Land Rover Defender Workshop 1993 Rover Manual

							ROCKER COVER - RIGHT HAND - RENEW 10. Apply Bostik  1775 impact  adhesive to rocker 
cover  seal face  and gasket,  using a brush  to 
1.  Disconnect  battery negative  lead.  ensure an even  film. Allow  adhesive 
to 
2. Disconnect  purge pipe from  charcoal  canister  become touch dry. 
at  plenum.  11. 
Place  one end of gasket  into cover  recess 
3. Remove  breather  pipe from  rocker  cover.  with 
edge  firmly  against  recess wall, holding 
4. Remove  coolant pipes from inlet manifold.  remainder of gasket 
clear. Work around  cover, 
5. Remove  spark plug leads  from plugs  and  pressing gasket into place ensuring edge 
retaining  clips. 
6. Remove four rocker  cover bolts.  Moving  fuel  12. Allow 
cover  to  stand  for  thirty  minutes  before 
13.  Fit rocker cover to cylinder head with four 
8. screws, short screws, inboard,  tighten to 8 Nm. 
9. 15.  Fit breather pipe to rocker cover,  tighten clip. 
pipes aside, remove rocker cover.  fitting. 
Remove  plug lead  retaining  clips from rocker 
cover, 
fit to new rocker  cover. 
Clean  and 
dry rocker  cover and cylinder  head 
matng 
faces using  Bostik  cleaner  6001.  16.  Fit breather pipe  to  inlet manifold, tighten 
bolts. 
17.  Fit spark  plug leads 
to plugs  and retaining NOTE: Gasket fits one  way  round  only. It 
Subsequent  movement  will destroy 
18. Connect  purge pipe from  charcoal  canister at 
must be  fitted accurately,  first time. clips. 
bonding. plenum,  tighten clip. 
ROCKER  COVER - LEFT HAND - RENEW 
1. Remove  air flow  sensor. 
2. Remove  plenum chamber. 
3. Remove  dipstick. 
4. Remove  spark plug leads  from plugs  and 
retaining  clips. 
5. Disconnect HT lead from  coil. 
6. Remove  alternator  heat shield  from rocker 
cover. 
7. Remove  air flow meter harness  clip. 
8. Remove  dipstick tube clip. 
9. Remove  four rocker  cover bolts, remove 
rocker  cover. 
11.  Remove  plug lead retaining  clips from  rocker 
cover,  fit 
to new rocker  cover. 
12. Clean and dry rocker  cover and cylinder  head 
mating  faces, using Bostik  cleaner 
6001. 
NOTE: Gasket  fits one  way  round  only. It 
must be fitted  accurately,  first time. 
Subsequent  movement 
will destroy 
13. Apply  Bostik  1775 impact  adhesive to rocker 
cover  seal face and gasket,  using a brush 
to 
ensure  an even  film. Allow  adhesive  to 
become  touch dry, approximately  fifteen 
minutes. 
10. 
Discard  gasket 
I 
bonding. 
RR3820M 
ENGINE 
firmly contacts recess wall. 
14.  Position  fuel  pipes.  
						

							14. Place one end of gasket  into cover  recess 
with edge firmly  against  recess wall, holding 
remainder  of gasket  clear. Work around  cover, 
pressing  gasket into place  ensuring  edge 
firmly  contacts  recess wall. 
2. Loosen  four rocker  shaft fixings 
ROCKER SHAFT RENEW 
1. Remove  rocker covers  as required, 
RR3821M 
15.  Allow  cover to stand  for thirty  minutes  before 3. Remove  rocker shaft assembly. 
fitting. 
16.  Fit 
rocker  cover to cylinder  head with four  NOTE: Each rocker  shaft  is notched  at 
screws,  short screws  inboard,  tighten to 8 Nm.  ONE end. Notch  must be uppermost  and 
17.  Locate  and tighten  dipstick  tube clip.  towards 
front of engine  on right  hand  side, 
18.  Fit and  tighten  air flow  meter  harness  clip.  towards  rear 
on left  hand  side. 
19.  Fit alternator  heat shield  to rocker  cover. 
20.  Connect  HT lead  to coil.  4. Clean  rocker  pedestal  locations  on cylinder 
21.  Connect  spark plug leads  to plugs  and  head. 
retaining  clips.  5. 
Fit rocker  shaft assembly,  locating push rods 
22.  Fit dipstick.  to 
rockers. 
23.  Fit plenum  chamber.  6. 
Tighten rocker  shaft fixings  to 38  Nm. 
24.  Fit  air  flow meter.  7. 
Fit rocker  covers.  
						

