Land Rover 90 110 Workshop Rover Manual
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DEFENDER ENGINE n 12 Fitting connecting rods and pistons 1. Ensure that the essentric headed big end bolts and shell bearings are correctly located in the connecting rods and as a precaution against possible damage to the crankshaft journals during installation of the pistons, cover the bolt threads with a layer of adheasive tape. Check that the number on the connecting rod is the same as the piston and cylinder and that they are correctly orientated. 2. With the cylinder block vertical, and 2 and 3 crankshaft journals at BDC lubricate and install 2 and 3 piston connecting rod assemblies so that the piston rings are resting on the block face. illustrated, then using a suitable tool compress the piston rings and gently push each piston 4. Pull both connecting rod big ends on to the journals and fit the caps ensuring the the numbers match and orientation is correct. Retain the caps with new nuts but do not tighten at this stage. at BDC and install the pistons and connecting rods as previously discribed. the correct torque and check that the crankshaft is free to rotate before securing the next connecting rod cap nuts. which when tightened restricts the freedom of the crank shaft. sideways on its journal and if necessary check the actual side clearance using a feeler gauge. The correct clearance is given in the data section. 9. To allow for shrinkage after fitting leave the 3. Stagger the piston rings on both pistons as seals standing proud of the crankcase face then using a sharp blade, trim the seals off to face. .. approximately 0,80 mm above the crankcase into the cylinder bore. 5. Tum the crankshaft so that I and 4 journals are 7. Tighten both nuts on one connecting rod to 8. Investigate and rectify any big end bearing 9. Check that each big end is free to move 59
. ENGINE DEFENDER Fitting rear main oil seal to flywheel housing The oil seal is manufactured from P.T.F.E. and is supplied with a former to maintain the correct shape which must not be removed until the seal is to be fitted. 18G 134-11 1. Make sure the seal housing is clean and dry and free from burrs. Do not touch the seal lip and ensure that the outside diameter is clean and dry. 2. Using special seal replacer 18C134-I 1 and with the lip side leading drive-in the seal as far as the tool allows. If the tool is not available fit the seal to the bottom of the housing to ensure squareness. Fitting flywheel housing 3. Clean the rear face of the cylinder block and flywheel housing, then apply a bead of Hylosil 102 sealant to the dimensions and configuration, illustrated. The illustration has been produced full size so that a template may be made to facilitate the application of the sealant. The bead should be 2,O mm diameter and must extend around the periphery of the bearing cap so that the joint between cap and block is sealed. ~-__ L,** I ST2988M 60
a DEFENDER ENGINE n 12 4. Examine the seal guide, number 18G1344 ensuring that it is perfectly smooth and not damage or scratched. Also check that the crankshaft oil seal journal is smooth and clea. 5. Locate the seal guide on to the crankshaft and lubricate the seal, guide and journal with concentrated Oildag in a 25% solution with clean engine oil. 6. Carefully locate the flywheel housing over the seal and on to the dowels. 7. Remove the seal guide and secure the flywheel housing, evenly tightening the retaining bolts to the correct torque. OVERHAUL AND FITJING FLYWHEEL Inspection Normal wear and scores on the flywheel clutch face can be repaired by machining provided that the overall width of the flywheel is not reduced below 36,96 mm (1.453 in) therefore check that the flywheel has not been previously machined before proceding further. The ring gear may be renewed if the teeth are chipped or damage. Reface the flywheel 1. Remove the clutch cover locating dowels. Machine the flywheel over the entire clutch face removing only the minimum of material necessary to achieve a smooth surface parallel with the crankshaft mating face within the dimensions given above. Renew Ring gear WARNING: Wear industrial goggles to protect the eyes from flying fragments. 2. To renew the ring gear, drill a 8 mm hole between the root of any two teeth and the inner diameter of the ring gear deep enough to weaken the gear. Take care not to allow the drill to enter the flywheel. ST2973M 7 61
