................................... BTDC

Bottom dead centre ......................................... BDC

Brake horse power

British Standards

............................................ bhP

................................................... BS

Miles per gallon ................................................. mpg

Miles per hour

Minute (angle)

................................................... mPh

.........................................................

Minus (of tolerance) ............................................... -

Negative (electrical) ................................................ -

Newton meters (torque) .................................... Nm

Carbon monoxide

Centimetre

.............................................. C O

.......................................................... cm

Centigrade (Celsuis) .............................................. C

Cubic centimetre ................................................ cm3

Cubic inch ............................................................ in3

Degree (angle) ........................................... d e g or

Degree (temperature) ................................. deg or

Diameter ............................................................. dia.

Direct current ..................................................... d.c.

Electronic Control Unit ................................... E.C.U.

Electronic Fuel Injection ................................... E.F.I.

Fahrenheit

Feet

............................................................... F

....................................................................... ft

Feet per minute ............................................... ft/min

Fifth

First

..................................................................... 5th

...................................................................... 1st

Fluid ounce ....................................................... fl oz

Foot pounds (torque) ........................................ ft Ib

Fourth .................................................................. 4th

Gramme (force)

.....................................................

Gramme (mass)

......................................................

Gallons

................................................................

Gallons (US) g f g gal

.................................................. US gal

High tension (electrical)

Internal diameter

.................................... H.T.

................................................ I.D.

Inches of mercury .......................................... in. Hg

Inches .................................................................... in

Kilogramme (force)

.............................................. kg f

Kilogramme (mass.)

.............................................. kg

Kilogramme centimetre (torque) ................... kgf.cm

Kilogramme per square millimetre ............... kgf/mm2

Kilogramme per square centimetre .............. kgf/cm2

Kilogramme metres (torque) ........................... kgf.m

Kilometres ........................................................... km

Kilometres per hour ......................................... km/h

Kilovolts ................................................................ kV

Left-hand steering .......................................... LHStg

Left-hand thread ............................................ LHThd

Litres ................................................................... litre

Number .............................................................. N o .

Ohms ............................................................... ohm

Ounces (force) .................................................... ozf

Ounces (mass) ...................................................... oz

Ounce inch (torque) ...................................... ozf.in.

Outside diameter

Percentage

............................................. O.D.

Part number ................................................. Part N o .

............................................................ %

Pints

.....................................................................

Pints (US)

........................................................ US pt

Plus (tolerance) ..................................................... +

Positive (electrical) ................................................ +

Pound (force) ....................................................... Ibf

Pounds inch (torque) ...................................... in.lbf.

Pound (mass) ......................................................... Ib

Pounds per square inch .................................... P.S.I.

Ratio ........................................................................

Reference ........................................................... ref.

Revolution per minute ..................................... r.p.m

Right-hand ........................................................... RH

Second (angle) .......................................................

Second (numerical order) ................................... 2nd

Specific gravity ................................................ sp.gr.

Square centimetres ............................................. cm2

Square inches ....................................................... in2

Standard wire gauge ....................................... s . w . ~ .

Synchroniser/Synchromesh ......................... synchro.

Third ................................................................... 3rd

Top dead centre ................................................ TDC

United Kingdom .................................................. UK

Vehicle Identification Number ............................

VIN

Volts ...................................................................... v

Watts .................................................................... W

SCREW T H READS

American Standard Taper Pipe .......................... NPTF

British Standard Pipe ........................................... BSP

Unified Coarse

Unified Fine

................................................. UNC

....................................................... U N F

6 loll

INTRODUCTION

Special Service Tools

The use of approved special service tools is important. They are essential if service operations are t o be carried o u t efficiently, and safely. Where special tools are specificed, only these tools should be used to avoid the possibility of personal injury or damage to the components. Also the amount of time which they save can be considerable.

Every special tool is designed with the close co-operation of Land Rover, and n o tools is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried o u t using existing tools o r standard equipment. The user is therefore assured that the tool is necessary and that it wilt perform accurately, efficiently and safely.

Special tools bulletins will be issued periodically giving details of new tools as they are introduced.

All orders and enquiries from the United Kingdom should be sent direct t o V. L. Churchill. Overseas orders should b e placed with the local V. L. Churchill distributor, where o n e exists. Countries where there is n o distributor may order direct from V. L. Churchill Limited, PO Box 3, Daventry, Northants, England, N N I 1 4 N F .

The tools recommended in this Workshop Manual Supplement are listed in a multi-language illustrated catalogue obtainable from Messers. V. L. Churchill at the above address under publication number VLC

23721187 or from Land Rover Merchandising Service, quoting publication number SMR 681 MI, PO Box 534,

Erdington, Birmingham, 624 OQ5.

DEFENDER

LOCATION OF VEHICLE IDENTIFICATION & UNIT NUMBERS

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VEHICLE IDENTIFICATION NUMBER (VIN)

The Vehicle Identification Number and the recommended maximum vehicle weights are stamped o n a plate riveted t o the top of the pedal box behind the brake servo

The number is also stamped on the right-hand side of the chassis forward of the spring mounting turret.

Always quote this number when writing t o Land

Rover.

ST3067M

PAINT

The Vehicle Identification Number identifies the manufacturer, model range, wheel base, body type, engine, steering, transmission, model name and place of manufacture. The following example shows the coding process.

SAL World manufacturer identifier

LD Land Rover

C Class 100 inch

Class

90 inch

Class

110 inch

A Basic

B 2 d o o r

M 4 d o o r

H High Capacity

F Tdi o r

5 speed LHD o r

5 speed RHD

H 1991 MY

A Solihull site

ENGINE SERIAL NUMBER

Tdi ENGINE

The engine number is stamped o n the cylinder block o n the right hand side of the engine above the camshaft front cover plate. Commencing Serial

Number IIL 00001.

A. Type approval

B. VIN (minimum of 17 digits)

C. Maximum permitted laden weight for vehicle

D. Maximum vehicle and trailer weight

E. Maximum road weight

- front axle

F. Maximum road weight

- rear axle

LOCATION OF VEHICLE IDENTIFICATION & UNIT NUMBERS

MAIN GEARBOX LT77

5 SPEED

The serial number is stamped o n a cast pad on the bottom right hand side of t h e gearbox.

-------

. RR1513M

TRANSFER GEARBOX LT230

The serial number is stamped o n the left hand side of the gearbox casing below the mainshaft rear bearing housing adjacent to the bottom cover.

FRONT A N D REAR AXLES

Serial number is stamped o n t o p of the left hand axle tube.

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S P

CIFICA

ION DA

I04

Tdi

ENGINE

Type ................................................................................. Direct injection, turbocharged, intercooled

Number of cylinders ......................................................... 4

Bore .................................................................................. 90,47 mm (3.562 in)

Stroke ............................................................................... 97,OO mm (3.822 in)

Capacity ............................................................................ 2495 cc

Compression ratio ............................................................ 19.5:l + - 0.5:l

Valve operation ................................................................ O.H.V. pushrod operated

Turbo charger ................................................................... Carrett T25

Crankshaft

Main journal diameter

Regrind dimensions

...................................................... 63,475

.......................................................... 63,2333

63,487 mm (2.499

2.4993 in)

2.490 in)

Crankpin journal diameter

Use 0.010'in U/S bearings

................................................ 58,725 - 58,744 mm (2.312

Regrind dimensions .......................................................... 58,4708 .

2.31275 in)

. in)

Crankshaft e n d thrust

Crankshaft e n d float

.......................................................

Use 0.010 in U/S bearings

Taken o n thrust washers

......................................................... 0,05 . of centre main bearing

- 0.006 in)

Main bearings

Number and type ............................................................. 5 halved shells with oil grooves

Diametrical clearance ........................................................ 0,0792

0,0307 mm (0.0031 - 0.0012 in)

Connecting rods

Length between centres ................................................... 175,38

175,43 mm (6.905

6.907 in)

Diametrical clearance (big-end bearings) .......................... 0,025

End float o n crankpin ....................................................... 0,15

0,356 mm (0.006 . 4 in)

Pistons

Type .................................................................................

Skirt diametrical clearance

Aluminium alloy, combustion chamber in crown

(at right angle t o gudgeon pin ......................................... 0,025 . mm (0.001 .

Maximum height above combustion face ........................ 0,8 mm (0.031 in)

Gudgeon pins

Type ................................................................................. Floating

Fit in piston ...................................................................... Hand push in

Diameter ........................................................................... 30,1564 - 30,1625 mm (1.1

Clearance in connecting rod ............................................ 0,0036

7 . 1 8750 in)

0,0196 mm (0.00014

0.00077 in)

Pistons rings

Type

. ................................................................................ Chamfered friction edge, chrome plated

Second ........................................................................... Taper faced control ..................................................................... Expander ands rails

Cap in bore:

- Top ................................................................................ 0,40

- Second

. mm (0.0157

........................................................................... 0,30 - 0,50 mm (0.0118

0.0196 in)

Oil control ..................................................................... 0,3

0,6 mm (0.011 . in)

Clearance in piston grooves:

................................................................................ 0,167 .

0.0091 in)

........................................................................... 0,05 control ..................................................................... 0,05

0,08 mm (0.0019 .

. mm (0.0019 .

GENERAL SPECIFICATION DATA

Camshaft

Timing Belt

Location

.......................................................................

...........................................................................

End float ...........................................................................

Number of bearings

Material

.........................................................

............................................................................

Valves

30 mm (1.2 in dry toothed belt

Right hand side (thrust side)

0 , l

0,2 mm (0.004

0.008 in)

Steel shell, white metal lined

Tappet clearance:

. ............................................................

Seat angle:

. ................................................................................

Exhaust ...........................................................................

Head diameter:

. ................................................................................

...........................................................................

Stem diameter:

. ................................................................................

Exhaust ...........................................................................

Valve lift:

................................................................................

...........................................................................

Cam lift

................................................................................

...........................................................................

Valve head stand down

- Inlet and exhaust ............................................................

Valve spring length fitted .................................................

0,20 mm (0.008 in)

30"

39,35

39,65 mm (1.549

1.560 in)

36,35 - 36,65 mm (1.431

1.443 in)

7,960

7,975 mm (0.313

0.314 in)

7,940

7,960 mm (0.212

0.313 in)

9,93 mm (0.401 in)

10,26 mm (0.404 in)

6,81 mm (0.268 in)

7,06 mm (0,278 in)

0,9

1,l mm (0.035

0.040 in)

40,4 mm (1.590 in) at pressure . Ib) lubrication

System ..............................................................................

Pressure, engine warm at normal operating speeds ..................................................

Wet sump, pressure fed

25- 55 p.s.i. (1.76

3.86 kgf/cm2)

Oil pump:

Type ...............................................................................

Drive ..............................................................................

- End float of both gears ..................................................

- Radial clearance of gears ................................................

Backlash or gears ...........................................................

Oil pressure relief valve ....................................................

Double gear 10 teeth, sintered iron gears

Splined shaft from camshaft skew gear

0,026

0,135 mm (0.0009

0.0045 in)

0,025

0 , l

0,075 mm (0,0034

0.0067 in)

0,2 mm (0.0034

0,0067 in)

Non-adjustable

Relief valve spring:

Full length ......................................................................

- Compressed length at 2.58 kg (5.7 Ib) load ..................

Oil filter ............................................................................

Engine oil cooler ..............................................................

67,82 mm (2.670 in)

61,23 mm (2.450 in)

Screw-on disposable canister

Combined with coolant radiator and intercooler

(-?$

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48B DEFENDER

GENERAL SPECIFICATION

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FUEL

SYSTEM

Tdi Engine injection pump type ......................................................... Bosch rotary VE4/11 F (see section 05) injection pump timing ...................................................... see section 05 injectors ........................................................................... see section 05

Heater plugs ..................................................................... see section 05

Fuel lift pump type ........................................................... Mechanical with hand primer

Fuel lift pump pressure ..................................................... 42

55 kpa at 1800 rpm

Fuel filter .......................................................................... Paper element in disposable canister

Air cleaner ........................................................................ Paper element type

Turbo charger ................................................................... Carrett T25 (see section 05)

COOLING

SYSTEM

Tdi engine

System type ...................................................................... Pressurised, spill return, thermostatically controlled water and anti freeze mixture. Pump assisted

Cooling fan thermosyphon. Coolant radiator combined with oil cooler and turbo intercooler.

...................................................................... 7 blade axial flow 395 m m diameter. 1.1:l drive ratio. Viscous coupling.

Pump type ........................................................................ Centrifugal, impellor, belt driven.

Thermostat opening ......................................................... 88°C

Expansion tank cap pressure ............................................ 15 p.s.i. (system pressure)

CLUTCH

Tdi engine

Type ................................................................................. Valeo iaphragm spring

Centre plate diameter ...................................................... 235 mm (9.25 in)

Facing material .................................................................. Verto F202 grooved

Number of damper springs

Damper spring colour

.............................................. 8

...................................................... 2 off white/green

2 off pigeon blue

- suffix 'C'

- suffix 'A'

4 off ruby red - suffix 'B'

Eelease bearing ................................................................ Ball journal

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ENGINE TUNING DATA

105

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Tdi ENGINE TUNING DATA

ENGINE

Firing order ....................................................................... 1-3-4-2 injection pump timing ...................................................... 1,54 mm lift at T.D.C.

Timing marks:

Valve timing ...................................................................... Slot for peg in flywheel and TDC mark o n front injection timing pulley

................................................................ Statically timed with special tool inserted in Bosch pump hub

Tappet clearances inlet and exhaust ................................. 0,20 mm (0.008 in) cold

Valve timing: inlet

............................................................................ 16" B.T.D.C.

............................................................................ 42" A.B.D.C.

............................................................................... 103" A.T.D.C.

.................................................................................. 9,93 mm (0.401 in)

Exhaust

51" B.B.D.C.

13" A.T.D.C.

109" B.T.D.C.

10,26 mm (0.404 in)

Maximum governed speeds:

. load (flight speed)

....................................... 3800 r.p.m.

.................................................... 4100 .

.. Idle speed ...................................................................... 780 . rpm

INJECTION PUMP

Makeltype ......................................................................... Bosch rotary VE 411 1 F 1900R 347-1 Type with boost control and negative mechanical torque control.

Two speed mechanical governor with speed advance and solenoid electrical shut-off. Tamper proof sealing on flight speed and fuel adjustment

Peak pumping pressure screws

Direction of rotation ........................................................ Clockwise, viewed from drive end

Advance box (single stage) .............................................. 9" advance (7.38 mm)

.................................................... 650 bar

INJECTORS

Makeltype ......................................................................... Bosch two spring (04321 93879 assembly number)

Nozzle sizeltype ............................................................... DSLA 145P208

Nozzle holder ................................................................... KBEL 98 P52

Opening pressure (working pressure) .............................. initial pressure 200 atmospheres

Secondary 280 atmospheres injector pipe type ............................................................. Guido high pressure cold drawn steel

Injector pipe size .............................................................. 1,8 mm dia. Length 490 mm

HEATER PLUGS

Makeltype ......................................................................... Probe type, Beru 11 volts

Time to reach operating temperature of 850°C ............... 8 seconds

TURBOCHARGER

Makeltype ......................................................................... Carrett T25

Maximum boost pressure ................................................. 0.82 bar (12 P.S.I.C.) measured at wastegate actuator 'T' piece

Fuel specification .............................................................. Diesel 852869 (certain levels down to 45 with adjustment

Tdi ENGINE

Bearing cap to cylinder block

Clutch cover plate t o flywheel

...................................

Camshaft thrust plate to cylinder block ....................

.................................

Connecting rod to cap .............................................

Dipstick tube assembly to cylinder block .................

Dipstick mounting bracket to inlet manifold ............

Earthing strap stud t o cylinder block ........................

Engine mounting foot to cylinder block ...................

Housing flywheel t o cylinder block ..........................

Flywheel t o crankshaft ..............................................

Ladderframe to cylinder block ..................................

Oil filter adaptor to cylinder block

Oil pressure switch

...........................

...................................................

Oil pump cover t o pump body ................................

Oil pump relief valve plug

Oil pump to cylinder block

........................................

......................................

Oil pump strainer t o oil pump .................................

Oil squirt jet assembly to cylinder block

Oil strainer t o mounting bracket

..................

..............................

Plug

- blanking oil gallery .........................................

- drain oil sump ................................................

Plug

........................................

- drain flywheel housing ...................................

.......................