							ENGINE 
HYDRAULIC TAPPETS RENEW  CRANKSHAFT  PULLEY 
ASSEMBLY 
1. Remove  rocker shafts. 1. Remove  viscous coupling,  see viscous 
2.  Remove  inlet manifold. 
3.  Remove  push rods,  retain  in removal  2. Remove  water pump  drive belt. 
coupling, 
fan blades,  pulley and fan cowl. 
3.  Remove  alternator  drive belt. 
Remove  power steering  pump drive belt. 
5.  Raise  vehicle  on ramp. 
6.  Remove  bell housing  bottom cover. 
7.  With  assistance  to stop  flywheel  rotation, 
remove  crankshaft  pulley assembly  retaining 
bolt. 
4 
sequence. 
8. Remove  crankshaft  pulley assembly. 
9.  If required:  Place assembly  in vice  and 
remove  pulleys. 
10.  Fit pulleys  to torsional  vibration damper. 
11.  Lubricate  seal face  of assembly. 
13.  With  assistance  to stop  flywheel  rotation, fit 
retaining  bolt, tighten  to 280  Nm. 
14.  Reverse  instructions  1 to  6. 
12. 
Fit pulley  assembly. 
I 
4. Remove  hydraulic  tappets 
5. Fit tappets,  push rods and rocker  assemblies. 
6. Fit inlet  manifold. 
7. Reverse  remaining  removal procedure. 
FRONT COVER OIL SEAL - RENEW 
1. Remove  crankshaft  pulley, 
2.  Remove  eight screws  and remove  mud 
excluder. 
3.  Fit  button 
of 18G1328 to crankshaft, fit 
extractor to seal. 
4.  Turn  centre  bolt 
of extractor to remove  seal. 
5. Remove  seal from  extractor. 
6. Clean  seal seating. 
7. Lubricate  outside diameter  of seal. 
8.  Locate  seal in front  cover. 
9. Fit adaptor  18G1291/5  to 18G1291/4. 
10. Fit tool to seal. 
11.  Fit and  tighten  centre bolt 
to crankshaft, 
tighten  centre locknut 
to seat seal. 
12. Slacken  locknut and remove tool. 
13. Lubricate  seal lip. 
14.  Fit mud  excluder  and tighten  screws. 
15.  Fit crankshaft  pulley assembly.  
						