El ENGINE DEFENDER 3. Secure the flywheel in a soft jawed vice and cover it with a cloth to avoid personal injury. Place a cold chisel above the drilled hole and strike it sharply to split the ring gear. 4. Heat the new ring uniformally to between 225°C and 250°C but do not exceed the higher figure. 5. Place the flywheel, clutch face down, on a flat surface and press the starter ring firmly against the flange until the ring contracts sufficiently to grip the flywheel. Allow the ring to cool naturally. Do not hasten cooling in anyway otherwise distortion may occur. 5 ST2640M Fitting flywheel 6. Locate the flywheel on the crankshaft and secure with the reinforcing plate and retaining bolts. Temporarily fit the damper to front of crankshaft and use special service tool FRIOI or LST127 to restrain the crankshaft whilst the eight retaining bolts are being tightened to the correct torque. mount a dial test indicator so that the stylus rests, in a loaded condition, on the clutch pressure face at a radius of 114 mm (4.5 in) from the centre of the flywheel. 8. Tum the flywheel, and check that run-out does not exceed 0,05 to 0,07 mm (0.002 to 0.003 in). Should any run-out be excessive, remove the flywheel, and check again for irregularities on flywheel and crankshaft mating faces and dowel. 7. To check the flywheel for possible run-out, ST2991M Fitting clutch If the original clutch cover is being refitted, ensure any marks made during dismantling are aligned to maintain original balance. 1. Clean the flywheel and place the friction plate with the raised centre section outwards away from the flywheel. three dowels and loosely secure with the six bolts. . 3. Centralise the centre plate using special tool R0605022 or a spare primary shaft and tighten the six bolts evenly to the correct torque. 4. Remove the tool and smear the splines of the centre plate with Molybdenum disulphide grease, such as Rocol MTS1000. 2. Fit the clutch assembly locating it over the ST2611 M
e DEFENDER ENGINE n 12 T . .. .... .. Fitting camshaft Inspection 1. Mount the camshaft on v blocks on a surface plate for convenience and examine the cams for wear, scores, pitting and chipped edges. 2. Examine the journals for obvious wear and scores and signs of overheating, in particular, check the thrust plate. If the journals are visibly sewiceable, check with a dial gauge or micrometer for overall wear, ovality, taper and runout. CAUTION: If the skew gear is worn and requires renewal, the camshaft must also be renewed even though the camshaft gear may appear satisfactory. Once the two gears have run together they become a matched pair. 3. Lubricate the camshaft bearings and journals with clean engine oil and carefully insert the camshaft into the cylinder block. Fit the thrust plate and secure with the two bolts and tighten to the correct torque. Fitting camfollowers 1. Examine all the components for wear and damage particularly the rollers and pushrod seating in the slides and ensure that the tappet slides move freely in the guides. If the same parts are being refitted, ensure that they are returned to their original positions. Note: The tappet retaining screws have a micro encapsulated locking compound applied to the threads to ensure that they do not become loose. Once the screw has been used the locking ability is lost. \ - / ST2968M 4. To check the camshaft end-float, temporarily fit the camshaft gear and mount a dial test indicator so that the stylus rests in a loaded condition upon the machined face of the gear. 5. Zero the dial and move the camshaft back and forward and note the reading. The end -float should be within 0,06 to 0,13 mm (0.0025) to 0.0055 in) If necessary fit another thrust plate to achieve the correct end float. . , 1. 63
112) ENGINE e DEFENDER 2. Insert the tappet guides into the cylinder block, retaining each with a new screw which should be screwed in sufficiently to allow the rollers and slides to be installed. Ensure the rollers are fitted in accordance with any marks made during removal. New rollers, however, may be fitted either way around. 3. Before fitting the tappet slides make sure the oilways are clear to the running surface of the roller and the pushrod seating. insert the the tappet slides with the word FRONT or F to the front of the engine. 4. Finally tighten the screws to the correct torque to secure the guides. Fitting skew gear bush. Inspect the skew gear bush for wear and renew if necessary. 1. Insert the bush into the cylinder block and secure with a new screw to the correct torque. Do not over tighten as this may damage the bush. Overhaul and fitting skew gear 1. Remove the circlips retaining the skew gear shaft to the bearing and the bearing in the housing. 2. Press the bearing and shaft assembly from the housing and the shaft from the bearing. Discard both rubber 0 rings, examine all components especially the bearing and skew gear for wear and damage and renew if necessary. CAUTION: If the original skew gear and camshaft are to be re-used, they must be fitted so that the teeth on each, mesh in the original position. If either the skew gear or the camshaft are renewed, the mating component must also be renewed. 1 . h 4, ST2995M Assembling 3. Press the bearing into the housing and secure with the circlip. Support the housing and press the shaft into position and secure with the circlip. 4. Fit a new rubber 0 ring to the outside of the housing and to the intemal annular groove in the shaft ready for installation. r-