Side cover t o cylinder block .....................................

Starter motor to flywheel housing ............................

Sump t o ladderframe ................................................

Sump to ladderframekylinder block .........................

Sump to cylinder blocUfront cover ..........................

Support brackets

- exhaust manifold to cylinder block ........................

Vacuum pump to cylinder block ..............................

Vertical drive shaft gear to cylinder block ................

Alternator and heat shield to mounting bracket .......

Adjusting link to alternator .......................................

Adjusting link to pas pump plate ..............................

Cylinder head to cylinder block ...............................

Breather cylcone to rocker cover .............................

Engine lifting bracket to cylinder head .....................

Electrical hamess clip to cylinder head .....................

Exhaust manifold to cylinder head

Glow plug terminal n u t

...........................

............................................

Glow plug to cylinder head ......................................

Heater stud (water) to cylinder head ........................

Injector clamp stud t o cylinder head ........................

Injector clamp t o injector nut ...................................

Inlet manifold t o cylinder head ................................

Rocker cover t o cylinder head ..................................

Rocker shaft t o cylinder head ...................................

Tappet adjusting nut .................................................

Thermostat housing to cylinder head .......................

Water outlet t o thermostat housing water temperature switch to

......................... thermestat heusing ....

Cowl mounting bracket to front cover .....................

Fan assembly to water pump hub ............................

Front cover plate t o cylinder block ..........................

Front cover plate t o front cover

Front cover to cylinder block

...............................

................................... injector pump t o front cover ...................................

Injector pump stud to front cover ............................

T n

O

R Q

U

E W

RE

N C

H

106

Nm

130 .136

7 - 1 0

30 . 3 8

56 . 6 2

22 . 2 8

7 - 1 0

21 . 3 0

80 .90

40 . 5 0

139 .153

22 . 2 8

40 . 5 0

1 5 .19

20 . 2 8

27 . 3 3

22 . 2 8

40 . 5 0

14 . 2 0

22 . 2 8

32 . 4 2

40 . 5 0

10 . 1 4

23 . 2 7

23 . 3 0

40 . 5 0

22 . 2 8

20 . 2 4

22 . 2 8

See section 12

7 - 1 0

22 . 2 8

22 . 2 8 '

20 . 2 6

3 - 5

15 . 3 0

1 5 . 3 0

6 - 1 0

20 . 2 5

20 . 2 6

3, 5 . 5

28 . 3 2

22 . 2 6

22 . 2 8

7 . 1 0

75 . 7 3

6 - 1 0

Tdi ENGINE (continued)

Injector pump t o support bracket ............................

Tensioner (timing belt) t o cylinder block

Timing pulley t o camshaft

.................

........................................

Timing pulley t o injector pump hub ......................... lV damper pulley t o crankshaft ................................

Water p u m p t o cylinder block

Water pump t o cylinder block

..................................

- stud .......................

Water p u m p t o front cover

Oil

...................................... drain adaptor t o cylinder block

Turbo ..............

Oil drain pump t o turbo ...........................................

Oil feed pipe adaptor t o cylinder block ......

Oil feed pipe t o turbo ..............................................

Outlet elbow t o turbo

- nut .....................................

Outlet elbow t o turbo

- stud ...................................

Turbocharger t o exhaust manifold ...........................

Belt tensioner assembly t o front cover plate compressor ...............................

Compressor t o mounting bracket

Compressor mounting bracket t o front cover and plate

............................

...........................................

Banjo bolt - fuel pump

Banjo bolt

.............................................

- boost pipe ............................................

Banjo bolt

- spill rail .................................................

- fuel filter ...............................................

- injector spill rail ....................................

Fuel lift pump t o fuel filer unions .............................

Fuel lift pump t o cylinder block ...............................

Injector pipes t o injectors and injector pump ..........

P.A.S. p u m p t o mounting plate ................................

P.A.S.

P.A.S. p u m p mounting plate t o front cover p u m p pulley to hub

.............

.......................................

Tappet guide retaining screw ...................................

N m

22 . 2 8

40 . 5 0

22 . 2 8

333 . 3 5 0

23 . 3 0

23 . 3 0

22 . 2 8

32 . 4 8

22 . 2 8

15 . 2 2

21 . 2 6

22 . 2 8

21 . 2 6

14 . 1 6

40 . 5 0

10 . 1 4

20 . 3 0

14 . 2 0

10 . 1 4

22 . 2 8

22 . 2 5

14 . 1 6

22 . 2 8

14 . 1 6

13 . 1 5

(!?:

..... :

& . ~

...% i

,:;-

. .,.. -

;:.!!

. ,..

,w>;:.

+ -

RECOMMENDED LUBRICANTS, FLUIDS A N D CAPACITIES

109

ENGINE OIL

Tdi ENGINES

The minimum performance level oil required for satisfactory engine performance and protection is defined by specifications BLS 22.0L.09 and CCMC PD1.

The engine oil and filter must b e changed every 10,000 km (6000 miles) and it is important that only oils listed below, or clearly marked as meeting the required specification, should b e used. Superior engine protection can b e obtained by the use of Super High Performance Diesel (SHPD) oils t o specification CCMC D3. Some of t h e oils meeting the above specifications are listed below:-

Oils to

BLS

22.OL.09tCCMC PD1

Agip Superdiesel or Sint Turbo Diesel

Vanellus C3 or Visco Diesel

Caltex RPM Delo 400*

Castrol Syntron X, TXT, or GTX

Century Superb

Duckhams QXR or Hypergrade

Esso Superlube EX 2, Superlube

Super Oil

+, Ultra Oil or

Gulf Super Diesel or Engine Oil T

Mobil Delvac Super, Mobil 1 Rally Formula o r Mobil

1 Formula 15Wl50

Kuwait Q8 Auto-4 or Q8 Auto-7

Shell Rimula X or Rotella MTX

Texaco Dieseltex

SHPD oils t o CCMC D3

Agip Sigma Turbo

BP Vanellus C3 Extra

Castrol Turbomax

Century Centurion

Caltex RPM Delo 450

Duckhams Fleetmaster SHPD o r Fleetmaster Extra

Elf Multiperformance 4D

Esso Super Diesel Oil TD o r Special Diesel Oil

Fina Kappa LDO

Gulf Superfleet Special

Mobil Delvac 1400 Super

Texaco Ursa Super TD

Shell Myrina

Total Rubia TIR or Total Diesel

Silkolene Turbolene D

In markets where oils t o the above specifications are not available use products t o MIL-L-2104D or API CD.

Under severe operating conditions, eg. off road in mud, airborne sand, dust, operating at high speeds in high ambient temperatures above 40°C or continual stoptstart operation, the oil and filter change period should not exceed 5000 km (3000 miles). Continuous off road operation in mud, dust and wading conditions requires a monthly oil and filter change. Failure t o adhere t o the recommended service and operating instructions may result in premature engine wear or damage.

Oil Viscosity

Ambient Temperatures Applications Chart

SPECIFICATION I

!jAE

v'scos'Ty

AMBIENT TEMPERATURE "C I

-30" -20" -10" 0" 10" 20" 30" 40" 50"

Oils must meet

BLS.22.OL. 09 or

CCMC PD1 or

CCMC D3

5Wf30

5Wi40 )

5Wt50 1

1 Owl30

10Wi40 )

10W150 )

15Wl40 )

15Wt50 )

20Wf40 )

1 7

CAPACITIES

The following capacity figures are approximate and are provided using the dipstick or level plugs as applicable. as a guide only. All oil levels must b e set

Engine sump oil ................................................................ 6,OO litres (10.56 pints)

Extra when filling following new filter .............................. 0,85 litres (1.50 pints)

Transfer box oil ................................................................ 2,30 litres (4 pints)

Cooling system ................................................................ 11,lO litres (20 pints)

Anti-freeze

Ethylene Glycol based anti-freeze (containing n o methanol) with non-phosphate corrosion inhibitors only are suitable for use in Tdi engines t o ensure protection of t h e cooling system against frost and corrosion. N o inhibitors should be used. Only anti-freeze, summer and winter even in climates where anti-freeze is not necessary.

O n e part anti-freeze, o n e part water, i.e. 50% anti-freeze in coolant. Complete protection below -36°C.

See cooling system section 26 for engine protection information.

... ..

. .

, .

...

. ,

ENGINE

11 2

..._

. . . . .

ENGINE

CLUTCH AND FLYWHEEL HOUSING

COMPONENTS ST3066M

LAND ROVER Tdi e n g i n e

I . Clutch housing

Bell housing stud (9)

Starter motor stud (1)

Allen bolts (4)

5. Plug (2)

6. Screw housing t o block (6)

Washer (6)

Bolt housing t o block (2)

9. Spring washer ( 2 )

10. Bracket ( 2 )

11. Harness clip ( 2 )

12. Oil seal

13. Flywheel

14. Starter ring

15. Reinforcing plate

16. Bolt flywheel t o crank

17. Clutch cover

18. Clutch plate

19. Dowel

20. Screw

21. Spring washer

$"'!

...

..,

-->"d

DEFENDER

ST3066M

ENGINE 12

12 ENGINE

SUMP AND OIL PUMP COMPONENTS ST3065M

LAND ROVER Tdi engine

1. Sump

Drain plug

Joint washer

4. Flange bolt M8x20 (8)

5. Flange bolt M8x60 (1 2)

6. Oil pump housing lower

7. Oil pump housing upper

8. Dowel

9. Oil pump gears

10. Spindle

11. Screw

12. Spring washer

13. Support bracket

14. Screw

15. Lock washer

16. Casket

17. Filter

18. 0 ring

19. Lock washer

20. Screw

21. Spring washer

22. Plain washer

23. Drive shaft

24. Oil relief plunger

25. Spring

26. Joint washer

27. Oil relief plug

DEFENDER

.._

, I .

,..

-DEFENDER

ST3065M

24 \

ENGINE

FRONT COVER COMPONENTS ST3064M

LAND

ROVER Tdi engine

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

10.

11.

12.

13.

14.

15.

1. Viscous unit

Fan assemb!y

Bolt (4)

Plain washer (4)

Pulley

Screw (4)

Spring washer (4)

Water pump assembly

16.

17.

7 8.

Gasket

Flange bolt M8x85 (2)

Flange bolt M8x75 (1)

Flange screw M8x35 (3)

Stud M 8

Flange nut M 8

By pass hose

Hose clip

Crank pulley

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

Flange bolts (4)

Crank pulley bolt

Washer

Torsional vibration damper

Inspection plate

Gasket

Flange screw M6x20 (3)

Front cover plate

Gasket

Cover plate seal

Flange screw M8x25 (3)

Flange bolt M8x100 (2)

Flange bolt M8x70 (2)

Flange bolt M8x75 (3)

Flange bolt M8x50 (1)

Front cover

Front cover gasket

Front covedwater inlet gasket

43.

44.

Front cover dowel

Flange screw M8x20 (2)

Flange bolt M8x65

Crankshaft oil seal

Camshaft oil seal

Gasket

- centre bolt

- block front face

Plug

Timing belt

Timing belt tensioner assembly 45.

46.

47.

48.

49.

50.

Slotted washer

Flange bolt M10x70

Tensioner pivot pin

Crankshaft gear wheel

Camshaft gear wheel

51. Bolt

52. Washer

53. 0 ring

54. Retaining plate

55. 0 ring

56.

57.

Injection pump timing gear

Flange screw (3)

58.

59.

Retaining plate

Nut

60.

61.

Spring washer (3)

Stud injection pump t o front cover (3)

DEFENDER

ENGINE

11 2

12 ENGINE

CYLINDER BLOCK COMPONENTS ST3063M

LAND

ROVER Tdi engine

1. Oil filter element

2. Oil filter adaptor

Gasket

Screw (2)

Spring washer (2)

Oil cooler adaptor

Thermostat bulb

10.

0 ring

Spring

Washer

11. Screw (2)

12.

13.

Washer (2)

Oil pressure switch

14.

15.

16.

17.

18.

19.

Copper washer

Blanking plug

Skew gear

Dowel pin

Bush

Locking screw

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

50.

51.

0 ring

Snap ring

- external

Deep groove bearing

Snap ring

0 ring

- internal

- bearinghousifig

Bearing housing

Rear side cover

Casket

Dowel

- flywheel housing (2)

Socket screw (2)

Washer (2)

Flange bolts (6)

Froct side cover breather

Gasket

Baffle plate

Screw No.6 (2)

Flange bolt M8x40 (1)

Flange screw M8x25 (5)

Cylinder block

Pushrod

Tappet slide

Roller follower

Tappet guide

Set bolt

Washer

Camshaft

Locking plate

Screw (2)

Spring washer (2)

Camshaft bearing

- front

Camshaft bearing

- interhear (3)

Camshaft key

52.

53.

54.

55.

56.

57.

Piston

Piston rings

Gudgeon pin

Circlip (8)

Connecting rod

Gudgeon pin bush

58.

59.

60.

67.

68.

69.

70.

71.

Connecting rod bolt

Big end bearing

Big end bearing cap

Connecting rod nut 61.

62. Crankshaft

63. Crankshaft main bearing

64. Main bearing cap

- rear

65. Main bearing cap - centre

66. Thrust washers

Main bearing cap (3)

Main bearing cap bolt

Crankshaft key

Crankshaft dowel

Crankshaft bush

72.

73.

77.

Packing strip let adaptor

74. joint washer

75. Dowel

76. Joint washer

Relief vaive assembly

78.

79.

Drain plug joint washer

80.

81.

82.

83.

Dipstick tube

Dipstick

Oil gallery plug c u p plug (5)

84.

85.

86.

87.

88.

89. c u p plug

Oil gallery plug

Camshaft oil feed plug (3)

Ring dowel (2)

Oil feed adaptor

Oil drain adaptor

90. Ladder frame

91. Flange bolt M8x125 (3)

92. Flange bolt M8x60 (4)

93. Flange screw M8x30 (3)

- .

ENGINE

ST3063M

12 ENGINE

CYLINDER HEAD COMPONENTS ST3062M

LAND

ROVER Tdi engine

1. Oil filler cap

Rocker cover

Rocker cover gasket

Flange headed bolt

Washer

Sealing washer

Breather cyclone

Flange headed screw

Rocker shaft bolt (3)

Rocker shaft bolt (2) 10.

16. -

17.

18.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

45.

46.

47.

48.

49.

50.

11.

12.

13.

14.

15.

19.

20.

21.

Rocker arm RH

Rocker arm LH

Rocker arm bush

Tappet adjuster screw

Locknut

Rocker shaft

Rocker shaft spacer

Rocker shaft spring

Rocker shaft clamp

Rocker shaft seal

38.

39.

40.

41.

42.

43.

44.

Exhaust manifold

Manifold stud

- exhaust

Self locking nut

Plair; washer

Stud turbocharger mounting

Inlet manifold

Manifold stud

- inlet

Flarlge nut

Manifold gasket

Engine lifting brackets

Cylinder head

Cylinder head gasket

Head bolts M12 short (4)

Head bolts M 1 2 long (10)

Head bolts M10 (4)

Adaptor cooling system

Ring dowel

Valve

- inlet

Valve seat insert

Valve

- exhaust

Valve seat insert

Valve guide

Valve stem seal

Valve spring seat

Valve spring

Valve spring cup

Split cotters

Injector

Injector clamp

Injector clamp nut

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

71.

Injector clamp stud

Injector clamp dowel

Injector sealing washer

Spill return pipe

Banjo bolt 6mm

Copper washers

Glow plug

Glow plug cable

Nut and washer

Thermostat housing

Casket

Flange screw (3)

Thermostat

Gasket

Thermostat housing cover

Flange bolt M6x40 (3)

Thermal transmitter

Joint washer

Flange bolt

Cup plug (1)

Cup plug (2)

121

ENGINE

The following list of operations can be carried out with the engine installed using the appropriate sections of the ENGINE OVERHAUL PROCEDURE.

OPERATION

Cylinder Head

Heater plugs injectors

Rocker cover

Rocker shaft

Removing cylinder head

Front cover oil seals/timing beltlcamshaft

Water pump

Front cover plate or seal

Front pulley damper

Front cover plate

Removing timing belt

Removing timing belt gears

Removing injection pump

Removing front cover

Vacuum pump/skew gear/bush/oil filter adaptor

Fuel pump and side cover

Front side cover plate

Cam followers

Removing camshaft

Sump and oil pump

Removing oil pump

Remove

Page

Overhaul

Page

Refit

Page

62 - 66

The foregoing list of remove and refit operations are those which can be carried-out with t h e engine in t h e vehicle. Cross reference, where necessary, is made to thr relevant instructions in the engine overhaul procedure 12.41.05. Each operation is numbered with the appropriate Repair Operation Time Contained in publication SMR 670 EN RT A91.

