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Land Rover 90 110 Workshop Rover Manual

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    							DEFENDER ENGINE 
    CYLINDER HEAD REMOVE. 
    12 
    .. ._... . I.. .-.I .. 
    39  
    						
    							121 ENGINE a DEFENDER 
    Rocker cover remove. 4. Having  removed  the rocker  shaft, lift-out the 
    push  rods and insert  them through  holes in a 
    piece 
    of card  marked  from 1 to 8 to ensure 
    assembly  to their  original  locations. 
    5. Remove  the cap  from  each valve  stem. 
    1. Release the crankcase  ventilation  hose 
    connections,  evenly slacken  and remove  the 
    three bolts then lift-off the rocker cover. 
    See fitting rocker cover 
    See fitting rocker shaft 
    ST2948M 
    Rocker shaft  remove. 
    2. Evenly  release  the five rocker shaft  retaining 
    bolts  but do not  remove  the bolts  from the 
    shaft,  especialy  the 
    two end ones, to prevent 
    the  assembly  from falling  apart when  removed 
    from  the cylinder  head. 
    ST294CM 
    40  
    						
    							. .I ., .,..  .. 
    e DEFENDER ENGINE n 12 
    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  or see  fitting  cylinder 
    head 
    ST2951 M 
    Note:- If..necessary, at  this  stage  the cam 
    followers  may be removed  for inspection. 
    See  Cam  follower  removal 
    FRONT  COVER 
    OIL SEALS/TIMINC 
    BE LT/CAM S HA fi 
    See radiator removehefit 
    Water  pump 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 four screws, to 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 
    one  nut to remove  the water  pump from the 
    front  cover plate. 
    See  water  pump  inspection  and fitting. 
    ST2952M 
    Front  cover  plate or seal  remove 
    Front  pulley  and damper. 
    5. Release  the four bolts  and  remove the 
    crankshaft  pulley from the damper. 
    1. 
    41  
    						
    							12 
    6. To remove the crankshaft damper retaining 
    bolt  use pecial  service  tool 
    FR I01 tor LST 127 
    o restrain  the damper  and a 30 socket  to 
    remove  the special  bolt. 
    ENGINE a DEFENDER 
    Removing front  cover plate. 
    9. Unscrew the 11 bolts and one  nut to release 
    the cover  plate. 
    See fitting front cover plate 
    ST3125M 
    7. Fit the  pressure  button 18G1464/5 to the  end 
    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  to 
    TDC so 
    that the valves of number  one cylinder  are 
    closed  with number  four cylinder  valves on 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 do not turn it back  but  continue  on 
    round  until the above conditions are  achieved. 
    e. Q, .. J/ 
    A3  
    						
    							DEFENDER ENGINE 11 2 1 
    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 to  the  appropriate 
    slot  in the  flywheel  periphery.  Note that there 
    are 
    two slots  in the  flywheel  one being  wider 
    than  the othe.  The narrowest 
    slot determines 
    TDC for this engine  and it is therefore 
    important  that the correct  slot is used. 
    4. To lock the  pump,  Slacken  the locking  screw 
    anticlockwise  and remove  the inhibiting  plate. 
    Turn  the screw  clockwise  to 
    lock the pump 
    shaft.  Remove  the timing  pin from  the flywheel 
    housing. 
    I .:!. c. *. 
    a* 0 
    ST2954M 
    3. Remove  the three  screws  to 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  to the  valves  and crankshaft 
    and  can 
    be locked  ready for removing.  Leave 
    the  pin in position  in the  pump. 
    CAUTION: It is  important  to ensure  that 
    once  the injection  pump has been  locked 
    no  attempt  must be made  to rotate  it. 
    Therefore  take care  not 
    to allow  the 
    crankshaft  to be  turned  until the pump  has 
    been  removed. 
    NOTE:- If renewing  the timing belt,oil seals 
    or  gears  (with the cylinder  head fitted)  and 
    there 
    is any  possibility  that the crankshaft 
    will  need  to be  rotated  after removal 
    of the 
    timing  belt, it would  be advisable  to remove 
    the  rocker  shaft. This will prevent  the 
    pistons  contacting  the valves  as the 
    crankshaft  is turned. 
    If necessary, See 
    rocker  shaft removal. 
    .. ...I .: .. .. - . .,... 
    43  
    						