e DEFENDER ENGINE 1121 Fitting skew gear If the original skew gear and camshaft are being re -used it is important that the gear teeth mesh in the original position as follows. 1 . $:. d _. 5. Turn the camshaft so that the key aligns with the oil groove as illustrated. * I. . .. .. . ,! .. 6. Fit the skew gear assembly so that the ventilation slot in the gear housing is towards the front of the engine as illustrated and ensuring that any alignment marks made during dismantling are realigned. If both components are new it is only necessary to correctly align the ventilation slot as described above. 65
1121 ENGINE DEFENDER OVERHAUL AND FITTING OIL FILTER ADAPTOR Oil temperature thermostat 1. Remove the two bolts and carefully withdraw the thermostat extension housing complete with, the ’0’ ring (21,thermostat (3),washer (41, and spring (5). 2. Clean the adaptor housing (6) with lint-free cloth. inspect all the parts and renew as necessary. 3. Fit the spring, washer and thermostat with the pin uppermost. 4. Fit the extension housing using a new ’0’ ring. Ensure that the pin protruding from the thermostat locates in the hole in the extension housing and secure with the two bolts and .+ washers. 1- ???? - ST2596M 5. Using a new joint washer fit the oil filter adapto. Ensure that the retaining bolts pass through the two small holes in the joint washer. Tighten the two retaining bolts evenly to the correct torque. Oil filter 6. Smear the filter sealing ring with oil and screw the filter clockwise until the seal touches the machined face, then tighten the filter a further half turn only. Do not over tighten. see Maintenance operations, section 10. Fitting vacuum pump 7. Using a new gasket fit the vacuum pump so that the brake servo connection is towards the front of the engine, ensuring that the cross-pin in the skew gear locates in the pump drive shaft then secure with three screws tightened to the correct torque. I Fitting front and rear side covers and fuel lift Pump 8. Check that the front side cover baffle plate is secure and fit the cover using a new gasket securing with only four of the six fixing bolts at this stage, leaving out the two which secure the injection pump support bracket as illustrated. P ST3000M 66
e DEFENDER ENGINE n 12 Fitting rear cover 9. Fit the rear cover also using a new gasket and secure with six bolts tightened to the correct torque. Fitting fuel lift pump 10. Check that the lift pump is serviceable and refit using a new gasket, ensuring that the pump actuating lever locates correctly onto the camshaft . , I,, ST3003M FllTlNG FRONT COVER TIMING BELT AND GEARS 1. Clean the front cover and remove the crankshaft and camshaft oil seals taking care not to damage the seal housing. Examine the cover for damage, cracks and distortion. Check the mating face of the cylinder block and the cover plate for burrs. 2. Clean the front face of the cylinder block and use a little grease to hold in position a new joint washer. 3. Also fit a new joint washer to the coolant aperture and to the tapped hole for the jockey pulley clamp bolt. 4. Fit the front cover locating it over the single stud and secure with the three retaining bolts tightening evenly to the correct torque. The correct bolt length for each hole is given in the following chart. - ST3005M Front cover seals 5. Lubricate a new crankshaft oil seal. With the lip side leading, drive -in the seal, squarely, using special service tool 18C1456. 6. Similarly, lubricate and drive-in a new camshaft oil seal, lip side leading, using special service tool 18G1482. 67
112) ENGINE e DEFENDER Fitting injection pump 1. Insert the timing pin in the pump hub and body. Fit the injection pump and secure with the three nuts and tighten evenly to the correct torque. 2. Fit the pump rear support bracket to the front side cover and secure to the pump with two bolts and nuts. 3. Inspect the pump drive gear for wear and damage, ensure it is thoroughly clean and dry before fitting to the pump. Retain the gear with three bolts and renforceing plate. Do not overtighten the bolts at this stage. Injection pump, valve timing and drive belt. Drive belt. During use, a belt develops a wear pattern relative to its running direction, therefore, if the original belt is to be re-used it must be fitted so that it continues to rotate in the original direction, otherwise the belt must be renewed. Cleanliness and accuracy are vital when carrying out the timing operations and fitting the drive belt. 1. Check the gear wheels are not damaged or scratched and that they are thoroughly clean and dry. 2. Ensure that the belt adjustment idler bearing is sound and not leaking lubricant. 3. Fit the crankshaft and camshaft gears ensuring that the camshaft gear is retained with the special bolt, washer and new 0 ring but do not tighten at this stage. 4. Rotate the camshaft so that the centre dot on the camshaft gear is aligned with the arrow in the front cover. 5. Temporarily refit the crankshaft pulley and turn th crankshaft so that one and four pistons are at TDC and the crankshaft key is aligned with the arrow in the front cover. Drive belts must be stored on edge on a clean flat surface and in such a manner that bends are not less than 50 mm (2 in) radius. Do not bend the belt at an acute angle or radius less than 50 mm (2 in) otherwise premature failure of the fibre reinforcement could result. 68