Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual
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12ENGINE 12 REPAIR CAMSHAFT OIL SEAL Service repair no - 12.13.05 Remove 1.Remove camshaft gear. See Camshaft gear 2.Remove camshaft oil seal from front cover using special toolLRT-12-083. Refit 3.Lubricate a new camshaft oil seal with clean engine oil. 4.With lip side leading, drive in seal squarely using special toolLRT-12-082. 5.Fit camshaft gear. See Camshaft gear INJECTION PUMP GEAR Service repair no - 19.30.06 Remove 1.Remove camshaft drive belt. See Camshaft drive belt 2.Slacken 3 bolts on front of injector pump gear. 3.Remove special tool pin from gear. 4.Remove 3 bolts and withdraw gear and retaining plate. Refit CAUTION: It is important to ensure that when the injection pump is locked no attempt must be made to rotate it. Take care not to allow the crankshaft to be turned. 5.Fit gear and retaining plate. Tighten bolts to 25 Nm (18 lbf/ft). 6.Insert pin from special toolLRT-12-045in injection pump gear and through into pump flange. 7.Fit camshaft drive belt. See Camshaft drive belt
ENGINE 13 REPAIR FRONT COVER GASKET Service repair no - 12.65.10 Remove 1.Remove camshaft drive belt. See Camshaft drive belt 2.Remove crankshaft gear.See Crankshaft gear 3.Remove camshaft gear.See Camshaft gear 4.Remove injection pump gear.See Injection pump gear 5.Remove fuel injection pump.See FUEL SYSTEM, Repair, Fuel injection pump 6.Remove engine oil sump.See Engine oil sump 7.Remove oil pick up strainer.See Oil pick-up strainer 8.Remove 10 bolts securing timing gear housing to block. 9.Withdraw timing gear housing complete with gasket. 10.Clean all gasket material from mating faces. Refit 11.Fit slave guide studs to locate gasket. 12.Fit new gasket to cylinder block. 13.Align flats on oil pump with flats on crankshaft. 14.Fit front cover to block taking care not to damage oil seal.15.Secure with bolts of correct length in locations where slave studs are not fitted, see J6149. 16.Remove slave studs and fit correct length bolts. 17.Tighten all bolts to 25 Nm (18 lbf/ft). 1- 25 mm,2- 35 mm,3- 80 mm. 18.Fit oil pick-up strainer. See Oil pick-up strainer 19.Fit oil sump.See Engine oil sump 20.Fit fuel injection pump.See FUEL SYSTEM, Repair, Fuel injection pump 21.Fit injection pump gear.See Injection pump gear 22.Fit camshaft gear.See Camshaft gear 23.Fit crankshaft gear.See Crankshaft gear 24.Fit camshaft drive belt.See Camshaft drive belt
12ENGINE 14 REPAIR ENGINE OIL SUMP Service repair no - 12.60.44 Remove 1.Disconnect battery. 2.Drain engine oil. NOTE: A chassis undertray may be fitted on some vehicle derivatives to conform to legal requirements. When under chassis remove and refit procedures are required, it may be necessary to remove the undertray and/or integral access panels. See CHASSIS AND BODY, Repair, Front undertray orSee CHASSIS AND BODY, Repair, Rear undertray 3.Slacken sump securing bolts. 4.Break sealant around sump flange, using a sharp knife. 5.Remove 22 bolts and withdraw sump. Refit 6.Clean mating faces of sump, timing gear housing and cylinder block. 7.Apply a 2,0 mm bead of Hylosil RTV102 to the sump flange, ensuring bead is applied inboard of the bolt holes. 8.Secure sump to block with 22bolts. Tighten to 25 Nm (18 lbf/ft). 9.Refill engine oil.See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Capacities 10.Reconnect battery.OIL PICK-UP STRAINER Service repair no - 12.60.20 Remove 1.Disconnect battery. 2.Drain engine oil. 3.Remove engine oil sump. See Engine oil sump 4.Remove 2 bolts securing pipe support bracket to main bearing cap fixings. 5.Remove bolts from pipe flanges. 6.Withdraw pick-up strainer assembly. Refit 7.Postion pick-up strainer assembly, fitting a new O ring seal at oil pump connection. 8.Apply Loctite 242E to threads of bolts at main bearing cap. Fit bolts, tighten to 9 Nm (7 lbf/ft). 9.Fit bolts to pipe flanges. Tighten to25 Nm (18 lbf/ft). 10.Fit sump.See Engine oil sump 11.Reconnect battery.
