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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

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    							12ENGINE
    2
    OVERHAUL GASKET - EXHAUST MANIFOLD
    Service repair no - 30.15.12.01
    Remove
    NOTE: The following procedure covers
    both EU3 and non EU3 engines
    NOTE: EU3 engine illustrated.
    1.Remove 3 bolts securing heater pipe to cylinder
    head and turbocharger heat shield.
    2.Remove heater pipe.
    3.Remove bolt and remove turbocharger heat
    shield.
    4.Remove and discard 2 Allen screws securing
    EGR pipe to exhaust manifold.
    5.Remove banjo bolt securing oil feed pipe to
    turbocharger and discard sealing washers.
    6.Loosen turbocharger drain hose union at
    cylinder block.
    7.Remove 10 nuts and remove exhaust manifold
    and turbocharger.
    8.Remove manifold gasket.Refit
    1.Clean exhaust manifold mating faces.
    2.Position exhaust manifold to cylinder head using
    new gasket and fit manifold nuts.
    3.Working from the centre outwards, fit and tighten
    nuts to25 Nm (18 lbf.ft).
    4.Clean turbocharger drain and feed hose unions.
    5.Fit turbocharger oil drain hose to cylinder block
    and tighten union to48 Nm (35 lbf.ft).
    6.Fit new sealing washers to turbocharger oil feed
    pipe, fit banjo bolt and tighten to25 Nm (18
    lbf.ft).
    7.Position EGR pipe to exhaust manifold. Fit new
    Allen screws and tighten to10 Nm (7 lbf.ft).
    8.Position turbocharger heat shield.
    9.Position heater pipe to cylinder head and tighten
    bolts to25 Nm (18 lbf.ft).
    10.Position exhaust manifold heatshield and tighten
    M6 bolts to9 Nm (7 lbf.ft)and M8 bolt to25
    Nm (18 lbf.ft). 
    						
    							ENGINE
    3
    OVERHAUL GASKET - CYLINDER HEAD
    Service repair no - 12.29.02.01
    Remove
    CAUTION: The following procedures
    should only be carried out when cylinder
    head is to be overhauled; for replacement
    of cylinder head gasket only, see Repairs section -
    Gasket - Cylinder head.
    NOTE: The following procedure covers
    both EU3 and non EU3 engines
    1.Remove exhaust manifold gasket.See
    MANIFOLD AND EXHAUST SYSTEM, Repair.
    2.Remove inlet manifold gasket.See MANIFOLD
    AND EXHAUST SYSTEM, Repair.
    3. Models with EGR cooler:Remove and discard
    2 Allen screws securing EGR pipe to cooler.
    4.Progressively loosen then remove 13 bolts
    securing camshaft cover, remove cover; remove
    and discard gasket.
    5.Remove isolators and sealing washers from
    cover.
    6.Disconnect injector multiplug from camshaft
    carrier.
    7.Disconnect multiplug from ECT sensor.
    8.Remove bolt securing alternator strap bracket to
    cylinder head.
    9.Set engine to TDC firing - No. 1 cylinder -
    coloured links on timing chain are aligned with
    timing mark on camshaft sprocket.
    10.Fit timing pinLRT-12-058into slot in camshaft. 
    						
    							12ENGINE
    4
    OVERHAUL
    11.Disconnect alternator/vacuum pump oil feed pipe
    union from cylinder head, remove and discard
    ’O’ring.
    12.Remove camshaft sprocket access plug from
    front of cylinder head, remove and discard’O’
    ring.
    13.Remove timing chain fixed guide Allen screw.
    14.Remove timing chain tensioner, remove and
    discard sealing washer.
    15.Remove and discard 3 bolts securing camshaft
    sprocket to camshaft; release sprocket from
    camshaft.
    16.Remove bolt and nut securing front of cylinder
    head to timing chain cover.
    17.Using sequence shown, progressively loosen
    then remove 12 cylinder head bolts; discard
    bolts together with their captive washers.
    18.Using assistance, remove cylinder head and
    place on 2 wooden blocks.
    CAUTION: Cylinder head is dowel located,
    do not tap it sideways to free it from
    cylinder block. Support both ends of
    cylinder head on blocks of wood. With the
    camshaft carrier bolted down, the injector nozzles
    and some of the valves will protrude from the face
    of the cylinder head.
    19.Remove the cylinder head gasket.
    20.Note the gasket thickness indicator and ensure
    the same thickness gasket is used on refitment
    of the cylinder head.
    CAUTION: If new pistons, connecting rods
    or crankshaft are fitted, it will be
    necessary to measure piston stand proud
    in order to determine thickness of gasket
    required.See this Section.
    21.Remove and discard 2 plastic locating dowels
    from cylinder block.
    22.Carry out cylinder head overhaul procedures.
    See this Section. 
    						