    							E[ ENGINE e DEFENDER 
    5. To verify any timing  error, check  that the 
    timing  marks inside  the front  cover  line-up 
    with the gear  wheels. 
    6. 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 to be  re-fitted,  mark its 
    direction 
    of rotation  with soft chalk before 
    removing 
    it. 
    ST2959M/ 1 
    NOTE:- A used  drive  belt develops  a wear 
    pattern  relative  to the  driving  loads and its 
    direction 
    of rotation. If the  belt  is to  be 
    re
    -used  it must be refitted so that  it 
    continues  to operate  in the  original 
    direction. 
    S ee fitting  Timing  gears and belt.  Removing 
    timing 
    belt gears 
    9. If the crankshaft  gear wheel cannot  be 
    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. 
    18G 1464-2 \\ ST2960M 
    10. Remove  the camshaft  gear wheel  retaining  bolt 
    assembly  to enable  the gear  to be  removed. 
    Use special  service tool 18G 1462-2 and 
    button 
    18G  1464-6. Assemble as shown and 
    withdraw  the the gear. 
    ST2960M 18G 1464-2 \\?--. 
    The  camshaft  and crankshaft oil seals  may be 
    renewed  at this  stage  with the engine  in the  vehicle 
    without  removing  the front  cover. 
    See fitting  front cover  seals 
    44  
    						
    							DEFENDER ENGINE n 12 
    Removing injection pump 
    Removing  front cover I * .I 
    11. Release the injection  pump from the rear 13. To remove  the front cover,release the three 
    support  bracket. 
    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 
    45  
    						
    							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 to be re-used  it should  be fitted so that  the 
    teeth  on the  gear  and camshaft  engage in the 
    original  running  position. 
    15. 
    To ensure orininal re-engagement of the  gears 
    turn  the 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  to the  one 
    of the  three  bolt holes for 
    securing  the vacuum  pump. Also mark the 
    skew  gear housing  flange to the  same  bolt 
    hole.  16. 
    To remove 
    the skew  gear assembly,  tap the 
    flange  round 
    so that the edge  overlaps  the 
    cylinder  block, then tap the  flange  upwards 
    to 
    enable  the skew  gear assembly  to be  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 
    adaptor  and gasket  from the engine. 
    19. Using  a 6 mm alien key  remove  the retaining 
    screw  and bush. 
    46  
    						
    							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 solid  rollers 
    held  in position  against the cam  by a slide 
    inside  a 
    fixed guide. If the guide is removed 
    before  the roller,  it 
    is possible  that the 
    roller  can fall behind  the camshaft  and 
    become  jammed.  Furthermore  the roller 
    could  slip past  the cam  and fall into  the 
    crankcase. 
    It is  therefore  important  to adopt 
    the  following  procedure  for removal. 
    1. Slacken  back the guide  locating  screw so that 
    the  end  is below  the bore 
    of the guide. 
    x n 
     i 
    2. Using  a length of thin  wire  with  a hooked  end 
    3. With the same  piece of wire remove  the roller 
    4. Remove  the guide  locating  screw and lift-out 
    6. As each  assembly is removed  number it, from 
    lift-out 
    the slide. 
    the  guide. 
    one  to eight, 
    for refitting  to its  original 
    location. 
    See fitting  cam followers 
    47  
    						
    							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 retaining 
    bolts  and washers  and remove  the assembly 
    complete  with the friction  plate. 
    fitting clutch 
    Removing  flywheel 
    1. In  the  intrests of safety,  fit two long 8mm bolts 
    into  the clutch  bolt holes,  diametrically 
    opposite,  to 
    use as handles for lifting the 
    flywheel 
    off the  crankshaft. 
    2. temporarily  fit the  the crankshaft  damper and 
    use  special  service 
    tool FR 101 to 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 
    A8  
    						
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