ENGINE 15 REPAIR FLYWHEEL Service repair no - 12.53.07 Remove 1.Disconnect battery. 2.Remove gearbox. See MANUAL GEARBOX, Repair, R380 gearbox 3.Remove clutch.See CLUTCH, Repair, Clutch assembly 4.Fit 2, long, 8 mm bolts into the clutch bolt holes, as shown, to use as handles when lifting the flywheel off the crankshaft. 5.Remove fan cowl. See COOLING SYSTEM, Repair, Fan cowl 6.Fit crankshaft pulley retainerLRT-12-080and secure with 4 bolts, to restrain crankshaft while removing flywheel retaining bolts. 7.Remove bolts and lift off flywheel. Refit NOTE: To prevent excessive flywheel run-out, ensure that mating faces of flywheel and crankshaft are clean. 8.Locate flywheel on crankshaft, remove lifting bolts, and secure flywheel with new patched retaining bolts, progressively tighten to 147 Nm (108 lbf/ft). 9.Check the flywheel for possible run-out by mounting a dial test indicator with the stylus in a loaded condition resting on the flywheel face at a radius of 114 mm (4.50 in) from the centre. 10.Turn flywheel and check that run-out does not exceed 0,07 mm (0.003 in). 11.Should run-out be excessive, remove flywheel and check again for irregularities on crankshaft and flywheel mating faces and location dowel. 12.Remove crankshaft pulley retainer. 13.Fit fan cowl. See COOLING SYSTEM, Repair, Fan cowl 14.Fit clutch.See CLUTCH, Repair, Clutch assembly 15.Fit gearbox.See MANUAL GEARBOX, Repair, R380 gearbox 16.Reconnect battery.
12ENGINE 16 REPAIR CRANKSHAFT REAR OIL SEAL Service repair no - 12.21.20 Remove NOTE: The crankshaft rear oil seal is retained in its own housing, if the seal requires replacing, the complete housing assembly (1) must be renewed. Housing and seal assemblies are supplied with their own former/seal guide (2) already fitted. This former must not be removed before fitting the assembly to the engine. If a seal and housing assembly is received without a former/guide fitted it must be returned to the supplier. Used formers/guides must be discarded immediately after use, under no circumstances should they be reused on other assemblies. NOTE: A different rear oil seal housing, with integral O ring seal and gasket, was fitted on earlier engines. They must be replaced with the current housing and gasket (3) shown below. 1.Disconnect battery. 2.Remove gearbox. See MANUAL GEARBOX, Repair, R380 gearbox 3.Remove clutch.See CLUTCH, Repair, Clutch assembly 4.Remove flywheel.See Flywheel 5.Remove 5 bolts and withdraw seal housing, complete with gasket. Refit NOTE: The raised side of groove at the bottom of seal housing gasket must be fitted to cylinder block face. 6.Insert slave studs to locate seal housing gasket. 7.Position new gasket over slave studs and crankshaft flange onto cylinder block. 8.Fit new seal housing assembly, with former/guide in-situ, over crankshaft flange. This action will eject former/guide. 9.Secure assembly to cylinder block, removing slave studs individually and inserting bolts. Tighten to 25 Nm (18 lbf/ft). 10.Refit flywheel.See Flywheel
ENGINE 17 REPAIR 11.Refit clutch. See CLUTCH, Repair, Clutch assembly 12.Refit gearbox.See MANUAL GEARBOX, Repair, R380 gearbox 13.Reconnect battery. CRANKSHAFT BEARING BUSH Service repair no - 12.21.45 Remove 1.Disconnect battery. 2.Remove gearbox. See MANUAL GEARBOX, Repair, R380 gearbox 3.Remove clutch.See CLUTCH, Repair, Clutch assembly 4.Remove flywheel.See Flywheel 5.Remove bearing bush. NOTE: The bearing bush can be removed by using one of the following methods. Method 1. Obtain a short length of steel rod of a diameter having a good slide fit in the bore of the bush. Pack the bore with grease and insert the steel rod into the end of the bore, give a sharp blow with a hammer and the grease should drive out the bush. It is recommended that the bush and rod be covered by a suitable cloth or rag to prevent grease from splashing.Method 2. Thread the bore of the existing bush and using a suitable bolt extract the bush. Thoroughly clean bush location ensuring all swarf is removed. Refit 1.Fit new bush using a suitable shouldered drift, inserting bush flush with end of crankshaft. 2.Refit flywheel. See Flywheel 3.Refit clutch.See CLUTCH, Repair, Clutch assembly 4.Refit gearbox.See MANUAL GEARBOX, Repair, R380 gearbox 5.Reconnect battery.