OPERATION Number Page

Cams haft

Power steering pump bracket

Cylinder head

Fuel

Air injection pump cleaner

Turbo charger

Inter Cooler

Cooling system

Fan cowl

Fan and coupling

Radiator

Water pump

Exhaust and inlet manifolds

Power steering pump

Altemator

12.1 3.02

72.35.22

12.29.02

19.30.07

19.10.01

19.42.01

19.42.1 5

26.1 0.01

26.25.1 1

26.25.1 9

26.40.01

26.50.01

30.1 5.01

57.20.14

86.1 0.02

ENGINE 12

.:'

.....

. .

...

CAMSHAFT

Service Repair No. 12.13.02.

Remove and refit

1. Remove the bonnet and disconnect the battery.

2. Disconnect the radiator bottom hose and allow

3. the coolant t o drain and reconnect the hose.

Remove the radiator top coolant hose,

4. Remove the fan and viscous coupling assembly, see operation 26.25.1 9. instructions

4 t o 7.

5. Remove the fan cowl.

6. Remove the radiator, s e e operation 26.40.01. instructions 3 t o 5 and 7 t o 8.

7. Remove the air cleaner, see operation

19.1 0.01. instructions 1 t o 5.

8. Remove the alternator, see operation 86.10.02. instruction 5 t o 9.

9. Remove the power assisted steering p u m p bracket, see operation 12.25.22 instructions 4 t o 9.

10. Remove the air conditioning compressor, where fitted, and t h e mounting bracket together with the platform secured by four socket headed bolts. Note that t h e hoses must not be removed from the compressor but it should be carefully secured t o o n e side. .

11. Remove the exhaust and inlet manifolds, s e e operation 30.15.01 instructions 4 t o 15.

12. Remove the cylinder head, s e e operation

12.29.02 instructions 6 to 7 and 9 t o 17.

13. Now follow the instructions in ENGINE

OVERHAUL section 12. SEE

INDEX:-

Operations with engine installed in vehicle

Refitting

14.

16.

Follow the instructions for fitting the camshaft and assembly of the engine u p t o the fitting of the rocker cover, crankshaft damper and pulley.

15. Fit the inlet and exhaust manifolds see operation 30.15.01 instructions 1 6 t o 24 and

27.

Fit the power assisted steering pump bracket

17. and secure and the four bolts.

Fit the power steering pump t o the bracket with the single pivot bolt and clamp bolts.

Leave the bolts slack at this stage.

18. Fit the alternator t o t h e common bracket, see operation 86,10.02 instructions 1 0 t o 15.

19. Where applicable, fit the air conditioning compressor and tension the drive belt as follows:- Move the compressor clockwise about the pivot bolts (do not use a lever against the pump) until the belt deflects 1 2 mm (0.5ins.I at the mid point of the run between the compressor and crankshaft pulleys . Tighten the pivot and clamp bolts.

M m e the drive belt dampei so that is is jiisi iii contact with the belt or 1,Omm clear of the belt and tighten the damper bolts.

ENGINE

POWER STEERING PUMP BRACKET

Service Repair N o . 12.25.22

Remove a n d refit

Disconnect t h e battery.

Remove the air cleaner, s e e operation

19.1 0.01.

3. Remove the alternator, instructions 2 t o 9 operation 86.1 0.02.

4. Remove the steering p u m p two adjustment clamp bolts and remove the drive belt.

5. Remove the single pivot bolt.

\\ I I c

20. Fit and tension the power steering pump drive belt, see operation 57.20.14 instruction 10.

Take note of the CAUTION when tensioning the belt.

21. Fit the air clemer, s e e operation 19.10.01 instructions 1 2 t o 14.

22. Fit the radiator, see operation 26.40.01 instructions 9 t o 15.

23. Fit the fan cowl in position but d o not secure t o the radiator.

24. Fit the fan and coupling assembly, s e e operation 26.25.19 instructions 8 to 11.

25. Fill the cooling system, see operation 26.10.01 instructions 5 to 8.

ST3026M \y

6 . Move the pump aside with the two hoses still attached t o gain access to t h e bracket f o u r retaining bolts.

Remove the single long bolt through the cylinder block into the bracket.

Remove t h e single bolt frpm t h e front into the cylinder block.

C o n t i n u e d

I - .

.I,

DEFENDER

9. Remove the two bolts inside the bracket into the front cover and remove the bracket and triangle shaped packing plate.

I .

Refitting

10.

11.

Fit the bracket t o the cylinder block with the f o u r bolts, reversing instructions 7 to 9.

Loosely secure the pump to the bracket with

12. the three bolts.

Fit and tension the drive belt.

CAUTION:- Do not apply any pressure against the pump casing when tensioning the drive belt since it will damage the casing, permanently, beyond repair.

13. Tighten the two clamp bolts and single pivot bol. The belt is correctly tensioned when the belt can be deflected by thumb pressure 1 2 mm (0.5ins.)

14. Fit the alternator and tension the drive belt,

15.

16. see operation 86.10.02.

Fit the air cleaner.

Connect the battery, run the engine at a fast idle for approximately three to five minutes.

Stop the engine and check the drive belt tensions.

ENGINE

11 2

CYLINDER HEAD

Service Repair No. 12.29.02.

Remove and refit

1. Remove the bonnet and disconnect the battery.

Drain the coolant.

Remove the radiator t o p hose.

Remove the exhaust and inlet manifolds, complete with turbo charger see operation

30.29.02.

Remove the heater rail.

Remove the thermostat t o waterpump hose.

Disconnect the electrical leads fromthe

9. thermostat housing sensors.

Disconnect the harness from the alternator.

Remove the heater h o s e from the cylinder head.

10. Remove the axle breather pipe bracket from the rear of the cylinder head.

11. Remove the fuel pipes from the injectors and injector pump.

12.

13.

Remove the spill return pipes from the injectors.

Remove the injectors and washers and place in a clean, sealable container, for safe keeping.

14. Remove the electrical leads from the heater plugs.

15. Remove the heater plugs and store in a safe place.

16.

17.

Remove the hose from the breather valve.

Follow the instructions in the ENGINE

OVERHAUL section 12. SEE INDEX:-

Operations with engine installed in vehicle.

Continued

121

ENGINE

Refitting

18. Follow the instructions in ENGINE OVERHAUL from "fitting cylinder head" and continue until the rocker cover is fitted.

19. Fit the heater plugs and connect the electrical leads. Do not allow any part of the lead or insulation t o touch t h e cylinder head when fitted.

20. Fit the injectors

- s e e ENGINE OVERHAUL.

21. Fit the spill retum pipes t o the injectors.

22. Fit the supply pipes to the injectors and pump.

23. Fit the hose t o the breather valve.

24. Fit the axle breather bracket.

25. Fit the heater hose to cylinder head.

2 6 . Connect the hamess t o the altemator.

27. Fit the waterpump t o thermostat hose.

28. Connect the leads t o the thermostat sensors.

29. Fit the inlet and exhaust manifolds and heater

- rail.

30. Fit the radiator t o p hose.

31. Fill the cooling system, s e e operation 26.10.01.

32. Fit the bonnet. f-;

.' .

DEFENDER

. I

CAMSHAfl TIMING BELT

Service Repair No. 12.65.18

Renew

1. Disconnect t h e battery.

2. Remove the fan and viscous coupling assembly, see operation 26.25.19.

3. Slacken and remove the power steering pump drive belt, see operation 57.20.14.

4. Slacken and remove the air conditioning compressor drive belt.

5. Remove the air conditioning compressor from the mounting bracket but d o not detach the fluid hoses from the compressor. Move the compressor aside taking care not t o strain the

6. hoses.

Remove the compressor mounting bracket

7. Using an 8,O mm Allen Key, remove the four socket headed bolts that secure the compressor bracket mounting platform t o the front cover and cover plate.

8. Remove the water pump and alternator drive belt, s e e operation 86.10.02 insturctions 4 t o

9. Remove the hoses from the water pump.

NOTE: From this stage onwards reference should be made t o the instructions in the

ENGINE OVERHAUL section 12. SEE INDEX:-

Operations with engine installed in vehicle. b e !c!lcwed the point when the timing belt has been fitted and the engine and injector pump are correctly timed.

ENGINE

Assembling

10.

11.

Fit the front cover plate using a new gasket and a new gasket washer o n the centre bolt boss.

Secure the cover with the various length bolts tightening evenly t o the correct torque. Refer t o the bolt length chart in ENGINE OVERHAUL

12. Using a new gasket fit the water pump, see instructions 9 t o 12 operation 26.50.01.

13. Connect the hoses to the water pump.

14. Fit the air conditioning compressor bracket mounting platform and secure with the f o u r socket headed bolts.

15.

16.

Fit the compressor mounting

U bracket.

Refer t o ENGINE OVERHAUL for the correct method of fitting the crank shaft damper.

17. Fit the pulley t o the damper and evenly tighten the four bolts t o the correct torque.

18. Fit the water pump pulley and secure with the four bolts. Use a tommy bar in the hole provided t o restrain the pulley while tightening the bolts.

19. Fit and tension the water pump/alternator drive belt.

20. Fit and tension the compressor drive belt. SEE

OPERATION 12.13.02

21. Fit and tension the power steering pump drive bel.

22. Fit the fan cowl into position but d o not secure t o the radiator until the fan is fitted.

23. Fit the fan and viscous coupling assembly to the water pump spindle. Tighten the left hand thread t o the correct torque using a tommy bar in the hole provided in the fan pulley to restrain the coupling.

24. Secure the fan cowl to the radiator with the two nuts and fit the top hose.

MS.768

ENGINE

ENGINE OVERHAUL PROCEDURE.

Service Repair No. 12.41.05

Special service tools

Handle set, seat cutter

Pilot, seat cutter

Valve seat cutter

Cylinder head bolt degree plate

Adaptor, crankshaft rear seal

Crankshaft rear seal saver

Valve spring compressor

Drift, valve guide removal

Distance piece, valve guide fitting

Drift, valve guide fitting

Mandrel, clutch plate

Replace, crankshaft front seal

Remover. crankshaftkamshaft gear

Replace, camshaft oil seal

Flywheel timing pin

Crankshaft damper restraining tool

Rear main cap sea1 guide

Crankshaft damper tool injection pump timing pin

- part of LST129 pump remover tool

MS76B

MS150-8

MS621

LSTI 22

18G134-I 1

18C1344

MS1519A

R0274400

R0605774A

LSTI 30

R0605022

18C1456

18C1464

18C1482

LSTl28

LSTI 27

270304

LSTI 36

LSTI 2912

Die. Range 28.5” - 44 mm 15 b 45

18G. 134- 11

DEFENDER

MS. 1519A

186.1344 -

Dia 7.9 mm

8.5 mm

R0.27-

18G 1456

18G. 1464

. . .

::..:

. . .

ST2344M

1BG. 1482

ENGINE 12

LST. 128

LST. 127

E

G

E

LST136

DEFENDER

ST2677M

CAUTION A N D WARNING

Note that where the use of special service tools is specified, only these tools should be used t o avoid the possibility of personal injury and or damage to components.

WARNING. Where the use of an engine stand is recommended, it is absolutely essential t o follow the stand manufactures instructions t o ensure safe and effective use of the equipment. in the intrests of safety and efficient working, secure the engine t o an engine stand recognised by the garage repair trade. Drain and discared the sump oil whilst strictly observing the the handling and disposal instructions in the Introduction section 01.

Remove the following ancillary equipment prior t o dismantling the engine.

Air conditioning compressor-where fitted .

Power steering pump and alternator.

Starter motor

Engine electrical harness.

Air Inlet manifold.

Exhaust manifold and turbo charger.

Whilst dismantling, make a note of the the position of miscellaneous brackets, clips, hamess, pipes, and hoses, that are removed at the same time, and any non standard items, to facilitate assembly.

DEFENDER

CYLINDER HEAD REMOVE.

ENGINE 12

. - . I

121

ENGINE

Rocker cover remove.

1. Release the crankcase ventilation hose connections, evenly slacken and remove the three bolts then lift-off the rocker cover.

See fitting rocker cover

4. Having removed the rocker shaft, lift-out the push rods and insert them through holes in a piece of card marked from 1 t o 8 t o ensure assembly t o their original locations.

5. Remove the cap from each valve stem.

See fitting rocker shaft

ST2948M

Rocker shaft remove.

2. Evenly release the five rocker shaft retaining bolts but d o not remove the bolts from the shaft, especialy the two end ones, to prevent the assembly from falling apart when removed from t h e cylinder head.

ST294CM

ENGINE

Removing cylinder head

8. Evenly slacken and remove the eighteen bolts retaining the cylinder head and lift the cylinder head from the cylinder block and remove the gasket.

See cylinder head overhaul o r s e e fitting cylinder head

.,..

ST2951 M

Note:- If..necessary, at this stage t h e cam followers may b e removed for inspection.

See Cam follower removal

FRONT COVER OIL SEALS/TIMINC

BE LT/CAM S HA fi

See radiator removehefit

Water p u m p remove.

1. If necessary remove the viscous coupling complete, with the fan, from the water pump spindle, using a cranked open-ended spanner, noting that it has a left-handed thread.

2. Remove the f o u r screws, t o release the pulley from the water pump hub.

3. If necessary release the two Jubilee clips and remove the by-pass hose.

4. Evenly release and remove the six bolts and o n e nut t o remove the water pump from the front cover plate.

See water p u m p inspection a n d fitting.

ST2952M

Front cover plate o r seal remove

Front pulley a n d damper.

5. Release the four bolts and remove the crankshaft pulley from the damper.

1 .

4 1

12 ENGINE

6. To remove the crankshaft damper retaining bolt use pecial service tool FR I 0 1 tor LST 1 2 7 o restrain the damper and a 30" socket t o remove the special bolt.

Removing front cover plate.

9. Unscrew the 11 bolts and o n e nut t o release the cover plate.

See fitting front cover plate

ST3125M

7. Fit the pressure button 18G1464/5 t o the e n d of the crankshaft and using service tool LST

136, extract the damper as illustrated.

See fitting front damper and pulley

STZ 91 8M

75"

Removing timing belt

1. Use the xstraining tool LST 127 to turn the crankshaft in a clockwise direction t o TDC so that the valves of number o n e cylinder are closed with number four cylinder valves o n the

"rock" and the crankshaft key aligned with the arrow cast into the front cover as illustrated. If the crankshaft is turned inadvertently beyond

TDC d o not turn it back but continue o n round until the above conditions are achieved. e.

'J/

A 3

.. .

.,...

.:!.

* .

DEFENDER

2. Now screw the body of the timing pin tool LST

128 into the flywheel housing and check that the pin can be inserted in t o the appropriate slot in the flywheel periphery. Note that there are two slots in the flywheel o n e being wider than the othe. The narrowest slot determines

TDC for this engine and it is therefore important that the correct slot is used. a*

ENGINE

11 2

4. To lock the pump, Slacken the locking screw anticlockwise and remove the inhibiting plate.

Turn the screw clockwise t o lock the pump shaft. Remove the timing pin from the flywheel housing.

ST2954M

3. Remove the three screws t o release the injection pump access cover from the front cover plate and insert the locking pin LST129/2 through the "U" shaped cut-out in the pump hub and into the hole in the pump body. This will confirm that the injection pump is correctly timed in relation t o the valves and crankshaft and can be locked ready for removing. Leave the pin in position in the pump.

CAUTION: It is important t o ensure that o n c e t h e injection p u m p has been locked n o attempt must b e m a d e t o rotate it.

Therefore take care not to allow t h e crankshaft t o b e turned until t h e p u m p has been removed.

NOTE:- If renewing t h e timing belt,oil seals o r gears (with t h e cylinder head fitted) and there is any possibility that t h e crankshaft will need t o b e rotated after removal of t h e timing belt, it would b e advisable t o remove t h e rocker shaft. This will prevent t h e pistons contacting t h e valves as t h e crankshaft is turned. If necessary, See rocker shaft removal.

5. To verify any timing error, check that the timing marks inside the front cover line-up

6. with the gear wheels.

