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Land Rover 90 110 Workshop Rover Manual

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    							121 ENGINE a DEFENDER 
    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  Overhaul  Refit 
    Page  Page  Page 
    38 
    38 
    38 
    39 
    39 
    40  40 
    40 
    40 
    40 
    41 
    41 
    - 42 
    43  44 
    44 
    44 
    - 45 
    46 
    46 
    46 
    47 
    48  48  72 
    78 
    66 
    63 
    70 
    76 - 77 
    80 
    80 
    79 
    78 
    76 
    62 
    - 66 
    70 
    66 
    69  69 
    68 
    66  67 
    66 
    65 
    65 
    62 
    62 
    72  72 
    63 
    - 64 
    The 
    foregoing  list of remove and refit  operations  are those  which  can be carried-out with  the engine  in the 
    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 injection  pump 
    Air 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  30 
    31 
    32 
    81 
    84 
    35 
    86 
    87 
    88 
    88 
    89 
    90 
    91 
    93 
    94 
    30  
    						
    							.: ?: ,i .,. .!.-. ..... . +_I._ - : . . U .. . . .,.. 
    e DEFENDER 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 
    the  coolant  to drain  and reconnect  the hose. 
    3. Remove  the radiator  top coolant  hose, 
    4.  Remove  the fan and  viscous  coupling 
    assembly, 
    see operation  26.25.1 9. instructions 
    4  to  7. 
    5.  Remove  the fan cowl. 
    6.  Remove  the radiator,  see operation  26.40.01. 
    7. Remove the air cleaner, see operation 
    instructions 
    3 to 5 and 7 to 8. 
    19.1 0.01. instructions 1 to 
    5. 
    instruction 
    5 to  9. 
    bracket, 
    see operation 12.25.22 instructions 4 
    to  9. 
    where  fitted, and the mounting  bracket 
    together  with the platform  secured by four 
    socket  headed  bolts. Note that the hoses  must 
    not  be removed  from the compressor  but it 
    should 
    be carefully  secured to one side. . 
    - 8. Remove  the alternator, see operation 86.10.02. 
    9. Remove  the power  assisted  steering  pump 
    10.  Remove  the air conditioning  compressor, 
    ... 
    11. Remove the exhaust  and inlet  manifolds,  see 
    operation  30.15.01 instructions  4 to  15. 
    12.  Remove  the cylinder  head, see operation 
    12.29.02 instructions  6 to 7 and 9 to 17. 
    13. Now  follow  the instructions  in ENGINE 
    OVERHAUL section  12. SEE INDEX:- 
    Operations  with engine  installed  in vehicle 
    Refitting 
    14. 
    15. 
    16. 
    17. 
    18. 
    19.  Follow 
    the instructions  for  fitting the camshaft 
    and  assembly 
    of the engine  up to the fitting of 
    the rocker cover,  crankshaft  damper and 
    pulley. 
    Fit  the  inlet  and exhaust  manifolds 
    see 
    operation 30.15.01 instructions  16 to 24  and 
    27. 
    Fit  the  power  assisted steering  pump bracket 
    and  secure  and the four  bolts. 
    Fit  the  power steering  pump to the  bracket 
    with  the single  pivot bolt and clamp  bolts. 
    Leave  the bolts  slack at this  stage. 
    Fit  the  alternator  to the  common  bracket, see 
    operation 
    86,10.02 instructions  10 to 15. 
    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  12 
    mm (0.5ins.I at the mid point of the  run 
    between  the compressor and  crankshaft 
    pulleys 
    . Tighten  the pivot  and clamp  bolts. 
    Mme 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. 
    31  
    						