12ENGINE 18 REPAIR FLYWHEEL HOUSING Service repair no - 12.53.01 Remove 1.Disconnect battery. 2.Remove gearbox. See MANUAL GEARBOX, Repair, R380 gearbox 3.Remove clutch.See CLUTCH, Repair, Clutch assembly 4.Remove flywheel.See Flywheel 5.Remove 3 fixings and withdraw starter motor. 6.Remove 2 bolts from top of flywheel housing. 7.Remove 4 bolts securing bottom of flywheel housing to engine mounting brackets. 8.Remove inner bolts and lift off flywheel housing.Refit 9.Clean rear face of housing and mating face on block, ensuring all old sealant is removed. 10.Apply sealant to flywheel housing mating face on cylinder block. 11.Fit housing to cylinder block. Tighten retaining bolts to 45 Nm (33 lbf/ft). 12.Remove surplus sealant from block. 13.Fit starter motor. 14.Fit flywheel. See Flywheel 15.Fit clutch.See CLUTCH, Repair, Clutch assembly 16.Fit gearbox.See MANUAL GEARBOX, Repair, R380 gearbox 17.Reconnect battery.
ENGINE 19 REPAIR OIL FILTER Service repair no - 12.60.01 Remove 1.Place drain tray under oil filter. 2.Unscrew filter anti-clockwise, using a strap wrench, if necessary. Refit 3.Clean mating face of oil filter adaptor. 4.Coat rubber sealing ring of new filter with clean engine oil. 5.Screw on filter until sealing ring touches machined face, then tighten a further half turn by hand only. DO NOT over tighten.OIL TEMPERATURE CONTROL VALVE Service repair no - 12.60.69 Remove 1.Clean adaptor housing. 2.Disconnect oil cooler feed pipe from thermostat extension housing and plug to prevent ingress of dirt. 3.Remove 2 bolts and carefully withdraw thermostat extension housing (1) complete with O ring seal (2), thermostat (3), 2 washers (4) and spring (5). 4.Inspect all parts and renew as necessary. Refit 5.Fit thermostat to extension housing ensuring pin locates in hole. 6.Fit two washers and spring to thermostat. 7.Fit a new O ring to extension housing. 8.Insert spring into adaptor and secure extension housing to adaptor. Tighten bolts to 9Nm(7 lbf/ft).
12ENGINE 20 REPAIR OIL FILTER HEAD GASKET Service repair no - 12.60.03 Remove 1.Clean filter head adaptor. 2.Disconnect oil cooler pipes and plug to prevent ingress of dirt. 3.Disconnect oil pressure switch lead. 4.Remove 4 bolts and withdraw filter head, complete with gasket. 5.Clean mating faces of filter head and cylinder block. 6.Fit head with new gasket. 7.Tighten bolts to 45 Nm (33 lbf/ft). 8.Reconnect oil pressure switch lead. 9.Reconnect oil cooler pipes.CYLINDER HEAD GASKET Service repair no - 12.29.02 Remove 1.Disconnect battery 2.Remove bonnet. 3.Drain coolant. See COOLING SYSTEM, Repair, Drain and refill cooling system 4.Remove air cleaner.See FUEL SYSTEM, Repair, Air cleaner 5.Detach crankcase ventilation valve and side breather hose from rocker cover and move to one side. 6.Remove fuel injectors and pipes. See FUEL SYSTEM, Repair, Fuel injectors 7.Remove heater plugs.See FUEL SYSTEM, Repair, Heater plugs 8.Disconnect radiator top hose from thermostat. 9.Disconnect bleed hose at thermostat. 10.Disconnect water pump hose at thermostat. 11.Disconnect water temperature sensor lead.
ENGINE 21 REPAIR 12.Remove induction manifold. See MANIFOLD AND EXHAUST SYSTEM, Repair, Induction manifold 13.Remove exhaust manifold and turbocharger assembly. See MANIFOLD AND EXHAUST SYSTEM, Repair, Exhaust manifold 14.Disconnect heater hose from water pump and move heater rail aside. 15.Disconnect heater hose from rear of cylinder head. 16.Remove bolt securing air cleaner mounting bracket to support strut. 17.Remove bolt securing harness bracket to cylinder head. 18.Remove rear engine lifting bracket. This will also release clips securing transmission and engine breather pipes and multi-plug. Note loose spacer beneath inner clip. 19.Unscrew 3 bolts, with sealing washers and remove rocker cover. 20.Remove 3 nuts and 2 bolts and lift rocker shaft assembly from cylinder head. 21.Remove push rods and store as an identified set to allow refitment to same location. 22.Remove valve stem caps. 23.Evenly slacken and then remove cylinder head to block retaining bolts in the sequence shown in J6157. Two of the bolts also secure the air cleaner mounting bracket. 24.Lift off cylinder head and remove gasket. Refit 25.Thoroughly clean mating faces of cylinder block and head. 26.Select new gasket of correct thickness. CAUTION: Three gaskets, of different thicknesses, are available and can be identified by the number of small holes punched in the RH side of the gasket. One hole identifies the thinnest gasket, two holes the middle thickness and three holes the thickest. When renewing a gasket it must be of the same thickness as the one removed. 27.Position gasket on cylinder block with identification holes on RH side and TOP identification mark uppermost.