If necessary temporarily fit the damper and restrain the crankshaft with service tool FR 101 while the three screws securing the pump timing gear to the pump hub and the camshaft gear wheel retaining bolt is being slackened.

7. Remove the single bolt, special washer and remove the tensioner.

8. If the original belt is t o be re-fitted, mark its direction of rotation with soft chalk before removing it.

Removing timing belt gears

9. If the crankshaft gear wheel cannot b e removed by hand, use special service tool 18C

1462-2 and pressure button 18G 1464-5.

Assemble the tool and withdraw the gear wheel as illustrated.

ST2960M

18G 1464-2 \\\

10. Remove the camshaft gear wheel retaining bolt assembly t o enable the gear t o b e removed.

Use special service tool 18G 1462-2 and button 18G 1464-6. Assemble as shown and withdraw the the gear.

ST2959M/

NOTE:- A used drive belt develops a wear pattern relative t o the driving loads and its direction of rotation. If the belt is t o be re-used it must be refitted so that it continues to operate in the original direction.

S ee fitting Timing gears and belt.

ST2960M

18G 1464-2 \\?--.

The camshaft and crankshaft oil seals may b e renewed at this stage with the engine in the vehicle without removing the front cover.

See fitting front cover seals

DEFENDER

Removing injection pump

11. Release the injection pump from the rear support bracket.

ENGINE

Removing front cover

13. To remove the front cover,release the three bolts securing it to the cylinder block front face and the three bolts that pass up through the sump and ladder frame into lower face of the cover.

See fitting front cover timing belt and gears

12. Remove the three nuts securing the pump flange to the front cover and withdraw the pump and gasket complete with hub and timing pin.

Removing vacuum pump

14. Mark the position of the brake servo vacuum pump with relation to the cylinder block. Using a 6mm Allen key remove the three screws and lift-out the pump.

See fitting vacuum pump

112)

ENGINE

DEFENDER

Removing skew gear

During normal operation of the engine the camshaft and skew gear teeth develop a mated a wear pattern. It is therefore important that if the skew gear is t o be re-used it should b e fitted so that the teeth o n the gear and camshaft engage in the original running position.

15. To ensure orininal re-engagement of the gears turn t h e camshaft so that the camshaft key is aligned with the oil groove in the thrust plate and mark the position of the skew gear in relation t o the o n e of the three bolt holes for securing the vacuum pump. Also mark the skew gear housing flange t o the same bolt hole.

16. To remove the skew gear assembly, tap the flange round so that the e d g e overlaps the cylinder block, then tap the flange upwards to enable the skew gear assembly t o b e lifted out.

If necessary the oil pump drive shaft may be removed at this stage

Removing skew gear bush

17. Unscrew the oil filter cartridge, anti-clockwise, using a strap wrench. Dispose of the oil safely,

18. Release the two bolts and remove the oil filter

19. adaptor and gasket from the engine.

Using a 6 mm alien key remove t h e retaining screw and bush.

Removing f u e l p u m p a n d side cover

20. Use a 6 mm allen key t o release the fuel lift pump t o gain access to the side cover retaining bolts.

21. Release the six bolts and remove the cover plate.

See fitting l i f t pump.

Remove front s i d e cover plate

22. Release the six bolts and remove the front side cover plate complete with the crankcase ventilation pipe.

ENGINE

1. Slacken back the guide locating screw so that the end is below the bore of the guide.

' i' x n

I 111

Remove camfollowers

See cylinder h e a d remove

CAUTION: T h e camfollers a r e solid rollers held in position against t h e cam by a slide inside a fixed guide. If t h e guide is removed before t h e roller, it is possible that t h e roller c a n fall behind t h e camshaft a n d b e c o m e jammed. Furthermore t h e roller could slip p a s t t h e cam a n d fall into t h e crankcase. I t is t h e r e f o r e important t o adopt t h e following p r o c e d u r e for removal.

Using a length of thin wire with a hooked end lift-out the slide.

With the same piece of wire remove the roller

Remove the guide locating screw and lift-out the guide.

6 . As each assembly is removed number it, from o n e to eight, for refitting t o its original location.

See fitting cam followers

ENGINE

Removing the camshaft.

Release the two screws and remove the camshaft thrust plate.

Carefully Withdraw the camshaft taking care not to allow the end of the shaft to drop o n t o the bearings as it is removed.

See fitting camshaft

ST2552M

Removing Clutch and Flywheel housing

See engine unit removal

2 .

Mark the relationship of the cover t o the flywheel t o ensure original balance is maintained.

Evenly slacken and remove the six retaining bolts and washers and remove the assembly complete with the friction plate.

See fitting clutch

Removing flywheel

In the intrests of safety, fit two long 8mm bolts into the clutch bolt holes, diametrically opposite, t o use as handles for lifting the flywheel off the crankshaft. temporarily fit the the crankshaft damper and use special service tool FR

101 t o restrain the crankshaft while slackening the flywheel eight retaining bolts. Remove the bolts and reinforcing plate and lift-off the flywheel.

See overhaul and fitting flywheel

Removing flywheel housing.

1. Remove the eight internal and two external and five ladder frame securing bolts, then ease the flywheel housing from the two locating dowels and crankshaft.

See fitting rear main oil seal to flywheel housing.

ST2972M i

A 8

ENGINE

Removing s u m p a n d oil p u m p

1. If necessary drain the engine oil. When working with t h e engine on a work stand, invert the cylinder block so that the sump is uppermost. Remove t h e screws and ease the sump from t h e ladder frame t o reveal the oil

Pump.

...

ST2553M

Note: After removing t h e oil s u m p when t h e engine is in t h e vehicle, refit a n d tighten two of t h e retaining bolts t o t h e left side of t h e cylinder block to maintain pressure o n t h e l a d d e r f r a m e cylinder block joint seal.

See fitting s u m p

Removing ladder frame

Note: The ladder f r a m e a n d flywheel housing are s e c u r e d by five bolts which are inaccessable with t h e gearbox bell housing fitted. Therefore it is n o t possible t o remove t h e ladder frame w h e n t h e e n g i n e is in t h e vehicle without first removing t h e gearbox or engine unit, flywheel flywheel housing, engine sump a n d oil p u m p

3. With the engine removed, release t h e remaining ten bolts and separate the ladder frame from the crankcase by gently tapping to break the seal.

See fitting ladder frame

Removing oil p u m p

Two bolts secure the oil pump t o the crankcase. Access to the right hand bolt may require t h e u s e of a socket with a universal joint. Removal of the two bolts will enable the pump t o b e withdrawn.

See fitting oil p u m p

1121

ENGINE

Removing pistons and connecting rods

Note: On this version of the Tdi engine, it is not possible t o remove the connecting rods or pistons with the engine in the vehicle because of the method by which the ladder frame is secure.

See note under Ladder frame removal.

1. Turn the crankshaft t o bring all the connecting rod cap nuts t o an accessable position and

2. slacken t h e nuts using a 15mm socket.

Remove t h e connecting rod nuts and remove t h e caps complete with lower bearing halves.

DEFENDER

Before removing the piston assemblies, number each piston from one t o four so that it can b e identified with the bore from which it was removed.

Taking care not t o damage the bores, push each connecting rod and piston, in turn, up t h e bore until it can b e withdrawn from the cylinder block combustion face. As each piston assembly is removed fit the corresponding cap and bearing shell to the connecting rod noting that t h e shell locating tags are together o n the same side as the connecting rod number.

See piston and connecting rods

Removing crankshaft.

2. If difficulty is experienced removing t h e cap a suggested method is t o lever t h e cap from both sides, as illustrated.

Slacken the ten mainbearing bolts with a

14" socket.

Insert a suitable bar in t h e hole in the inside face of t h e cap and lever against the crankshaft journal o n the outside face. Ensure that blocks of timber are used under t h e levers particularly

4. t o protect the crankshaft.

Release the remaining bolts and remove t h e mainbearing caps complete with the lower bearing shells.

5 0

DEFENDER

5 . Lift-out the crankshaft either by hand or hoist.

If a hoist is used be sure to insert adequate protection between the sling and joumals to avoid damage.

6 . Remove the mainbearing upper shells from the

7. cylinder block.

Remove the two thrust washers from each side of the centre bearing location.

8. Remove the four cylinder lubrication, jet tubes.

CYLINDER BLOCK

INSPECTION

AND OVERHAUL

Inspection

1. Degrease the cylinder block and carry o u t a thorough visual examination checking for cracks and damage. To check each main bearing cap and its location on the cylinder block, fit the bearing caps without the bearing shells.

2. Fit the bolts and tighten to the correct torque, then remove o n e bolt from each bearing cap and check with a feeler gauge that n o clearance exists at the joint face as illustrated.

3. A clearance indicates either a bent bolt, damaged dowl, distortion of the caps o r block, o r that the cap has been filed or machined in an attempt t o reduce any clearance d u e t o wear in the bearings. Main bearing caps are not available separately from the cylinder block therefore any clearance should be investigated and rectified or the block renewed.

ENGINE

Cylinder bores

4. Measure the cylinder bores for ovality, taper and general wear, using any suitable equipment. However, an inside micrometer is best for checking ovality and a cylinder gauge for taper. Check the ovality of each bore by taking measurement at the t o p of t h e cylinder just below the ridge at two points diametrically opposite.

5. The difference between the two figures is the ovality at the t o p of the bore. Similar measurements should b e made approximately

50 mm (2.0 ins) up from the bottom of the bore so that t h e overall ovality may be determined. The taper of each cylinder is determined by taking measurements at the t o p and bottom of each bore at right angles to the gudgeon pin line, the difference between the two measurements is the taper. n

ST2566M

To establish maximum overall bore wear, take measurements at as many points as possible down the bores at right angles t o the gudgeon pin line. The largest recorded figure is the maximum wear and should b e compared with the original diameter of the cylinder bore.

Maximum permissible ovality

0,127 mm (0.005 in).

Maximum permissible taper

0,254 mm (0.010 in).

Maximum permissible overall wear

0,177 mm (0.007 in).

12 ENGINE

DEFENDER

If t h e above figures are exceeded the cylinders must

' b e rebored or sleeved depending upon the condition of the bores and t h e amount of wear.

Altematively, if t h e overall wear, taper and ovality are well within the acceptable limits and the original pistons are serviceable n e w piston rings may be fitted. It is important however, that ,the bores are deglazed, with a hone, t o give a cross-hatched finish t o provide a seating for the new ring.

Fitting cylinder sleeves

Cylinder bores that cannot b e rebored can be restored by fitting sleeves t o enable standard size pistons t o be fitted. Sleeving o n e cylinder only will distort the adjacent bore so sleeving must b e carried o u t in pairs, i.e. cylinders 1 and 2 or 3 and 4.

6. Machine the cylinder bores t o accept the sleeves t o 94,425

0,012 mm (3.7175

0.0005 in). This will give the sleeve a 0,076 t o

0,114 mm (0.003

Press the sleeves squarely into the bore using a pressure of two o r three tons. Excessive pressure could damage the sleeve and cylinder block.

The sleeves must not b e proud of the cylinder block top face or more than 2,54 mm (0.10 in) below the surface.

7, Bore and hone the sleeves t o accomodate the pistons with the required clearances, see piston and connecting rod examination.

Camshaft bearings

8. Measure the intemal diameter of each camshaft bearing at several points using an internal micrometer.

A comparison of the bearing diameters with those of t h e respective camshaft joumals will give the amount of clearance. The bearings should be renewed if the clearance exceeds 0,0508 mm (0.002 in). Or, in any event, if they are scored or pitted.

This work should only b e entrusted t o line boring specialists.

It is vital t o thoroughly wash the cylinder block after machining t o remove all traces of abrasive material, ensuring that all oil galleries are clean.

Check crankcase main bearings

Discard scored, pitted, cracked and w o m bearing shells. To determine the maximum wear, assemble the main bearing shells and caps t o t h e crankcase and tighten the bolts t o the correct torque figure.

Using an inside micrometer, measure each bearing at several points and note t h e greatest figure. The maximum wear is t h e difference between this figure and the smallest diameter of the corresponding crankshaft journal.

The main bearing running clearance is given in t h e data section.

CRANKSHAm

1. Degrease t h e crankshaft and clear o u t t h e oil ways which can b e c o m e clogged after long service.

2. Examine visually, the crankpins and main

3. bearing joumals for obvious wear, scores, grooves and overheating. A decision at this stage should be made as t o whether t h e condition of t h e shaft is worth continuing with a more detailed examination.

With a micrometer, measure and n o t e the ovality and taper of each main bearing journal and crankpin as follows.

4. Ovality

Take two readings at right angles t o each other at various intervals. The maximum

5. Taper

- exceed 0,040 mm (0.0015 in).

Take two readings parallel t o each other at both e n d s of t h e main bearing journal and crankpin. The maximum permissible taper must not exceed 0,025 mm (0.001 in).

6. To check for straightness, support t h e front and rear main bearing joumals in 'V' blocks and postion a dial indicator to check t h e run-out at the centre main bearing journal.

Run-out must not exceed 0,076 mm (0.003 in) taking into account any ovality ir. t h e centre journal. The overall wear limit should not exceed 0,114 mm (0.0045 in) f o r main bearing joumals and 0,088 mm (0.0035 in) for crankpins.

7. A crankshaft w o m beyond t h e limints of maximum taper, ovality and overall wear, can b e ground to0,25 mm (0.010 in).

When grinding t h e crankshaft main bearing and crankpin joumals, rotation of the grinding wheel and crankshaft must b e in the same direction, anti-clockwise, viewed from t h e flywheel e n d of the crankshaft.

DEFENDER

* ..

Finai finishing of the joumals should be achieved by using a static lapping stone with the crankshaft rotating in a clockwise direction viewed from the flywheel end of the crankshaft.

It is important to ensure that, when grinding, the s t o n e travels beyond the e d g e of the joumal ' A t o avoid formation of a step 'B' as illustrated. Also care must be taken not t o machine o r damage the fillet radii

'C.

It is vital t o thoroughly wash the crankshaft after machining t o remove all traces of abrasive material, ensuring that all oil galleries are clean.

ENGINE

ST1808M

Pistons and connecting rods

The following checks relating t o pistons and rings must also be carried out prior t o fitting new pistons t o rebored and sleeved cylinder blocks. Until it is decided if new components are required all parts must be kept in their related sets and the position of each piston to its connecting rod should be noted.

1. Remove the piston rings and gudgeon pin from each piston and detach the connecting rod.

2. Original pistons

Decarbonise and degrease all components and carry out a visual examination

3. of the piston and rings and discard any which are unserviceable. Pistons which appear serviceable should be subjected t o a more detailed examination described under 'New

Pistons'.

New pistons

Original pistons fitted to new engines at the factor? arespecially graded to facilitate assembly. The grade letter on the piston crown should be ignored when ordering new pistons.

Genuine Land Rover service standard size pistons are supplied 0,025 mm (0.001 in) oversize to allow for production tolorance o n new engines. When fitting new pistons t o a standard size cylinder, the bores must be honed t o accomodate the pistons with the correct clearances. In addition Land Rover pistons are available 0,50 and 1 , O l mm (0.020 and

0.040 in) oversize for fitting t o rebored cylinders.

Clearance limits for new standard size pistons in a standard cylinder bore measured at right angles to the gudgeon pin are in t h e data section. When taking the following measurements the cylinder block and pistons must b e the same temperature to ensure accuracy.

4. Using a suitable micrometer or vernier measure the pistons at the bottom of the skirt at right angles t o the gudgeon pin.

ST2657M

1121

ENGINE

5. With an inside micrometer or cylinder gauge measure the diameter of the bore at approximately half-way down and note the reading.

6 . The clearance is determined by subtracting the piston diameter from the bore diameter.

7. If gauge equipment is not available the clearance can b e assessed by placing a long, suitably sized, feeler gauge down the thrust side of the bore and inserting the appropriate piston, 'upside down', in the bore and position it with the gudgeon pin parallel t o the crankshaft axis. Push the piston down the bore and stop at the tightest point and whilst holding the piston still, slowly withdraw the feeler gauge. If a steady resistance of approximately 2,5 kg ( 6 Ibs) is felt, t h e clearance is satisfactory.

Piston ring gaps

8. When checking t h e piston ring gap in worn bores which are within the acceptable taper and ovality limits, t h e ring must be inserted squarely into the bottom of the cylinder at the lowest point of the piston travel. To ensure squareness push the ring t o the correct position using a piston.