							ENGINE 
FRONT COVER GASKET 29. Clean  threads  of cover  fixing bolts,  apply 
1.  Remove  crankshaft  pulley.  30. Fit timing  cover,  fit fixing  bolts,  tighten  to 28 
2.  Remove  water pump  pulley.  Nm. 
3.  Release  distributor  cap clips.  31. Fit alternator  support strut to front  cover. 
4.  Release  plug leads  from plugs  and clips. 
5.  Place  cap and  leads  to one  side.  Nm. 
6.  Turn  engine  until No. 1 piston  is at T.D.C. 
7.  Check  position  of rotor  arm.  34. Lubricate  distributor  O ring. 
8.  Remove  fixings securing  power steering  pump  35. Fit distributor  in position  marked. 
bracket  to water  pump  bracket.  36. 
Align  oil pump  drive,  if distributor  does not 
9.  Remove  power steering  pump bracket  from  seat correctly. 
water  pump.  37. 
Fit distributor  clamp, tighten to 20  Nm. 
tensioner.  bracket. Loctite 
372 to threads. 
32.  Tighten  sump to timing  cover fixings  to 10 
33.  Tighten  sump fixings  to 10  Nm. 
10.  Remove  clips securing  wiring to alternator  38. 
Locate  alternator  tensioner on water  pump 
11.  Disconnect  distributor feed wire.  39. 
Connect  heater hose, tighten  clip. 
12.  Pivot  power  steering  pump away from front  40. Connect  oil pressure  switch. 
41.  Connect  bottom hose, tighten  clip. 
13.  Disconnect  vacuum pipe from  distributor.  42. Connect  vacuum pipe to distributor. 
14.  Remove  water pump  bottom  hose.  43. Loosen  power steering  pump pivot, lower 
15.  Disconnect  oil pressure  switch.  pump. 
16.  Disconnect  heater hose at water  pump.  44. Connect  distributor  feed wire. 
17.  Remove  alternator  tensioner from water  pump,  45. Connect  wire ties to alternator  tensioner. 
move  tensioner  aside.  46. Fit power  steering  pump bracket  to water 
18.  Mark  distributor  position to front  cover.  pump, 
tighten  to 28  Nm. 
19.  Remove  distributor  clamp, remove  distributor.  47. Fit power  steering  pump to bracket. 
20.  Remove  fixings sump to front  cover.  48. 
Position  distributor  cap. Fit plug  leads  to plugs 
21.  Loosen  four adjacent  sump fixings.  and clips. 
22.  Remove  alternator  support strut from  front  49. Clip distributor  cap in position. 
23.  Loosen  remaining  front cover  fixings  and  51. Fit crankshaft  pulley. 
24.  Remove  front cover  gasket.  53. Check  ignition  timing. 
54.  Refill  cooling  system. 
cover, 
tighten  pivot to retain  in position. 
cover,  move strut aside. 
remove  front cover.  52. Tension  drive belts correctly. 
50. Fit water  pump  pulley,  tighten to 10 Nm. 
Refit 
25. Clean  timing  cover,  clean block face. 
26.  Lightly  grease  gasket faces. 
27. Fit new  gasket  to block  face. 
28.  Apply 
hylosil to sump  gasket.  
						

							ENGINE 
TIMING CHAIN AND CHAINWHEELS 
Remove 
1.  Remove  engine. 
2. Remove flywheel. 
1.  Remove  front cover. 
3. Remove  dipstick. 
2. Remove  retaining  bolt and  washer,  remove 4. With assistance,  invert engine,  support on 
distributor  drive gear and spacer. 
3. Ensure  number  one piston  is at TDC. 
4.  Remove  chainwheels  and chain  as an 6. Remove  rear main  bearing  cap. 
assembly. 
7. Remove  cross seals from cap. 
8. Remove  crankshaft  rear oil seal. 
9. Clean  main bearing  cap and  oil seal  area of 
CRANKSHAFT  REAR OIL SEAL 
blocks. 
5. Remove  sump. 
Refit 
5. Clean chainwheels  and chain. 6. Fit  chainwheels  to chain,  aligning  timing 11. Apply Hylomar  SQ32M to block  as illustrated. 
marks. 
7. Ensure  camshaft  key is fitted  parallel  to shaft 
axis 
to ensure  adequate  lubrication  to 
distributor  drive gear. 
8. Engage  chainwheel  assembly on camshaft 
and  crankshaft  keys, ensure  chain wheels  are 
fully  located. 
9. Check  alignment  of timing  marks with straight 
edge. 
10. Fit  spacer  with flange  to front, 
11.  Fit distributor  drive gear with groove  towards 
spacer. 
12.  Fit retaining  bolt and washer,  tighten 
to 58 
Nm. 
13. Fit front  cover. 
10.  Fit new cross  seals to bearing  cap. 
FLYWHEEL 
Remove 
1.  Remove  gearbox and clutch. 
2. Slacken  starter motor bolts. 
3. Lock  flywheel,  remove flywheel  bolts and RR3827M 
flywheel. 12. Lubricate  bearing shell and cross  seals using 
13. Fit bearing  cap, do not  tighten  bolts. 
on  the  block. 
Refit clean  engine  oil. 
4.  Clean  components  for reassembly.  14. Ensure  cap is fully  home  and seated  squarely 
5. Fit flywheel. 
6. Lock flywheel,  fit flywheel  bolts, tighten  to 80 
Nm. 
block.  
						