    							ENGINE
    5
    OVERHAUL Refit
    1.Thoroughly clean cylinder block and cylinder
    head mating faces.
    2.Ensure coolant and oil passageways are clear
    and bolt holes are clean and dry.
    3.Ensure locating dowel holes in cylinder block are
    clean and dry.
    4.Fit new plastic locating dowels in cylinder block.
    5.Fit new cylinder head gasket of the correct
    thickness with the word’TOP’uppermost.
    CAUTION: Gasket must be fitted dry.
    6.Ensure that camshaft timing pinLRT-12-158is
    still in position and using assistance, fit cylinder
    head.
    7.Carefully enter new cylinder head bolts together
    with their captive washers,DO NOT DROP.
    Lightly tighten bolts.
    CAUTION: Cylinder head bolts are
    pre-lubricated and do not require
    additional lubrication.
    8.Using sequence shown, tighten cylinder head
    bolts to:
    Stage 1 -30 Nm (23 lbf.ft)
    Stage 2 -65 Nm (48 lbf.ft)
    Stage 3 -90
    °
    Stage 4 -Further 180°
    Stage 5 -Further 45°
    CAUTION: Ensure correct tightening
    sequence is followed for all 5 tightening
    stages. Do not tighten bolts 315°in one
    operation.9.Fit cylinder head to timing chain cover nut and
    bolt and tighten to25 Nm (18 lbf.ft).
    10.Clean camshaft sprocket and mating face on
    camshaft.
    11.Ensure engine is set to TDC firing - No.1
    cylinder.
    12.Check that mark on camshaft sprocket is
    positioned between the 2 coloured links on
    timing chain.
    13.Position sprocket to camshaft, fit and lightly
    tighten 3 new bolts then loosen bolts half a turn. 
    						
    							12ENGINE
    6
    OVERHAUL 14.Clean fixed guide Allen screw and apply Loctite
    242 to screw threads.
    15.Fit fixed timing chain guide Allen screw and
    tighten to25 Nm (18 lbf.ft).
    16.Clean timing chain tensioner and fit new sealing
    washer.
    17.Fit timing chain tensioner and tighten to45 Nm
    (33 lbf.ft).
    18.Tighten camshaft sprocket bolts to36 Nm (27
    lbf.ft).
    19.Remove toolLRT-12-058from camshaft.
    20.Lubricate a new’O’ring with engine oil and fit to
    camshaft sprocket access plug.
    21.Fit camshaft sprocket access plug.
    22.Clean alternator/vacuum pump oil feed hose
    union.
    23.Lubricate a new’O’ring with engine oil and fit to
    alternator/vacuum pump hose union.
    24.Fit and tighten alternator/vacuum pump oil hose
    union to10 Nm (7 lbf.ft).
    25.Fit bolt securing alternator strap bracket to
    cylinder head and tighten to25 Nm (18 lbf.ft).
    26.Connect multiplugs to ECT sensor and EUIs.
    CAUTION: Following cylinder head
    overhaul, it will be necessary, before
    fitting the camshaft cover, to adjust the
    fuel injector rockers using the following
    procedures:
    27.Rotate engine clockwise until No. 1 EUI lobe is
    at full lift.
    28.Tighten No.1 rocker adjusting screw until the EUI
    plunger is felt to’bottom out’.
    29.Loosen rocker adjusting screw 1 complete turn
    to give EUI plunger the required bump clearance
    and tighten rocker adjusting screw locknut to16
    Nm (12 lbf.ft).
    CAUTION: Ensure screw does not turn as
    locknut is tightened.30.Carry out above procedures for the remaining 4
    rocker arms.
    31.After completion of rocker adjustment, slowly
    rotate engine clockwise 2 complete turns by
    hand to ensure that no EUI’s are bottoming out
    on their plungers.
    32.Clean camshaft cover and mating face.
    33.Fit new sealing washers and isolators as
    necessary to camshaft cover.
    34.Fit new camshaft cover gasket to cover.
    CAUTION: Gasket must be fitted dry.
    35.Fit camshaft cover to camshaft carrier, fit bolts
    and working from the centre outwards, tighten
    bolts to10 Nm (7 lbf.ft).
    36.Fit inlet manifold gasket.See MANIFOLD AND
    EXHAUST SYSTEM, Repair.
    37.Fit exhaust manifold gasket.See MANIFOLD
    AND EXHAUST SYSTEM, Repair.
    38. EGR cooler fitted:-Position EGR pipe to cooler,
    fit new Allen screws and tighten to10 Nm (7
    lbf.ft). 
    						
