Land Rover Defender 90 110 Workshop Book 6 Supplement Rover

ENGINE a DEFENDER 
Removing fuel pump  and side  cover 
12 
20. Use a 6 mm allen key to release  the fuel  lift 
pump  to gain  access 
to the side  cover 
retaining  bolts. 
21. 
Release the six bolts  and remove  the cover 
plate. 
See  fitting 
lift pump. 
Remove  front side cover  plate 
22. 
Release the six bolts  and remove  the front  side 
cover plate  complete  with the crankcase 
ventilation  pipe. 
I 111 ST3003 M 
Remove camfollowers 
See cylinder  head remove 
CAUTION: The camfollers  are...

12 
Removing the camshaft. 
ENGINE e DEFENDER 
1. Release the two screws  and remove  the 
camshaft  thrust plate. 
2. Carefully  Withdraw  the camshaft  taking care 
not 
to allow  the end of the  shaft to drop on to 
the  bearings 
as it is removed. 
See  fitting  camshaft 
ST2552M 
Removing  Clutch and Flywheel  housing 
See 
1. 
2. 
See  engine 
unit  removal 
Mark the relationship of the  cover  to the 
flywheel  to ensure  original  balance 
is 
maintained. 
Evenly  slacken  and remove  the six...

I 
I ... 
e DEFENDER ENGINE n 12 
Removing sump and oil pump 
1. If necessary  drain  the engine oil. When 
working  with the engine  on a work  stand, 
invert  the cylinder  block 
so that the sump is 
uppermost.  Remove the screws  and ease  the 
sump  from the ladder  frame to reveal  the 
oil 
Pump. 
1 ST2553M 
Note: After removing  the oil sump when the 
engine 
is in  the  vehicle,  refit and tighten 
two of the retaining  bolts to the  left side  of 
the  cylinder 
block to maintain  pressure on...

1121 ENGINE DEFENDER 
Removing pistons and connecting  rods 
Note:  On this  version 
of the Tdi  engine, it is not 
possible  to 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  to bring  all the  connecting 
rod  cap  nuts  to an  accessable  position and 
slacken  the nuts  using  a 
15mm socket. 
2. Remove  the connecting  rod nuts  and remove...

DEFENDER ENGINE n 12 
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 
cylinder  block. 
7. 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  out a...

12 
If the above  figures  are exceeded the  cylinders must 
condition 
of the  bores  and the amount of wear. 
Altematively, if the overall  wear, taper and ovality 
are  well  within  the acceptable  limits and the original 
pistons are  serviceable new piston  rings  may  be 
fitted.  It 
is important  however, that ,the bores are 
deglazed,  with a hone,  to give  a cross
-hatched 
finish  to provide  a seating  for the  new  ring. 
 be rebored or sleeved  depending  upon the 
ENGINE DEFENDER...

DEFENDER ENGINE n 12 
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. 
.*  .. 11 
It is important  to ensure  that, when  grinding,  the 
stone  travels  beyond  the edge 
of the joumal A to 
avoid  formation 
of a step B as illustrated. Also care 
must  be taken  not to machine  or damage  the fillet 
radii 
C. 
It is vital  to thoroughly  wash the...

1121 ENGINE e DEFENDER 
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 
7. If gauge equipment is not available  the 
piston 
diameter from  the bore  diameter. 
clearance  can be 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...

DEFENDER ENGINE 
.- 
1 -,.:.

(121 ENGINE DEFENDER 
20. Connecting rod bearings that are worn,  pitted, 
scored  and show  signs 
of overheating  must be 
discarded. 
If more  than one of the bearings 
show  these  signs they must  all be  renewe. 
When  fitting new 
or used bearings  to 
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...