							RR3828M 
ENGINE 
15. Ensure oil seal guide  RO1014  and crank 
journal  are scrupulously  clean. Coat seal 
guide  and 
oil seal journal  with clean  engine 
oil. 
CAUTION: Do not  handle  oil seal  lip, check 
it is not  damaged.  Ensure outside  diameter 
remains  clean and dry. 
16.  Position  oil seal  guide  RO1014 on crankshaft 
flange. 
NOTE: lubricant  coating must cover  seal 
guide  outer surface  completely  to ensure 
that  oil seal 
lip is not  turned  back during 
assembly.  Position 
oil seal, lipped side 
towards  engine, on seal  guide.  Seal 
outside  diameter 
MUST be clean and dry. 
17.  Push  oil seal  fully and squarely  by hand  into 
recess 
in cap  and  block  until it contacts 
machined  step in recess.  Remove  seal guide. 
18. Tighten  rear main  bearing  cap to 90  Nm. 
19.  Fit sump. 
20. Reposition  engine, fit dipstick. 
21 
. Fit  flywheel. 
22. Fit  engine  to vehicle.  
						

							RO605351 
18G1150 
18G1150E 
18G79 
ENGINE 
LRT-12-041 Guide bolts 
RO605351 LRT
-12-013 
18G1150  Piston 
pin remover/replacer - Basic tool 
LRT-12-014 
18G1150E  Adaptor 
remover/replacer - piston pin 
LRT
-12-001  Clutch centralising tool. 
18G79  
						

							ENGINE 
MS1519A 
RO.600959 
LRT-12-034 Spring compressor 
MS1519A 
LRT
-12-038 
RO600959 
exhaust 
Drift - Valve  guide replacement - intake  and 
LRT
-12-515 
RO605774A  Distance 
piece for valve guide 
LRT-12-504 Valve seat cutter 
MS621 MS.621  
						

							RO.1014 
RO274401 
ENGINE 
LRT-12-010 Crankshaft rear seal  sleeve 
RO1014 
LRT-12-037 Drift for valve  guide  removal - intake  and RO274401A    exhaust 
LRT-12-047 Torque  adaptor  lambda sensor 
LST134 
LST134  
						

							EMISSION CONTROL The purpose of the crankcase  ventilation system is 
to ensure  that any noxious  gas generated  in the 
Three  systems  are used  to control  the vehicle  engine crankcase 
is rendered  harmless  by burning  in 
atmospheric  emissions these are: 
the combustion  chambers as follows: 
Oil  laden  noxious  gas in the  engine  crankcase  is 
Engine  crankcase  fume emissions. 
drawn through  an oil separator 
3 located  on the  right 
Fuel  tank Evaporative  emissions  cylinder head rocker  cover,  where  the  oil  is 
Engine  exhaust  gas emissions.  separated and returned  to the  stump.  The gas flows 
through  a restrictor 
in the  three  way connection 1 
Crankcase  ventilation  system and into the inlet  plenum  chamber  where it drawn 
into  the combustion  chambers and burned.  The 
The  crankcase  ventilation system which is an  volume  of fresh  air which 
is drawn  from the 
integral  part of the  air supply 
to the  engine  atmospheric  side of the throttle  butterfly  to mix  with 
combustion  chambers, is often  overlooked  when the gas,  depends  on the  position 
of the throttle  and 
diagnosing  problems associated  with engine  the engine  speed. 
performance. 
A blocked  ventilation  pipe or filter  or 
excessive  air leak  into the inlet  system  through  a The air filter 
2 fitted to the  left cylinder  head rocker 
damaged  pipe or leaking  gasket can effect  the  cover, must be maintained  in clean  condition 
to 
mixture,  performance  and economy of the engine.  ensure sufficient  air enters  the crankcase  under 
varying  throttle openings 
and manifold  depression, to 
prevent excessive  crankcase  pressure or depression 
developing. 
1 Three  way connector 
2 Air filter 
3  Oil  separator 
REISSUED: FEB 1993 1 
RR3534M