    							L 
    12 
    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, see  operation  19.10.01 
    instructions 
    12 to  14. 
    22.  Fit the  radiator, 
    see operation  26.40.01 
    ENGINE a DEFENDER 
    POWER STEERING  PUMP BRACKET 
    Service Repair No. 12.25.22 
    Remove  and refit 
    1. Disconnect  the battery. 
    2. Remove  the air cleaner,  see operation 
    19.1 0.01. 
    3. Remove  the alternator,  instructions  2 to 9 
    operation  86.1 0.02. 
    4.  Remove  the steering  pump 
    two adjustment 
    clamp bolts  and remove  the drive  belt. 
    5. Remove  the single  pivot  bolt. 
    \ II c 
    \y 4 ST3026M 
    instructions  9 to  15. 
    23.  Fit the  fan cowl  in position  but  do not  secure 
    to  the  radiator.  retaining bolts. 
    24.  Fit the  fan and coupling  assembly, see 
    operation  26.25.19 instructions 
    8 to 11. 
    25. Fill the cooling  system, see operation  26.10.01 
    instructions  5 to 
    8. 
    6. Move  the pump  aside with the two hoses  still 
    attached  to gain  access 
    to the bracket four 
    7. Remove  the single long bolt  through  the 
    8. Remove the single bolt  frpm the front  into the 
    cylinder 
    block into 
    the bracket. 
    cylinder block. 
    Continued 
    32  
    						
    							DEFENDER ENGINE 11 2 
    I- . 9. Remove the two bolts inside  the bracket  into 
    the  front  cover and  remove the bracket  and 
    triangle  shaped packing  plate. . -.  ~ I .I, .J 
    -. . Refitting 
    10. 
    11. 
    12. 
    13. 
    14. 
    15. 
    16. I. 
    Fit  the  bracket  to the  cylinder  block with the 
    four bolts,  reversing  instructions 7 to 9. 
    Loosely secure the  pump to the bracket  with 
    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. 
    Tighten the two clamp  bolts  and single  pivot 
    bol.  The belt  is correctly  tensioned when  the 
    belt  can  be deflected  by thumb  pressure  12 
    mm (0.5ins.) 
    Fit the  alternator  and  tension  the drive  belt, 
    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. 
    CYLINDER  HEAD 
    Service  Repair No. 
    12.29.02. 
    Remove  and refit 
    1. 
    2. 
    3. 
    4. 
    5. 
    6. 
    7. 
    8. 
    9. 
    10. 
    11. 
    12. 
    13. 
    14. 
    15. 
    16. 
    17. 
    Remove  the bonnet  and disconnect  the 
    battery. 
    Drain  the coolant. 
    Remove  the radiator  top hose. 
    Remove  the exhaust  and inlet  manifolds, 
    complete  with turbo  charger 
    see operation 
    30.29.02. 
    Remove  the heater  rail. 
    Remove  the thermostat  to waterpump  hose. 
    Disconnect  the electrical  leads fromthe 
    thermostat  housing sensors. 
    Disconnect  the harness  from the alternator. 
    Remove  the heater  hose from the cylinder 
    head. 
    Remove  the axle  breather  pipe bracket  from 
    the  rear 
    of the cylinder  head. 
    Remove  the fuel  pipes from  the injectors  and 
    injector  pump. 
    Remove  the spill  return  pipes  from the 
    injectors. 
    Remove  the injectors  and washers  and place  in 
    a  clean, 
    sealable container, for safe  keeping. 
    Remove  the electrical  leads from the heater 
    Remove  the heater  plugs and store  in a safe 
    place. 
    Remove  the hose  from the breather  valve. 
    Follow  the instructions  in the 
    ENGINE 
    OVERHAUL section  12. SEE INDEX:- 
    Operations  with engine  installed  in vehicle. 
    plugs. 
    Continued 
    33  
    						
    							121 ENGINE a DEFENDER 
    _I 
    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  to touch  the cylinder  head when 
    fitted. 
    20.  Fit the  injectors 
    - see  ENGINE OVERHAUL. 
    21.  Fit the  spill  retum  pipes  to the  injectors. 
    22.  Fit the  supply pipes 
    to the injectors  and  pump. 
    23. Fit the  hose  to the  breather  valve. 
    24.  Fit the  axle  breather  bracket. 
    25.  Fit the  heater  hose 
    to cylinder  head. 
    26. Connect  the hamess  to the  altemator. 
    27.  Fit the  waterpump  to thermostat  hose. 
    28.  Connect  the leads  to the 
    thermostat sensors. 
    29. Fit the  inlet  and exhaust  manifolds and heater 
    - rail. 
    30. Fit the  radiator  top hose. 
    31. 
    Fill the  cooling system,  see operation  26.10.01. 
    32.  Fit the bonnet. 
    f-; .... . .., . . 
    34  
    						