9. With the appropriate feeler gauge check all the ring gaps in turn, including t h e oil control rings.

The correct gaps are listed in t h e data section. If any gap is less than that specified, remove the ring, and file the e n d s square, whilst holding the ring in a filing jig or vice. Should any gap b e excessively wide and not likely to close u p t o within the specified limits when hot, an oversize ring should b e fitted.

O n c e t h e rings have been selected for a particular cylinder and piston ensure that they are not again mixed up.

Piston ring groove clearance

10. It is important that the groove clearances are correct. Rings that are t o o tight may bind o r fracture when hot and cause loss of compression. Excessive clearance allows t h e rings to rock in t h e groove and may result in a pumping action and excessive oil consumption.

6 9 4 p

': z 4

DEFENDER

ENGINE

. -

11. Fit the oil control ring expander t o the bottom groove, then fit the oil control ring ensuring that it fits over the expander. Fit the second, narrow, compression ring with the word "TOP" uppermost. Likewise fit the first compression ring to the top groove, word "TOP" uppermost.

11- c

Gudgeon pins

14. Examine the g u d g e o n pin for obvious wear, cracks, scores, or overheating and ovality and taper using a micrometer.

Connecting rods

15. Check the connecting rods and caps for distortion as follows; fit the correct cap, less the bearing shells, t o each connecting rod as denoted by the number stamped near the joint

16. faces. This number also indicates the piston/cylinder/ crankshaft journal t o which it must be fitted.

Tighten both nuts t o the correct torque, then release o n e nut o n each cap, now check that n o clearance exists a t the joint face as illustrated. A clearance may indicate a bent bolt o r that either of the joint faces has been filed o r machined previously, in attempt t o rectify excessive bearing wear.

ST2636M

12. After fitting slide each ring around the groove to ensure that it is free and does not bind.

13. Using an appropriate feeler gauge check the groove clearance between the rings and piston. I f the clearances in excess of the figures given in data section the rings or the pistons should b e renewed.

ST2976M " I I

-17.

Use an accurate connecting rod alignment gauge t o check t h e rods for bend and twist.

The maximum allowable for both conditions must not exceed 0,127 mm (0.005 in).

18. Examine and check the small-end bush for wear. If necessary renew the bush. The correct

19. clearance of t h e gudgeon pin in the small-end bush is given in t h e data section.

When renewing a bush ensure that the oil hole in the bush lines u p with the hole in the connecting rod. Finish the bush t o the correct size and clearance.

ST2632M

_..

(121

ENGINE

20. Connecting rod bearings that are worn, pitted, scored and show signs of overheating must be discarded. If more than o n e of the bearings show these signs they must all be renewe.

When fitting new or used bearings t o serviceable crankpins the clearances must be checked.

Big end bearing nip and clearance

21.

22.

Clean the protective coating from new bearings before fitting.

Fit the bearing shells to each connecting rod and cap ensuring that the location tags are correctly seated and aligned. Fit and tighten both bolts t o the correct torque, next release o n e nut on each cap then check for a nip clearance of between 0,lO t o 0,20mm (0.004 t o 0.008).

DEFENDER

24. Insert a circlip in o n e side of the gudgeon pin boss and assemble the piston t o the connecting rod with the gudgeon pin. Secure the assembly with a circlip o n the opposite side of the piston.

ST2977M

- .

23. Check the joint face of faces of both cap rod and bearing shells if the nip clearance is excessive. Too little nip clearance will allow the shell bearings to move (possibly rotate) inside the connecting rod when the engine is running. After satisfactory fittting of the bearings temporary retain the shells and caps t o the appropriate connecting rod.

Assembling pistons to connecting rods

The piston must be assembled t o the connecting rod so that the arrow on t h e piston crown points t o the front of the engine and the off-set combustion chamber, bearing shell tags and connecting rod number are all o n the same, right hand side of the cylinder block viewed from the rear of t h e engine

(camshaft side).

ST2979M

'-?

.. e

ENGINE

ASSEMBLE ENGINE

Ensure that the cylinder block and all oilways are thoroughly clean using an air line, if available, prior t o assembly.

Refitting cylinder lubrication jet tubes

Oil jet tubes are fitted t o lubricate the pistons and bores directly from the main oil gallery.

1. Assemble and fit the jet tube as illustrated ensuring that the dowls locate in the holes in the cylinder block, and that the larger diameter washer fits under the bolt head. Tap the jet blocks down t o ensure that the locating dowel is fully home. Fit and tighten the retaining bolts to the correct torque.

The nip clearance which ensures that the bearings are correctly clamped, must b e within 0,IO t o 0,15 mm (0.004 t o 0.006 in). Investigate and correct any nip clearance errors before removing the main bearing caps prior t o fitting the crankshaft.

Fitting crankshaft

1. Insert two standard thickness thrust washers each side of the centre main bearing location

2. with the oil grooves towards the crank thrust faces.

Lubricate the cylinder block bearing shells and carefully install the crankshaft.

,.,-.

. . ,

~ .,

ST2980M

Crankshaft bearings.

Main bearing nip clearaqce

Clean the protective coating from new bearings before fittin.

1. Fit the bearing halves t o the cylinder block ensuring full engagement of the location tags.

L .

Instal! the othei half shells into the main bearing caps, again ensuring that the tags locate correctly.

3. Fit all the main bearing caps to their original

4. locations tightening the bolts to the correct torque, then release o n e bolt on each cap.

Check the clearance between the cap and the block as illustrated.

ENGINE

Crankshaft end float

3. To determine the crankshaft end-float mount a dial test indicator t o read-off the e n d of the crankshaft. Move the crankshaft away from the indicator and zero t h e dial, then Move the crankshaft in the opposite direction and note the indicator reading. The end-float should be

0,05 t o

0,15 mm (0.002 t o 0.006 in).

6 . Ensure that number five main bearing cap is clean and free from old seal material. Attach the seal guides number 270304 t o the crankcase, as illustrated, and ensure that they are parallel t o the crankcase edge.

Alternatively measure the clearance with a feeler gauge. If adjustment is required substitute with oversize thrust washers. Variation of thrust washer thicknesses at each side of the crankshaft joumal must not exceed 0,08 mm (0.003 in) to ensure that the crankshaft remains centralised.

Main bearing caps

4. Lubricate and fit the centre main bearing cap, tighten both bolts to the correct torque and ensure that the shaft is free to rotate before

5. fitting the next bearing cap.

Lubricate and fit 1-2 and 4 checking that the shaft is free t e rdate after tightening the bolts f o r each.

To prevent any seal material becoming trapped between the bearing cap and crankcase, chamfer the inner e d g e of the seal

0,40 t o

0,80 mm wide as illustrated. Smear the seals with engine oil and fit them t o the bearing cap.

Fit the bearing cap complete with shell bearing t o t h e crankcase and secure with new bolts and tighten t o the appropriate torque. Remove seal guides and check that the shaft is f r e e t o rorate. c-?: e 2

DEFENDER

9. To allow for shrinkage after fitting leave the seals standing proud of the crankcase face then using a sharp blade, trim the seals off to approximately

0,80 mm above the crankcase face.

ENGINE

Fitting connecting rods and pistons

1. Ensure that the essentric headed big end bolts and shell bearings are correctly located in the connecting rods and as a precaution against possible damage t o the crankshaft journals during installation of the pistons, cover the bolt threads with a layer of adheasive tape.

Check that the number o n the connecting rod

2. is the same as the piston and cylinder and that they are correctly orientated.

With the cylinder block vertical, and 2 and 3 crankshaft journals at BDC lubricate and install

2 and 3 piston connecting rod assemblies so that the piston rings are resting o n the block face.

3. Stagger the piston rings on both pistons

as

illustrated, then using a suitable tool compress

4. the piston rings and gently push each piston into the cylinder bore.

Pull both connecting rod big ends on t o the journals and fit the caps ensuring the the numbers match and orientation is correct.

Retain the caps with new nuts but d o not tighten at this stage.

5. Tum the crankshaft so that I and 4 journals are

7. at BDC and install t h e pistons and connecting rods as previously discribed.

Tighten both nuts on o n e connecting rod to the correct torque and check that the crankshaft is free t o rotate before securing the next connecting rod cap nuts.

8. Investigate and rectify any big end bearing which when tightened restricts the freedom of the crank shaft.

9. Check that each big e n d is free to move sideways o n its journal and if necessary check the actual side clearance using a feeler gauge.

The correct clearance is given in the data section.

DEFENDER

ENGINE

Fitting rear main oil seal to flywheel housing

The oil seal is manufactured from P.T.F.E. and is supplied with a former t o maintain the correct shape which must not be removed until the seal is t o b e fitted.

18G 134-11 \

1. Make sure the seal housing is clean and dry and free from burrs. D o not touch the seal lip and ensure that the outside diameter is clean

2. and dry.

Using special seal replacer 18C134-I 1 and with the lip side leading drive-in the seal as far as the tool allows. If the tool is not available fit the seal t o the bottom of the housing t o ensure squareness.

Fitting flywheel housing

3. Clean the rear face of the cylinder block and flywheel housing, then apply a bead of Hylosil

1 0 2 sealant t o the dimensions and configuration, illustrated.

The illustration has been produced full size so that a template may be made t o facilitate the application of the sealant. The bead should be 2,O mm diameter and must extend around the periphery of the bearing cap so that the joint between cap and block is sealed.

~-__

L,**

ST2988M

ENGINE

4. Examine the seal guide, number 18G1344 ensuring that it is perfectly smooth and n o t damage o r scratched. Also check that the crankshaft oil seal journal is smooth and clea.

5. Locate t h e seal guide o n t o the crankshaft and lubricate the seal, guide and journal with concentrated 'Oildag' in a 25% solution with clean engine oil.

Carefully locate the flywheel housing over t h e seal and o n t o the dowels.

Remove t h e seal guide and secure t h e flywheel housing, evenly tightening the retaining bolts t o the correct torque.

OVERHAUL AND FITJING FLYWHEEL

Inspection

Normal wear and scores o n the flywheel clutch face can b e repaired by machining provided that the overall width of the flywheel is not reduced below

36,96 mm (1.453 in) therefore check that the flywheel has not been previously machined before proceding further. The ring gear may be renewed if the teeth are chipped or damage.

Reface the flywheel

1. Remove the clutch cover locating dowels.

Machine the flywheel over the entire clutch face removing only the minimum of material necessary t o achieve a smooth surface parallel with the crankshaft mating face within the dimensions given above.

Renew Ring gear

WARNING: Wear industrial goggles t o protect the eyes from flying fragments.

2. To renew the ring gear, drill a 8 mm hole between the root of any two teeth and the inner diameter of the ring gear d e e p enough t o weaken the gear. Take care not to allow the drill t o enter t h e flywheel.

ST2973M 7

ENGINE

3 . Secure the flywheel in a soft jawed vice and cover it with a cloth t o avoid personal injury.

Place a cold chisel above the drilled hole and strike it sharply to split the ring gear.

4. Heat t h e new ring uniformally t o between

225°C and 250°C but do not exceed the higher figure.

5. Place t h e flywheel, clutch face down, o n a flat surface and press t h e starter ring firmly against the flange until t h e ring contracts sufficiently t o grip t h e flywheel. Allow the ring to cool naturally. D o not hasten cooling in anyway otherwise distortion may occur.

DEFENDER

ST2640M

Fitting flywheel

6 . Locate the flywheel o n the crankshaft and secure with the reinforcing plate and retaining bolts. Temporarily fit t h e damper t o front of crankshaft and use special service tool F R I O I or LST127 t o restrain t h e crankshaft whilst the eight retaining bolts are being tightened to t h e correct torque.

7. T o check the flywheel for possible run-out, mount a dial test indicator so that t h e stylus rests, in a loaded condition, o n the clutch pressure face at a radius of 114 m m (4.5 in)

8. from t h e centre of the flywheel.

Tum t h e flywheel, and check that run-out d o e s not exceed 0,05 t o 0,07 mm (0.002 t o 0.003 in). Should any run-out b e excessive, remove the flywheel, and check again for irregularities o n flywheel and crankshaft mating faces and dowel.

ST2991M

Fitting clutch

If t h e original clutch cover is being refitted, ensure any marks made during dismantling are aligned t o maintain original balance.

1. Clean the flywheel and place the friction plate with the raised centre section outwards away from the flywheel.

2. Fit the clutch assembly locating it over the three dowels and loosely secure with the six

3 . bolts. .

Centralise the centre plate using special tool

R0605022 or a spare primary shaft and tighten the six bolts evenly t o the correct torque.

4. Remove the tool and smear the splines of the centre plate with Molybdenum disulphide grease, such as Rocol MTS1000.

ST2611

. ..

ENGINE

Fitting camshaft

Inspection

1. Mount the camshaft o n "v" blocks o n a surface plate for convenience and examine the

2. cams for wear, scores, pitting and chipped edges.

Examine the journals for obvious wear and scores and signs of overheating, in particular, check t h e thrust plate. If the journals are visibly sewiceable, check with a dial gauge o r micrometer for overall wear, ovality, taper and runout.

CAUTION: If t h e skew gear is worn a n d requires renewal, t h e camshaft must a l s o b e renewed even t h o u g h t h e camshaft g e a r may a p p e a r satisfactory. O n c e t h e two gears have run t o g e t h e r they b e c o m e a matched pair.

3. Lubricate t h e camshaft bearings and journals with clean engine oil and carefully insert t h e camshaft into the cylinder block. Fit the thrust plate and secure with the two bolts and tighten t o t h e correct torque.

Fitting camfollowers

1. Examine all the components for wear and damage particularly t h e rollers and pushrod seating in the slides and ensure that the tappet slides move freely in t h e guides. If t h e same parts are being refitted, ensure that they are returned t o their original positions.

Note: The tappet retaining screws have a micro encapsulated locking compound applied t o t h e t h r e a d s t o e n s u r e that they do not become loose.

O n c e t h e screw has been used t h e locking ability is lost.

ST2968M

\ \ - /

4. T o check the camshaft end-float, temporarily fit the camshaft gear and mount a dial test indicator so that the stylus rests in a loaded condition upon t h e machined f a c e of the gear.

5. Zero t h e dial and move the camshaft back and forward and n o t e t h e reading. The end-float should b e within 0,06 t o 0,13 mm (0.0025) to

0.0055 in) If necessary fit another thrust plate t o achieve t h e correct end float.

3 .

Insert the tappet guides into the cylinder block, retaining each with a new screw which should be screwed in sufficiently to allow the rollers and slides t o b e installed. Ensure t h e rollers are fitted in accordance with any marks made during removal. New rollers, however, may be fitted either way around.

Before fitting the tappet slides make sure t h e oilways are clear t o t h e running surface of the roller and the pushrod seating. insert t h e t h e

4. tappet slides with t h e word 'FRONT' or 'F' t o the front of the engine.

Finally tighten t h e screws t o the correct torque t o secure the guides.

Fitting skew gear bush.

Inspect t h e skew gear bush for wear and renew if necessary.

1. Insert the bush into t h e cylinder block and secure with a new screw to t h e correct torque.

D o not over tighten as this may damage t h e bush.

Overhaul and fitting skew gear

1. Remove the circlips retaining t h e skew gear

2. shaft t o the bearing and the bearing in t h e housing.

Press the bearing and shaft assembly from t h e housing and the shaft from t h e bearing.

Discard both rubber "0" components especially the bearing and skew gear for wear and damage and renew if necessary.

CAUTION: If the original skew gear and camshaft are to be re-used, they must b e fitted so that the teeth o n each, mesh in the original position. If either the skew gear or the camshaft are renewed, the mating component must also be renewed.

4, 1'

. h\

ST2995M

Assembling

3 . Press t h e bearing into t h e housing and secure with the circlip. Support the housing and press

4. the shaft into position and secure with the circlip.

Fit a new rubber "0" of the housing and t o the intemal annular groove in the shaft ready for installation. r-

< -

ST2999M I

$:. d

Fitting skew gear

If t h e original skew gear and camshaft are being re-used it is important that the gear teeth mesh in the original position as follows.

5. Turn the camshaft so that the key aligns with the oil groove as illustrated.

* . .

6 . Fit the skew gear assembly so that t h e ventilation slot in the gear housing is towards the f r o n t of the engine as illustrated and ensuring that any alignment marks made during dismantling are realigned.

I f both components are new it is only necessary to correctly align t h e ventilation slot as described above.

