Land Rover 90 110 Workshop Rover Manual

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c  
						

							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 
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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.