Land Rover 90 110 Workshop Rover Manual

							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 
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							. .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. 
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							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/ 
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							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 .: .. .. - . .,... 
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							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 
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							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 
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							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