ENGINE

1121

1121

ENGINE

DEFENDER

OVERHAUL AND FITTING OIL FILTER ADAPTOR

Oil temperature thermostat

1. Remove the two bolts and carefully withdraw the thermostat extension housing complete with, t h e ’0’ (41, and spring (5). 2. Clean the adaptor housing

(6) with lint-free cloth. inspect all the parts and renew as necessary.

3. Fit the spring, washer and thermostat with the pin uppermost.

Ensure that the pin protruding from the thermostat locates in t h e hole in the extension housing and secure with the two bolts and washers.

1 -

? ? ? ?

Oil filter

6. Smear the filter sealing ring with oil and screw the filter clockwise until t h e seal touches the machined face, then tighten the filter a further half turn only. D o not over tighten. see

Maintenance operations, section 10.

Fitting vacuum pump

7. Using a new gasket fit the vacuum pump so that the brake servo connection is towards the front of the engine, ensuring that the cross-pin in the skew gear locates in t h e pump drive shaft then secure with three screws tightened t o the correct torque.

ST2596M

5. Using a new joint washer fit the oil filter adapto. Ensure that t h e retaining bolts pass through the two small holes in the joint washer. Tighten the two retaining bolts evenly t o t h e correct torque.

Fitting front and rear side covers and fuel lift

Pump

8. Check that the front side cover baffle plate is secure and fit the cover using a new gasket securing with only four of t h e six fixing bolts at this s t a g e , leaving o u t the two which secure the injection pump support bracket as illustrated.

ST3000M

Fitting rear cover

9. Fit the rear cover also using a new gasket and secure with six bolts tightened t o t h e correct torque.

Fitting fuel l i f t pump

10. Check that t h e lift pump is serviceable and refit using a new gasket, ensuring that t h e pump actuating lever locates correctly o n t o the camshaft

ENGINE

3. Also fit a new joint washer t o the coolant aperture and to the tapped hole for the jockey pulley clamp bolt.

4. Fit the front cover locating it over the single stud and secure with the three retaining bolts tightening evenly to the correct torque. The correct bolt length for each hole is given in the following chart.

I , ,

ST3003M

FllTlNG FRONT COVER TIMING BELT AND GEARS

1. Clean the front cover and remove t h e crankshaft and camshaft oil seals taking care not t o damage the seal housing. Examine t h e cover for damage, cracks and distortion. Check the mating face of the cylinder block and the cover plate f o r burrs.

2. Clean the front face of the cylinder block and use a little grease t o hold in position a new joint washer.

ST3005M

Front cover seals

5. Lubricate a new crankshaft oil seal. With the lip side leading, drive-in the seal, squarely, using special service tool 18C1456.

6. Similarly, lubricate and drive-in a new camshaft oil seal, lip side leading, using special service tool 18G1482.

112)

ENGINE

Fitting injection pump

1. Insert t h e timing pin in t h e pump hub and body. Fit the injection pump and secure with the three nuts and tighten evenly t o the correct torque.

Cleanliness and accuracy are vital when carrying o u t the timing operations and fitting t h e drive belt.

1. Check the gear wheels are not damaged or scratched and that they are thoroughly clean

3. and dry.

Ensure that the belt adjustment idler bearing is sound and not leaking lubricant.

Fit the crankshaft and camshaft gears ensuring that the camshaft gear is retained with the special bolt, washer and new '0' ring but d o not tighten at this stage.

3 .

Fit t h e p u m p rear support bracket to the front side cover and secure t o the pump with two bolts and nuts.

Inspect t h e pump drive gear for wear and damage, ensure it is thoroughly clean and dry before fitting to the pump. Retain the gear with three bolts and renforceing plate. Do not overtighten the bolts at this stage.

Injection pump, valve timing and drive belt.

Drive belt.

During use, a belt develops a wear pattern relative to its running direction, therefore, if the original belt is to be re-used it must b e fitted so that it continues to rotate in t h e original direction, otherwise the belt must be renewed.

Drive belts must be stored o n e d g e o n a clean flat surface and in such a manner that bends are not less than 50 mm ( 2 in) radius. Do not bend the belt at an acute angle or radius less than 50 mm (2 in) otherwise premature failure of the fibre reinforcement could result.

4. Rotate the camshaft so that t h e centre d o t o n the camshaft gear is aligned with the arrow in the front cover.

5. Temporarily refit the crankshaft pulley and turn th crankshaft so that o n e and four pistons are at TDC and the crankshaft key is aligned with the arrow in the front cover.

ENGINE

L ,

1 .

\\ i

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6. Screw the body of timing pin LST128 into the bottom of t h e flywheel housing and check that the pin will locate into the flywheel slot. It is important t o n o t e that there are two slots in the flywheel and that the narrowest is the one that must b e used for this direct injection engine.

ST2641 M

Fitting a n d tensioning belt drive

Note: It is vitally important that t h e following belt tensioning procedure it carried o u t carefully and accuratly. The p r o c e d u r e involves tensioning t h e belt twice. New a n d original delts a r e tensioned t o different figures.

8. Ensure that t h e crankshaft, camshaft and in jection pump are correctly aligned then carefully fit t h e belt observing any rotational marks made during removal. Feed the delt over t h e gears keeping it tight o n the drive side.

9. Fit the belt tensioner with the special washer and single bolt. Insert a 13 mm (0.5 in) square drive extension into the tensioner plate and with a dial type torque meter, apply a tension of 21.7 Nm (16 Lbf ft) for a new belt, o r 16.3

Nm for an original belt. When the tension is correct and t h e meter is in the vertical position, tighten the clamp bolt.

Note:

To

e n s u r e correct belt tension it is very i m p o r t a n t t h a t t h e tensioner is clamped w h e n t h e t o r q u e m e t e r is in t h e vertical position a n d t h e applied tension is correct.

10. Tighten the three bolts that secure the pump gear and reinforcing plate t o the pump hub t o the correct torque and remove t h e timing pin

LSTI 2912.

CAUTION: Unlock t h e injection p u m p a n d fit t h e keeper plate before attempting t o turn t h e crankshaft. Also e n s u r e that t h e flywheel timing pin LST128 is clear of t h e flywheel slot.

11. Rotate the crankshaft two complete revolutions and slacken the tensioner clamp bolt and tension the belt again, as previously described.

ST301 OM

121

ENGINE

DEFENDER

CAUTION:

The double tensioning procedure is vital otherwise the belt could fail resulting in serious damage to the engine.

12.

13.

Tum the crankshaft again in a clockwise direction until the flywheel timing pin locates in t h e T.D.C. slot. insert t h e timing pin in the pump hub and check that the crankshaft key aligns with the arrow o n the front cover. Also check that the d o t o n the camshaft gear aligns with the arro. if t h e timing pin cannot b e inserted fully into the p u m p hub slot, it is necessary toslacken the three pump gear retaining boltsand slightly turn t h e hub, in the appropriate direction, t o allow t h e pin t o locate. Retighten the bolts t o the correct torqu.

Fitting front cover plate

14. Remove the w o m seal from the cover and clean t h e recess. Support the cover o n a flat surface and using service tool 1861456 press in t h e new seal into the location, lip side leading, so that when fitted the lip faces away from t h e crankshaft.

15. Ensure that the front cover and plate joint faces are clean and fit a n e w gasket t o t h e

16. front cover using a little grease.

Fit a new gasket t o t h e centre hole in t h e cover plate and locate in position by inserting a bolt. Then fit the plate t o t h e cover securing with the eleven retaining bolts using t h e location chart showing t h e various lengths.

Tighten the bolts evenly t o t h e correct torque.

100"

ST2 91 8M

75"

Fitting front damper and pulley

17. Check that the damper rubber is in g o o d condition then locate t h e unit o n t h e crankshaft key and secure with t h e distance piece and special bolt. Apply a little Loctite

242 t o the bolt threads and tighten t o t h e correct torque using service tool LST127 t o restrain the crankshaft, as illustrated.

18. Refit the pulley securing with t h e four bolts and tighten to the correct torque.

ST3 25M

DEFENDER

ENGINE

- i:;.;:: .

...

I*^

WATER PUMP INSPECTION AND FllTlNC

The water pump is not a reconditionable unit but its condition can be determined by the following checks

Spin the p u m p spindle and listen for bearing noise, also push and pull the spindle and check for sideways movement. If the bearing in g o o d condition the clearance between the is

2. impeller and the pump body should not vary.

Inspect the vent hole in the pump body for signs of coolant or lubricant leaks. If there is any evidence of leakage, the pump should be renewed.

Fitting water pump

Lightly grease a new joint washer and place it in position o n the timing cover.

Clean the threads of the water pump retaining bolts and apply Loctite 572 thread lubricant sealant t o the threads of the long bolts which penetrate into the cylinder block.

Fit t h e pump t o the cylinder block and secure in accordance with the bolt chart. Tighten the six bolts and o n e nut evenly t o the correct torque.

35"

Fitting ladder frame

Since the sealant specified t o seal the ladder frame to the crankcase cures within fifteen minutes it is important t o fit sufficient bolts to ensure adequate compression while the sealeant cures.

Clean both sides of t h e ladder frame and remove all traces of old sealant. Check that the frame is not distorted and is free from burrs and damage o n the mating faces that could cause oil o r bypass gas t o leak.

Coat both faces with Hylogrip Primer to clean and hasten curing then apply a bead of

"Hylogrip 2000" 3,O mm wide t o t h e mating face with the crankcase.

Fit ten securing bolts through the ladder frame flange and two more through the sump face as illustrated. Tighten all bolts evenly to the correct torque.

6 . If separated, fit the fan blades t o the viscous coupling with the four screws. Fit the fan and viscous coupling assembly t o the water pump spindle noting that it is secured with a left-hand thread. I f air conditioning is fitted d o not at this stage fit the drive belt until the compressor belt is fitted.

ST3012M'

OIL PUMP

OVERHAUL

Bend back the lock washer and release the nut securing the strainer t o the oil p u m p body and remove the. strainer and sealing ring.

Remove the four bolts and washers, lift off the oil pump cover and remove the driving and driven gear.

Remove the oil pressure relief valve plug and sealing washer. Withdraw the relief valve spring and plunger and examine for wear and scores.

Examine the gears for wear, scores and pitting

5. and renew if necessary. Note: Gears must b e renewed in pairs only.

I f showing signs spind!e of wear the driven gear may be renewed.

ENGINE

6 .

Clean all the components then install both gears into the body ensuring that the recessed e n d of the driving gear is uppermost.

Place a straight e d g e across both gears as illustrated t o measure the end float of each using a feeler gauge. Also check the gear backlash and the clearance between the gears

8. and pump body. The correct clearances are given in the data section.

Examine the gear thrust face o n the pump cover, any slight scratches may be erased by rubbing on fine emery cloth o n a flat surface.

ST3014M

Pump assembly.

9. With gear tolorances correct, lubricate and fit the driven gear to t h e spindle and install the driving gear with the counter bored splined e n d of the gear uppermost in the pump

10. housing.

Fit the cover locating it over the two dowels

11. and loosley secure with the four bolts until the strainer is fitted.

Install the spring into the relief valve then lubricate and insert t h e valve into the relief valve bore retaining with the sealing washer

12.

1 3 .

14. and plug.

Fit a new '0' ring t o the oil strainer pipe and insert into the pump body and loosely secure with the lock washer and nut.

Secure the strainer bracket t o the pump body and tighten the four screws. Tighten the strainer pipe nut and secure with the lock tab.

Insert the pump drive shaft and check that the gears are free t o operate before refitting t o the engine.

DEFENDER

Fitting oil pump

1 5 . Ensure that the oil pump drive shaft is located in the appropriate spiines and fit the oil pump and strainer assembly into the cylinder block using a new gasket, tighten the two bolts t o the correct torque.

ENGINE

Fitting the sump

16.

17.

18.

19.

Ensure that all traces of old sealant are removed from the sump joint face and that the sump is thoroughly clean inside and out.

Remove the two two bolts securing the ladder frame t o the cylinder block to allow fitting of the sump.

Apply a 2,O mm wide bead of "Hylosil" RN102 black t o the sump face and fit the sump.

Install and tighten the twenty remaining bolts t o the correct torque. Note that the three long bolts pass through the sump and ladder frame into the front cover.

CYLINDER HEAD OVERHAUL

CAUTION: Since the cylinder head is manufactured from an aluminium alloy care must be taken t o ensure that the combustion face, in particular, is not damaged o r scratched by placing it on a hard or abrasive surface while carrying out the overhaul operations.

1. Using valve spring compressor MS 151 9A or a suitable altemative, remove the valve and spring assemblies identified t o their original locations.

ST3016M

ENGINE

DEFENDER

Discard the valve springs and valve guide oil seal. Remove carbon deposits from the valves and combustion chambers and degrease all parts ready for examination.

Examine the cylinder head for damage and distortio. Inspect the valve seat inserts for damage. Seat inserts that are beyond repair and require renewal should be replaced by a skilled specialist in this type of work.

Examine each valve guide and valve stem for wear and damage. Suspect guides should b e checked by inserting a new valve into the guide and with the valve lifted approximatly 8 mm clear of the seat the valve head should not rock more than 0,15 mm (0.006 in). If the valve head movement exceeds 0,15 mm (0.006 in) the guide should be renewed. inspect the valves for wear and damage. Valve heads that are burnt and cracked should be renewed. So should valves which are bent and distorted. Insert the valve into a new guide and check the side movement as described above to determine the wear o n the valve stem.

Renew valve guides

6. Support the cylinder head, combustion chamber uppermost o n pieces of timber of sufficient thickness t o allow clearance for the inlet or exhaust f o r the valve guides t o b e driven o u t using special tool

R0274400.

.. . .

Reface valve seat inserts

The special s e t of hand tools recommended for refacing include expandable pilots that fit tightly into new or worn guides to ensure that the valve seat is concentric with t h e valve guide. The refacing tool has tungsten carbide cutters and can b e used t o c u t a new seat in the insert. The valve seat cutter is numbered

MS621, the handle s e t

MS150-8.

MS76B and the pilot

Loosely assemble t h e pilot in the sequence illustrated. Ensure that the chamfered e n d of the expander is towards the collet.

, .

ST2598M

Turn the cylinder head over so that the combustion face is downwards. Lubricate the new valve guides and using special service tool

LST 130 and depth gauge RO 60774A press the guide into position t o the depth determined by the gmge d ?9,0 r r m (0.748 in).

U -

ST2644M

DEFENDER

;..

.:,*,

.;,

10. insert the assembled pilot into the valve guide from the combustion chamber side of the cylinder head until the shoulder contacts the valve guide and the whole of the collet is inside the guide. To lock the pilot in the guide turn the tommy bar clockwise whilst holding the knurled knob.

ENGINE

ST2670M

11. Check that the seat cutter MS621 is assembled correctly using the key MS76 ensuring that the angled end of each cutter is towards the seat and set so that the middle of the blade contacts the seat first. O n e end of the cutter is angled at 45" and the other end is 30".

Valve refacing

14. Valves that are satisfactory for further service can be refaced. This operation should be carried o u t using a valve grinding machine.

Only t h e minimum of material should b e removed from t h e valve face to avoid thinning of the valve edge. The valve is refaced correctly whan all pits are removed and the face is concentric with the stem.

Inlet valve seat f a c e

Exhaust valve seat face

Inlet valve face

Exhaust valve face

30"

45"

0,25"

30"

0,25"

45"

0,25"

I .

ST2645M

12. Using very light pressure tum the cutter clockwise until the angled face is approximatly

01,s mm wide.

13.

To check the effectiveness of the cutting operation smear a small quantity of engineers' blue round the valve seat and revolve a correctly ground valve against the seat. A good seating will produce a continuous fine polished line around the valve face. A slight gap of not more than 12 mm in t h e polished line, can b e corrected by lapping.

Lapping valves

15.

To ensure a gas tight seal between the valve face and valve seat it is necessary t o lap-in the appropriate valve t o its seat. It is essential t o keep t h e valve identified with its seat o n c e the lapping-in operation has been completed.

Unless the faces t o be lapped are in poor

16. condition it should only b e necessary t o use fine valve lapping paste.

Smear a small quantity of paste o n the valve face and lubricate t h e valve stem with engine oil. Insert the valve in the appropriate guide and using a suction type valve lapping tool employ a light reciprocating action while occasionally lifting the valve off its seat and turning it so that the valve returns t o a different position on the seat.

