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.