    							DEFENDER ENGINE n 12 . .I m I 
    CAMSHAfl TIMING BELT 
    Service Repair No. 12.65.18 
    Renew 
    1. Disconnect  the 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  do not  detach  the 
    fluid  hoses  from the compressor.  Move the 
    compressor  aside taking  care not to strain  the 
    Assembling hoses. 
    6. 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 to the 
    front  cover  and 
    cover plate. 
    8. Remove  the water  pump  and alternator  drive 
    belt,  see operation  86.10.02  insturctions  4 to 
    7. 
    9.  Remove  the hoses  from the water  pump. 
    NOTE:  From this stage  onwards  reference 
    should 
    be made  to the  instructions  in the 
    ENGINE 
    OVERHAUL section  12. SEE INDEX:- 
    Operations with engine  installed  in vehicle. 
    These imtructi~ns shnu!d be !c!lcwed the 
    point  when  the timing  belt  has  been fitted  and 
    the  engine  and injector  pump are correctly 
    timed. 
    10. Fit  the front  cover plate using  a  new gasket 
    and  a new  gasket  washer  on the  centre  bolt 
    boss. 
    11. Secure  the cover  with the various  length bolts 
    tightening  evenly to the  correct torque. 
    Refer 
    to the  bolt  length  chart in ENGINE OVERHAUL 
    12.  Using  a new  gasket fit the water  pump, see 
    instructions  9 to  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 
    four 
    socket  headed  bolts. 
    15. Fit the compressor mounting U bracket. 
    16. Refer to ENGINE OVERHAUL for the  correct 
    method 
    of fitting  the crank  shaft damper. 
    17.  Fit the  pulley  to the  damper  and evenly tighten 
    the  four  bolts  to the  correct  torque. 
    18.  Fit the water  pump pulley  and secure  with the 
    four  bolts.  Use  a 
    tommy bar in the  hole 
    provided  to 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  do not 
    secure  to 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  to 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. 
    35  
    						
    							12 ENGINE DEFENDER 
    J 
    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 
    Crankshaft  damper restraining  tool 
    Rear  main  cap 
    sea1 guide 
    Crankshaft  damper tool 
    injection  pump timing  pin 
    - part of LST129 pump remover  tool 
    _1 Flywheel  timing pin 
    MS76B 
    MS621 
    LSTI 22 
    18C1344 
    MS1519A 
    R0274400 
    R0605774A 
    LSTI  30 
    R0605022 
    18C1456 
    18C1464 
    18C1482 
    LSTl28 
    LSTI 27 
    270304  LSTI  36 
    LSTI 
    2912 
    MS150-8 
    18G134-I 1 
    MS.768 
    Dia 7.9 mm - 8.5 mm 1 
    S W5M  ~ 
    Die. Range 28.5” - 44 mm 15 b 45 
    18G. 134- 11 
    186.1344 
    -@ 
    MS. 1519A 
    11 
    36  
    						
    							e DEFENDER ENGINE 
    1 R0.27- 
    12 
    I I I 
    I 
    I 
    ! 
    LST. 128 
    18G 1456 1 
    I 
    18G. 1464 
    ., ,:_:i ::..: , .. . ... .. 
    I 
    ST2344M 1 
    1BG. 1482 
    LST. 127 
    37  
    						
    							72 
    LST136 
    ENGINE DEFENDER 
    ST2677M 
    CAUTION AND WARNING 
    Note that where the use of special service tools is 
    specified,  only these  tools should be used to 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 to follow 
    the  stand  manufactures instructions  to ensure  safe 
    and  effective 
    use of the equipment. 
    in  the  intrests 
    of safety  and efficient  working,  secure 
    the engine  to 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 
    to 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.  
    						
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