17. Continue the operation until a continuous matt grey band round the valve face is obtained.

To check that the lapping operation is sucessful, wipe off the valve paste from the valve and

18. seat and make a series of pencil lines across the valve face.

Insert the valve into t h e guide and while pressing the valve o n t o the seat revolve t h e valve a quarter of turn a few times. If all t h e pencil lines are cut through n o further lapping is necessary. Thoroughly wash the cylinder head ensuring n o lapping paste remains before

19.

20. fitting the valves.

Position the cylinder head with the combustion face uppermost, lubricate and insert the valves into their respective guides. To check the valve head stand-down or t h e correct dimension of the valve head below the combustion face, use either a dial test indicator or a straight e d g e and feeler gauge as follows.

Hold t h e straight e d g e across the centre of each valve in turn and measure the gap between the valve head and straight edge. The correct dimension should b e 1,l t o 0,9 mm (0.

040 t o 0.035 in). Using a dial gauge zero t h e gauge o n the combustion face then move the stylus across t o the valve head and note t h e reading.

-. -

- ! I I

ST2585M

Assembling valves to cylinder head

21. Insert the valves t o their respective guides and locate a spring protection washer over each guide. Fit new oil seals t o all the valve guides with t h e garter spring uppermost. Ensure that the seals fully locate o n valve guides.

ENGINE

22. Fit a spring and cup t o each valve and compress with special service tool MS1519A or a suitable altemative. Retain with the multi-groove cotters ensuring that they are fully located in the valve stem and cup.

25. The thermostat housing may b e removed from the cylinder head at this stage and if necessary the gasket renewed.

26. The "jiggle pin" which allows any air t o escape from below the thermostat, may b e fitted in any position. Renew the gasket when fitting the thermostat and apply a little Hylomar sealant to the threads of temperature sensor and transmitter before screwing into position.

FITTING CYLINDER H E A D

Piston protrusion and gasket selection

Before fitting the cylinder head, the protrusion of the pistons above the block face must b e checked in order that the correct thickness gasket may be selected from the range of three. The height of all the pistons above the cylinder block must be measured and the thickness of the gasket selected is based upon the largest value of dimension 'A', as exceed 0,8 mm (0.032 in). Al

Thermostat and housing

23. If necessary remove the temperature transmitter and temperature sensor from the housing.

24. Release the three bolts securing the thermostat cover and lift o u t the thermostat. The thermostat may be tested by immersing it in hot water of a known temperature and comparing its operation with the temperature range stamped o n the flange. Any leakage of wax (which is the colour of copper) from around the center pin of the thermostat, indicates that it is faulty and should be renewed. n

ST2646M

Three thicknesses of gasket are available and each size can b e recognised by the number of identification holes punched in the side of the gasket as illustrated. The table below gives the details of t h e gaskets available. The thickness of gasket fitted can be seen when the cylinder head is fitted since the identification holes can be seen protruding from the right hand side of the engine towards the rear.

Number of holes

Metric

Imperial Gasket

ERR0382

0.70 t o

0.61

0.024 to

0.0275

ERR038

ST3022M

0.80 t o

0.71

0.0279 t o

0.0314

ERR0384

ENGINE

Clean the cylinder block combustion face and turn the crankshaft so that number o n e and number four pistons are at

D.C. Use a dial test indicator t o determine the highest travel of t h e piston then zero the gauge and move the stylus over t o the cylinder block and note the reading. Repeat the procedure on the remaining pistons. The highest figure obtained will determine the gasket selected.

Bolt sizes:

M1 0 locations 3, 5, 1 2 and 13

M 1 2 locations 1, 2, 4, 6: 7, 8, 9, 10, 1 I i 14, 15,

16, 17, 1 8

ST2581M

2. Place the selected the head gasket in position o n the cylinder block so that the identification holes are towards the rear o n the right-hand side.

ST2619 M

5. Attach the special service tool degree disc

LST122 to a power bar. Make a suitable pointer from welding rod and attach it t o a bolt screwed into a rocker shaft securing bolt hol.

6 . Tighten all the bolts down through an angle of

60" strictly in the sequence illustrated. As each bolt is tightened scribe a line across the head with a piece of chalk o r crayon t o identify which bolts have been tightened, then tighten each bolt a further 60" again in the correct sequence t o complete the tightening procedure. Re-positioning of the pointer will, n o doubt, be necessary t o reach all bolts.

CAUTION: It is important that the double torquing procedure is observed and that on no account should the total angle of 120" be performed in o n e operation otherwise damage and distortion of the cylinder head may occur.

Clean the cylinder head face and if preferred, guide studs may be fitted to the cylinder block t o facilitate the lowering of the head into position. Locate the head over the two dowels.

Lubricate the threads of new bolts, with light oil, and fit to the positions illustrated according to length and diameter. Tighten the bolts down so that the heads just make contact with the cylinder head. Now, in the sequence shown, tighten all the holtr down tc!

40 Nm with a suitable torque wrench.

4!83 DEFENDER

ENGINE

OVERHAUL ROCKER S H A n

1 .

Remove the five rocker shaft retaining bolts and withdraw the bearing caps, rockers, washers and springs from the shaft.

Examine t h e rocker shaft for wear and discard if the bearing surface is wom, scored or pitted.

Check also that the oilways are clear.

Inspect the rockers and discard if the pads are worn. It is n o t permissible to grind pads in an attempt t o reclaim rockers.

Renew the bushes if the clearance exceeds

0,127 mm (0.005 in). Press in replacements

5. ensuring that the pre-drilled holes align with those in the rockers and machine the inside bore of the bushes to 18,018 mm. The rocker arm and bush oil drillings are shown in the cross section illustration.

Examine the tappet adjustment screws and check that t h e ball end is not worn or pitted and that t h e lubrication hole is clear.

6 . Assemble the rockers, bearing caps, new springs and washers to the shaft noting where the washers are fitted. Hold the assembly together with t h e five rocker shaft retaining bolts.

Push rods

1 . Examine the push rods and renew any that are bent or where the ball or cup ends are worn

2. or pitted.

Fit the push rods to the engine ensuring that the ball-end locates properly in each camfollower slide.

FlITlNG ROCKER S H A I T

1. Ensure that a new cap is fitted to each valve stem before fitting the rocker shaft.

2. Fit the rocker shaft t o the cylinder head ensuring that t h e retaining bolts and push rods are correctly located then evenly tighten the bolts to correct torque.

ST3131M

ST3129M

ENGINE

Adjust tappet clearances

WARNING If the crankshaft is rotated with excessive valve clearances, it is possible that the push rods may become dislodged from the tappet seating and fracture the tappet slide.

To prevent damage, eliminate all clearance from any loose rockers before tuming the crankshaft t o adjust clearances.

1. Tum the engine over until number eight valve

(counting from front of engine) is fully open.

Using a

0,20 mm (0.008 in) feeler gauge adjust the clearance of number o n e valve.

Test procedure crankcase ventilator

2. With the unit removed from t h e rocker cover seal off the two ports illustrated and apply a vacuum t o the third por. As t h e vacuum pump is operated the diaphragm valve will b e heard t o seat. While holding t h e vacuum unseal either of the other two ports and the diaphram valve will release.

3. Failure of the diaphragm valve t o seat during

4. test, indicates that the diaphragm is punctured and the unit should be renewed.

Refit the unit using a new rubber "0"

Continue t o adjust the remaining tappets in the following sequence:

Set No. 3 tappet with No. 6 valve fully open.

Set No. 5 tappet with No.

4 valve fully open.

Set N o . 2 tappet with No.

7 valve fully open.

Set No. 8 tappet with No.

1 valve fully open.

Set

No.

6 tappet with N o . 3 valve fully open.

Set N o . 4 tappet with No. 5valve fully open.

Set No.

7 tappet with No. 2 valve fully open.

Rocker cover and crankcase ventilator

7. If necessary release t h e single bolt and remove the oil separator ventilation valve unit, from the side of the rocker cover and thoroughly clean.

Its function is t o separate t h e oil from the crankcase ventilation atmosphere, allowing the oil t o retum t o the sump and t h e residues t o be drawn into the combustio:! chamber where they are bumed. The unit also contains a diaphragm valve which controls the purge rate of the crankcase fumes. The operation of the valve may be tested as follows.

Fitting rocker cover

5. Apply a continuous bead of RW Hylosil which starts and finishes 10 mm each side of the half

6. m o o n grooves at both e n d s of the rocker shaft and press the seals into position.

Locate a new seal in the rocker cover and fit t h e cover t o t h e cylinder head securing with t h e three special bolts and conical washers.

Tighten the bolts evenly t o t h e correct torque and reconnect t h e ventilation hoses.

E "

ENGINE 12

4. Fit the banjo-union end of the spill return rail t o the rear of the injector pump and secure with a copper washer each side of the banjo and the union bolt.

. ...

.. , ,

ST2948 M

FIITlNG HEATER PLUGS

If necessary check the operation of each heater plug before fitting and tighten t o the correct torque, d o not over-tighten.

Connect t h e electrical harness t o the plugs and secure with t h e single nut and washer. Ensure that each s p a d e terminal is fitted so that neither the terminal nor the insulation touches the cylinder head, o r oil separator.

FllTlNG INJECTORS A N D

PIPES

1. Ensure that the injector and seating in t h e cylinder head is clean then lightly grease a new copper washer in position o n the injector.

2. Fit the injectors with the spill return outlet facing towards the rear of the engine and secure each with a clamp and nut. The clamps are slightly curved and the convex side should be fitted uppermost. Tighten the nuts t o the

3. correct torque.

Fit the spill return rail t o the injectors, noting that there are two copper washers and o n e must be fitted each side of the retaining union screw. The in-board washer locates in a recess in the injector. Do not over-tighten t h e screws.

5. Fit t h e injector fuel supply pipes securing each end of the pipes t o their respective locations loosely, then tighten evenly. D o not, however, over-tighten.

Commencing at the front of the engine connect the pipes as follows:

A. To number 1 injector.

B. To number 2 injector.

C. To number 3 injector.

To number 4 injector.

... 19

FUEL SYSTEM

FUEL INJECTION PUMP

Service Repair No. 19.30.07

Remove and refit

Special tools:-

Flywheel timing pin

Pump gear retaining tool

Pump timing pin

LST 128

LST 12911

LST 12912

1. Remove the bonnet and disconnect the battery.

2. Drain the cooling system.

3. Remove the fan and viscous coupling assembly see operation 26.25.19

4. Remove the fan cowl see operation 26.25.11.

5. Disconnect the lower cooling hose from the

6 . waterpump.

Remove the oil filler cap so that the position of

7. number o n e cylinder valve rockers can b e s e e n t o assist in obtaining T.D.C.

Tum the crankshaft to align the T.D.C mark o n the crankshaft damper with the the w e b o n t h e front cover plate. At the same time check that the valves of number o n e cylinder are closed.

9. Remove the injector pump hub blanking plate.

10. Insert the injector pump timing pin LST 12912

Through the "U" shaped slot in the pump hub into the pump body. Ensure that the pin fits easily and is fully inserted.

LST 129/2

ST3044M

Remove the blanking plug from the bottom the flywheel housing

and

of fit the timing pin LST

128. Check that the pin can b e inserted into the appropriate slot in the flywheel. Note that there are two slots in the flywheel t h e narrowest o n e being that which determines

T.D.C. for this engine.

Continued

FUEL SYSTEM

11. Slacken the p u m p locking screw and remove the keeper plate. Tighten the screw t o lock t h e pump.

CAUTION: Once the timing pin LST 129/2 is inserted and the pump shaft locked, no attempt must be made to rotate the crankshaft.

14. Remove the injector pipes and disconnect the following items from the injector pump.

Throttle cable. s t o p control solenoid lucar.

Spill return pipe.

Turbo charger boost hose.

Main fuel supply pipe.

15. Remove the injector pump rear support bracket.

16. Remove the oil filter adaptor rear attachment bolt t o allow clearance for the pump t o be withdrawn.

12. Remove the pump drive gear three retaining bolts and remove the lock plate and timing pin.

13. Fit the pump gear retaining tool LST 129/1 and align and tighten the two bolts. insert the timing pin LST 129/2, again, through the hole provided in t h e retaining tool.

17. Remove the pump three retaining nuts and withdraw the pump and gasket, with LST 12912

18. Fit blanks t o the inlet and outlet ports t o prevent entry of dirt. Slacken the locking screw, fit the keeper plate and tighten t h e screw.

ST3037M

FUEL SYSTEM

Reff iting

19.

20.

Clean the pump flange and front cover mating face and place a new gasket in position over the the studs.

Fit the timing pin LST 129/2 t o the pump, if necessary, rotate t h e pump t o enable the pin

21. easily and fully.

Slacken the pump locking screw, remove t h e keeper plate and tighten the screw t o lock t h e pump-

DEFENDER

ST3043M

21

22.

23.

24.

25.

26.

Fit the pump t o the front cover and drive gear and secure with the three nuts tightening evenly t o the correct torqu.

Fit t h e rear support bracket t o the cylinder block and secure t h e pump t o the bracket.

Tighten all bolts the the correct torque.

Fit t h e oil filter adaptor rear attachment bolt.

Connect the items listed in instruction 14.

Fit t h e injector supply pipes securing each e n d to their respective locations, loosely then tighten evenly but do not over tighten.

Commencing at t h e the front of the engine connect the pipes as follows:-

B t o number o n e injector. t o number two injector.

C t o number three injector.

D t o number four injector.

27.

28.

29.

30.

31.

Remove t h e p u m p timing pin and the p u m p gear retaining tool LST 129/1. insert t h e pump timing pin again and fit t h e gear lock plate and secure with the three bolts and tighten to the correct torque.

Remove the timing pin. Unlock the pump, fit the keeper plate and tighten the bolt.

To check that the p u m p timing is correct, turn the crankshaft two complete revolutions and check that the timing pin LST 129/2 can b e inserted easily and fully into t h e pump. at the same time check that t h e flywheel timing pin can also b e inserted in t h e flywheel slot.

If, with t h e flywheel timing pin located, t h e timing pin cannot b e inserted cleanly into the pump, carry out t h e following instructions:-

1. Turn the crankshaft t h e small amount necessary to enable t h e timing pin t o b e inserted into the pump.

Remove t h e keeper plate a n d lock the pump.

Slacken t h e three p u m p gear retaining bolts.

Tum the crankshaft to T.D.C.

Check that t h e timing pin is an easy fit in the

6. pump and that t h e flywheel timing pin locates.

Tighten t h e p u m p gear retaining bolts t o the

7. correct torque.

Unlock t h e pump, fit t h e keeper plate and tighten t h e bolt. Remove t h e timing pin from the the p u m p and the timing pin tool from the flywheel.

32.

33.

Fit the p u m p aperture cover with a n e w gasket and secure with the screws.

Connect t h e cooling system bottom h o s e t o the waterpump.

Continued

34. Place the fan cowl in position but do not secure it t o t h e radiator until t h e fan and coupling is fitted.

35. Fit the fan and viscous coupling assembly t o the waterpump spindle. Tighten the left hand thread to t h e correct torque using a Tommy bar in the hole provided in the fan pulley t o restrain the coupling.

36. Secure the fan cowl t o the radiator with the

two

nuts.

37. Fit the t o p coolant hose.

38. Refil the cooling system with t h e correct concentration of water and anti-freeze s e e operation 26.10.01.

AIR CLEANER

Service Repair No.

Remove and refit

1. Disconnect t h e hose from the turbo charger

2. compressor housing t o air cleaner.

Disconnect, from the air cleaner, the engine breather hose.

3. Disconnect from the air cleaner, t h e air inlet

FUEL

SYSTEM

119

Unscrew the wing nut and withdraw the element.

Clean the interior of the casing and cover.

Fit a new element, fins leading, into the casing.

10. Secure the element with the wing nut.

11. Fit the end cover and aline the two arrows.

Refitting

12. The two clips o n the side of the casing locate in the square slots in the air cleaner mounting cradle. It is necessary therefore, t o twist t h e air cleaner clockwise into its final position and ensure that the clips engage in the slots.

13. Secure the air cleaner with the two fastners.

14. Connect all the hoses, reversing instructions 1

15. to 3.

Finally, reset the element change indicator, where fitted, by depressing the button.

5. To release and remove the air cleaner from its mounting cradle, twist the body of the air cleaner anti-clockwise (viewing it from the front of the engine) and remove it from the vehicle.