    							ENGINE
    7
    OVERHAUL CYLINDER HEAD GASKET SELECTION
    NOTE: There are three thicknesses of
    cylinder head gasket available and in order
    that the correct gasket is fitted, it will be
    necessary to determine the stand proud
    (protrusion) of each piston above the top face of
    the cylinder block. Gaskets have either 1, 2 or 3
    identification holes and the following procedures
    must be followed in order that the correct gasket
    is selected.
    1.Temporarily fit and lightly tighten a new
    crankshaft pulley bolt.
    2.Assemble a magnetic base DTI to cylinder block
    top face adjacent to No. 1 cylinder bore.
    3.Position stylus to cylinder block top face and
    zero gauge.
    4.Using crankshaft pulley bolt, rotate crankshaft in
    a clockwise direction until No.1 piston is at TDC -
    Woodruff key slot in crankshaft is at 12 o’clock.5.Position stylus of DTI at edge of piston and
    directly over gudgeon pin axis.
    6.Measure and record No.1 piston protrusion.
    CAUTION: Measurement must be taken at
    front and rear of piston.
    7.Establish average of the 2 readings taken.
    8.Repeat above procedures for remaining pistons.
    9.From readings obtained, determine HIGHEST
    piston protrusion figure and select the
    appropriate cylinder head gasket:
    Piston protrusion = 0.351 to 0.50 mm (0.014 to
    0.02 in) - Select the 2 hole gasket.
    Piston protrusion = 0.501 to 0.57 mm (0.021 to
    0.022 in) - Select the 1 hole gasket.
    Piston protrusion = 0.571 to 0.65 mm (0.022 to
    0.025 in) - Select the 3 hole gasket.
    10.Remove DTI.
    11.Fit cylinder head gasket.See this Section. 
    						
    							12ENGINE
    8
    OVERHAUL CYLINDER HEAD - OVERHAUL
    Service repair no - 12.29.19.01
    Dismantling
    1.Remove cylinder head gasket.See this
    Section.
    CAUTION: Due to the design of the
    cylinder head which incorporates drillings
    for the fuel injection system, it is important
    that absolute cleanliness is adhered to when
    carrying out overhaul procedures.
    2.Note the gasket thickness indicator and ensure
    the same thickness gasket is used on refitment
    of cylinder head.
    CAUTION: If new pistons, connecting rods
    or crankshaft are fitted, it will be
    necessary to determine thickness of
    gasket required.See this Section.
    3.Remove 4 glow plugs.
    4.Disconnect multiplugs from EUI’s and remove
    harness from camshaft carrier. Remove and
    discard’O’ring from harness multiplug.
    5.Loosen lock nuts and fully unscrew rocker
    adjusting screws; discard locknuts and screws.
    6.Remove and discard 6 bolts securing rocker
    shaft, remove shaft.
    NOTE: Dowel located.
    7.Using sequence shown, progressively loosen 13
    bolts securing camshaft carrier to cylinder head
    until valve spring pressure is released; remove
    bolts.
    CAUTION: Do not discard bolts at this
    stage. 
    						
    							ENGINE
    9
    OVERHAUL
    8.Gently tap camshaft carrier upwards to break
    sealant bond, remove carrier.
    NOTE: Dowel located.
    9.Remove camshaft.
    10.Remove and discard camshaft rear oil seal.
    11.Remove finger followers and lash adjusters.
    CAUTION: Store lash adjusters and finger
    followers in their fitted order and store
    lash adjusters upright. Maintain absolute
    cleanliness when handling components.
    12.Remove and discard 5 bolts securing EUI
    retainers.
    13.Using toolLRT-12-154/1remove EUI units from
    cylinder head and collect retainers. Remove
    reaction posts and keep in their fitted order.
    14.Using toolLRT-12-154/4, remove and discard
    sealing washer and’O’ring from each EUI unit.
    15.Support cylinder head clear of valves, use a
    hollow drift and tap each valve spring cap to free
    collets.
    16.Using toolLRT-12-034, compress valve spring.
    17.Remove 2 collets from valve stem using a stick
    magnet.
    18.Remove toolLRT-12-034.
    19.Remove valve spring cap, valve spring and
    valve.
    CAUTION: Keep components in their fitted
    order. 
    						
    							12ENGINE
    10
    OVERHAUL
    20.Using toolLRT-12-071, remove and discard
    valve stem oil seal.
    21.Repeat above operations to remove remaining
    valves.
    22. Engine Serial No. Prefixes 15P to 19P:-
    Disconnect spill return pipe from cylinder head
    and fuel connector block, remove and discard’O’
    rings. 
    						
    							ENGINE
    11
    OVERHAUL
    23.Remove 3 bolts and remove fuel connector
    block from cylinder head.
    24.Remove and discard gasket,’O’ring and fuel
    filter.
    25.Remove spacer block and gasket (if fitted).Cylinder head and camshaft carrier - cleaning
    1.Thoroughly clean cylinder head mating faces,
    ensure oil and coolant passages are clear and
    bolt holes are clean and dry.
    CAUTION: Take care to ensure that EUI
    drillings are clear.
    2.Using suitable solvent, remove all traces of
    sealant and gasket material.
    CAUTION: Do not use metal scrapers.
    3.Remove all traces of oil from camshaft bearings
    and journals.
    4.Clean glow plug threads.
    Cylinder head - Inspection
    1.Check core plugs for signs of leakage and
    corrosion, seal replacement plugs with Loctite
    243.
    2.Check cylinder head for warping across centre
    and from corner to corner.
    Maximum cylinder head warp =0.1 mm (0.004
    in).
    CAUTION: Cylinder heads may not be
    refaced, replace the head assembly if
    warping exceeds the limit given. 
    						
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