Renewing e l e m e n t

6 . Unscrew t h e handwhee! anti-c!nckwise and remove the e n d cover.

ST3036M

12’

FUEL SYSTEM

TURBO CHARGER

Service Repair No. 19.42.01

Remove and refit

Remove the bonnet and disconnect t h e battery.

Remove the turbo charger heat shield.

3. Disconnect the exhaust front pipe from the turbo charger elbow.

4. Release the front exhaust pipe from the support bracket attached t o t h e cylinder block.

5. Remove the five nuts and remove the elbow from the turbo charger.

6 . Remove the air inlet hose from the air cleaner

7. and turbo charger.

Disconnect, from t h e turbo charger, t h e

9. bottom hose from t h e intercooler.

Remove t h e boost pressure pipe from t h e turbo

Slacken the turbo charger oil feed pipe clamp.

10. Disconnect the oil supply pipe from t h e turbo charger centre housing.

11. Release the oil return drain pipe from the

12. turbo charger.

Remove t h e four nuts and lift the turbo charger from the exhaust manifold and retrieve the steel joint washer.

DEFENDER

Refitting

13. Fit the steel joint washer t o the t o the exhaust manifold

Gl%B DEFENDER

FUEL SYSTEM

. . . .

, ,.

14. Fit the turbo charger and secure with the four nuts and tighten evenly t o the correct torque.

15. connect the oil feed and retum pipes t o the turbo charger and tighten the feed pipe clamp.

16. Connect the boost pressure pipe t o the "T" piece and secure with the clip.

17. Connect the intercooler h o s e t o t h e turbo inlet.

18. Fit the hose t o air cleaner and turbo charger.

19. Fit the turbo charger elbow.

20. Connect the exhaust front pipe t o t h e elbow using Holts "Firegum" t o seal t h e joint.

21. Fit the heat shield and secure at t h e two fixing

22. points.

Fit the bonnet and connect the battery.

INTERCOOLER

Service Repair N o . 19.42.15

Remove, clean and refit.

1 . Remove the fan and viscous coupling assembly, see operation 26.25.1 9.

2. Remove the fan cowl, see operation 26.25.11.

Disconnect t h e t o p and bottom hoses from t h e Intercooler.

Remove the four bolts (two

5. retaining the radiator t o p support brackets.

Remove the four bolts (two each e n d ) securing the radiator surround t o p panel, and remove t h e panel.

6. Lift out the Intercooler.

Cleaning.

Flush the intercooler with ICI "GENKLENE" propriety cleaner, following the manufacturers instructions.

Dry the Intercooler completely ensuring that n o liquid remains in t h e element.

Refitting.

9. Slide the htercooler into position taking care not to damage the insulation material on the sides.

10. Fit the radiator surround t o p panel and secure with the four bolts.

11. Fit the two t o p brackets and secure with the four bolts.

12. Connect the top and bottom hoses.

13. Fit the fan cowl.

14. Fit the fan and coupling assembly.

ST2928M

...

COOLING

SYSTEM

DEFENDER

COOLING SYSTEM

Engine protection

To prevent corrosion of aluminium engine parts it is vital that the cooling system is filled with a solution of clean water and anti-freeze winter and summer.

Never fill o r top-up with water only. always add anti-freeze. Never use salt water otherwise corrosion will occur. In certain territories where the only available water supply may have s o m e salt content, use only clean rain water o r distilled water, with anti- freeze added.

Use only Universal anti-freeze or permanent type ethylene base, without methanol, containing, a suitable inhibitor for aluminiium engine parts. Use o n e part of anti-freeze t o o n e part water.

Anti-freeze should be used even in climates where it is not necessary.

Anti-freeze can remain in t h e cooling system and will provide adequate protection for two years provided that the specific gravity of the coolant is checked before the onset of the second winter and topped-up with new anti- freeze as required.

Land Rovers leaving the factory have the cooling system filled with a 50% anti- freeze mixture. This gives protection down t o minus 47 degrees

Centigrade (minus 53 degrees Fahrenheit).

After the second winter t h e system should be drained and thoroughly flushed. Before adding new anti-freeze examine all joints and renew defective hoses t o make sure that t h e system is leak proof.

See section 09 for protection quantities.

Service Repair No. 26.10.01

Drain and refil

WARNING: D o not remove the radiator or expansion tank filler cap when the engine is hot because the cooling system is pressurized and personal scalding could result.

1. Disconnect the battery.

2. Disconnect the bottom coolant hose from the radiator. Allow t o drain and reconnect the

3. hose.

To drain the cylinder block, remove the drain plug which is situated o n t h e left hand side of the engine immediately below front core plug.

Refit t h e plug, with a new washer, when t h e draining is completed.

To drain the expansion tank, remove the cap and disconnect the expansion hose from the radiator and allow it t o drain into a suitable container. Flush the tank with clean water and reconnect the hose.

Refilling.

5. Make up a solution of anti-freeze and water in a separate container in t h e concentration required. To allow for topping-up, and for filling the expansion tank, prepare a quantity in

6 . excess of the cooling system capacity.

Remove t h e radiator filler cap and fill t h e radiator until t h e coolant level is just below the filler neck and refit the cap.

7. Fill t h e expansion tank to approximately half

8. full and refit t h e cap.

Connect t h e battery and run the engine until normal operating temperature is attained.

Allow the engine t o cool completely and removethe radiator and expansion tank caps. If necessary, top-up t h e the radiator t o just below t h e filler neck. Top-up the expansion tank t o about half full. Fit both filler caps.

ST3032M

\ -

G83 DEFENDER

COOLING

SYST

M

FAN COWL

Service Repair No. 26.25.11

Remove and refit.

1 . Follow instructions 1 t o 7 operation 26.25.19.

2. Remove t h e cowl from t h e engine compartment.

Refitting.

3. Reverse instructions 1 and 2.

FAN AND COUPLING ASSEMBLY

Service Repair N o . 26.25.19

Remove and refit.

1. Disconnect t h e battery for safety reasons.

2. Drain the coolant by disconnecting the radiator bottom h o s e and reconnect when coolant has drained.

Remove the t o p hose.

Using a cranked o p e n e n d e d spanner and a restraining bar in the hole in the pulley hub, release anti-clockwise, the viscous coupling from the water pump spindle. Lower the fan and coupling assembly into the base of the cowl.

5. Remove t h e two nuts securing the cowl t o the radiator.

Refitting

8. Insert the fan and coupling into the base of the cowl reversing t h e removal procedure.

9. Fit the coupling t o t h e water pump spindle noting that it has a left hand thread. Tighten

10. the coupling using t h e restraining bar and cranked spanner.

Fit the cowl and secure with the two nuts.

Ensure that the cowl fits properly in its lower

11.

12. location.

Fit the t o p hose and refill the cooling system with the correct concentration of anti-freeze and water.

Connect the battery, run the engine and check for coolant leaks.

6 . Lift the cowl t o release it from its lower

7. location.

Move the cowl forward, towards the engine

236 ii4ihbixi the faii aiid coiipling i i ~ ~ e ~ b l y from the gap created between the cowl and radiator.

RADIATOR

Service Repair No. 26.40.01

Remove and refit

1. Remove the fan and viscous coupling assembly, see operation 26.25.19.

2. Remove the fan cowl, see operation 26.25.11.

3. Disconnect the h o s e s from the intercooler.

4. Disconnect the expansion tank hose from the radiator.

5. Disconnect the oil cooler pipes from the

6 . radiator and cover t h e ends to prevent entry of dirt.

Disconnect the b o t t o m hose from the radiator.

7. Remove the four bolts, two each side, retaining t h e radiator t o p securing brackets, and remove the brackets.

8. Lift o u t the radiator complete with the intercooler.

4;--

9. Check that the rubber grommets on the radiator locating pegs and beneath the radiator mounting brackets on the chassis cross member are in position.

10. Lower the radiator into position ensuring that the pegs locate in the mounting brackets.

lO----;-ii;LT

ST3033M

Z I

11. Fit the radiator top mounting brackets and secure with the four bolts.

12. Connect the radiator bottom hose.

13. Fit the oil cooler pipes to the radiator.

14. Connect the expansion tank hose.

15. Connect the top and bottom hoses to the intercooler.

16.

Place the fan cowl in position but do not secure at this stage.

17. Fit the fan and viscous coupling and secure the cowl with the two nuts.

18. Check that all the coolant hose and refill the cooling system with the correct concentration of operation 26.10.01. clips are tight water and anti-freeze, see

CO OLING SYSTEM

WATER PUMP

Service Repair

No.

26.50.01

Remove a n d refit

Remove the fan and coupling assembly operation 2. 25.19.

Remove the fan cowl operation 26.25.11.

Slacken the fan belt tension and remove it

4. from t h e pulley.

Remove the four bolts securing pulley t o hub.

DEFENDER

Refitting

9. Clean the water pump and front cover plate mating faces.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Lightly grease a new gasket and place in position on the cover plate.

Clean t h e threads of the water pump retaining bolts and apply Loctite 572 thread lubricant sealant t o the threads of all the bolts.

Fit the pump to the engine and secure with t h e six bolts and o n e nut in accordance with t h e chart below. Tighten t h e fixings evenly and t o the correct torque.

Connect the bottom hose t o the water pump.

Fit the pulley t o the water pump hub and secure with the four bolts.

Fit and tension the water pump/aiternator belt.

Fit the fan cowl.

Fit the fan and coupling assembly.

Check that all t h e coolant hose clips are tight and refill the cooling system with the correct

19. concentration of water and anti-freeze, s e e operation 26.10.01.

Connect the battery, run t h e engine and check for coolant leaks. r e

5 ., v

6 .

Remove the thermostat housing t o water pump hose.

Disconnect the bottom hose from the water

8. pump-

Remove the six bolts and o n e nut securing the water p u m p t o t h e front cover plate.

Remove the water p u m p and gasket.

DEFENDER

EXHAUST AND INLET MANIFOLDS

Service Repair No. 30.15.01

Remove and refit

Note: to remove the inlet manifold, the exhaust mainifold must b e removed first.

Disconnect the battery.

Remove t h e air cleaner to turbo charger inlet

3. hose from the turbo charger.

Disconnect hose from turbo charger t o

4. intercooler.

Remove t h e turbo charger heat shield.

5. Disconnect from the turbo charger, the oil

6. feed pipe.

Disconnect t h e front exhaust pipe from the turbo charger elbow.

M A NI

FOL

D S

AND EXHA U ST

130

Release the front exhaust pipe bracket from the cylinder block.

Disconnect the front exhaust pipe from the forward silencer pipe.

Release the heater rail from t h e exhaust manifold studs.

10. Disconnect the boost pressure turbo charger. pipe from the

11. Disconnect the turbo charger oil drain pipe from the cylinder block.

12. Remove the exhaust mainfold nuts and withdraw the manifold complete with t h e turbo charger.

Inlet manifold

13. Disconnect hose from inlet manifold

14. Remove the two bolts and two nuts and withdraw the inlet manifold.

15. Remove the common gasket.

ST2938M

Continued

Ref ittng

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Place a new gasket in position and fit the inlet manifold and secure with the two bolts and two nuts and tighten t o the correct torque.

Fit t h e exhaust manifold complete with turbo charger and secure with the nuts.

Fit t h e heater rail t o t h e manifold studs.

Connect t h e turbo charger oil drain pipe t o the cylinder block.

Connect t h e boost pressure pipe t o the turbo charger.

Using

"HOLTS"

"FIRE

GUM" fit the front exhaust pipe t o t h e turbo charger elbow and secure with the clamp. Note, before fitting the pipe t o t h e elbow make sure that the securing clamp is above t h e inlet manifold since the clip will not pass between the front pipe and manifold.

Connect t h e front pipe t o the forward silencer.

Fit-the front pipe support bracket t o the cylinder block with t h e single bolt.

Connect t h e turbo charger oil feed pipe.

Fit t h e intercooler t o turbo charger hose.

Fit t h e air cleaner t o turbo charger hose.

Fit t h e turbo charge heat shield.

Connect t h e battery, run the engine and check for exhaust gas leaks.

DEFENDER

STEERING

' .

POWER STEERING PUMP

Service Repair No. 57.20.14

Remove and refit

1. Working from beneath the vehicle, release the drive belt tension by slackening the two adjustment clamp bolts and the single pivot bolt and remove the belt.

ST3050M

2. Disconnect from the pump, the supply hose from the fluid reservoir and drain into a suitable container.

3. Remove the banjo union bolt from the rear of

4. t h e pump and allow fluid t o drain into a container.

Remove the three bolts slackened in instruction 1 and remove the pump complete with adjustment plate and pulley.

5. Remove the four bolts to release the drive

6 . pulley from the pump hub.

Since the adjustment plate can be fitted in more than o n e position on the pump, mark the relationship of the pump to the plate before removing the four attachment bolts.

Refitting

Fit the adjustment plate to t h e pump aligning the marks made when dismantling and secure with the four bolts.

Fit the drive pulley and retain with the four

9. screw.

Fit the pump and adjustment plate t o the engine bracket and loosely secure with the pivot bolt and two adjustment clamp bolts.

10. Fit the drive belt and lever the pump away from the engine t o tension the belt and tighten the two clamp bolts and single pivot bolt. The belt is correctly tensioned when, at the mid-point of its run it can b e deflected by thumb pressure 12" (. 5ins.)

CAUTION: Do not apply any pressure against the pump'casing when tensioning the drive belt since it will damage the casing permanently, beyond repair.

11. Connect the fluid h o s e and secure with the clip.

12. Fit the banjo bolt ensuring that a special steel washer is fitted each side of the banjo.

13. Top up the fluid reservoir with the correct make and grade of fluid, see section 09.

14. Run the engine and turn the steering from lock t o lock. Re-check the fluid level and the drive belt tension. Also examine for fluid leaks.

1. Pulley 6. Washer(specia1)

2. Adjustment plate 7. Banjo

Pump inlet hose

5. '0' rings

Washer(specia1) bolt

10. Union nut

,:\

ALTERNATOR

Service Repair No. 86.10.02

Remove and refit

1. Disconnect the battery.

2. Remove the air cleaner, s e e operation

19.10.01.

3. Remove the intercooler t o p hose assembly t o the inlet manifold.

4. Remove the intercooler bottom hose assembly t o the compressor housing.

5. Slacken the adjustment strap pivot bolt.

6 . Remove the adjustment strap clamp bolt.

Remove the alternator two pivot bolts.

Release the drive belt from the alternator pulley. Note, t o renew the drive belt, the

9. power assisted steering pump and air conditioning compressor drive belts must first be removed.

Disconnect t h e electrical leads and remove t h e alternator. n

ELECTRICAL

EQUIPMENT

I86

Refitting

10. Connect the electrical leads t o the alternator before placing it in position o n the common

11. bracket.

Secure the alternator with the two pivot bolts and nuts, but leave slack at this stage.

12. Fit the adjustment strap clamp bolt and leave slack.

13. Fit the drive belt t o the pulleys.

14. Tension the drive belt by levering the altemator away from the engine, taking care not t o damage the alternator, and then tighten the adjustment strap c!amp bok. The tensicn is correct when t h e belt can be deflected 12mm

(0.5ins.I at the the mid-point of the longest run between t h e pulleys.

15. Tighten the adjustment strap pivot bolt and the altemator two pivot nuts and bolts.

17. Reconnect the battery, run the engine and recheck the fan drive belt tension.

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DEFENDER

G E

E

L

E

GI

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G

CONTENTS

TO

QUE

COOLI

G

MANIFOLDS

EXHAUST

ELECTRICAL EQUIPMENT

INTRODUCTION

S

INTRODUCTION

INTRODUCTION

Class

Class

-------

n

E

E

S P

CIFICA

ION DA

ENGINE

D

T

FUEL

COOLING

CLUTCH

ENGINE TUNING DATA

O

U

RE

H

Nm

N m

RECOMMENDED LUBRICANTS, FLUIDS A N D CAPACITIES

BLS

v'scos'Ty

ENGINE

LAND

ENGINE

INDEX:-

ENGINE

E

G

E

ENGINE

ENGINE

ENGINE

ENGINE

INSPECTION

ENGINE

ENGINE

ENGINE

ENGINE

ENGINE

as

ENGINE

ENGINE

ENGINE

To

ENGINE

PIPES

FUEL SYSTEM

and

FUEL SYSTEM

FUEL SYSTEM

21

two

SYSTEM

FUEL SYSTEM

FUEL SYSTEM

COOLING