engine LAND ROVER DEFENDER 1999 Workshop Manual

12ENGINE
30
REPAIR Refit
10.Clean oil cooler and mating faces.
11.Fit oil pressure switch and tighten to9Nm(7
lbf.ft).
12.Position oil cooler using a new gasket and
tighten bolts to25 Nm (18 lbf.ft).
13.Position oil filter adaptor, fit new gasket and
tighten bolts to25 Nm (18 lbf.ft).
14.Position oil filter element hand tight then a
further half turn.
15.Position coolant hose to oil cooler and secure
clip.
16.Position coolant pipe and tighten clutch housing
bolt to50 Nm (37 lbf.ft).
17.Connect oil pressure switch multiplug.
18.Fit centrifuge assembly.See this Section.
19.Refill cooling system.See COOLING SYSTEM,
Adjustment.
20.Top up engine oil.CENTRIFUGE ASSEMBLY
Service repair no - 12.60.90
Remove
1.Remove fixings and remove underbelly panel.
See CHASSIS AND BODY, Repair.
2.Remove 2 bolts securing centrifuge drain pipe to
engine sump and discard gasket.
3.Remove turbocharger.See FUEL SYSTEM,
Repair.
Models with air conditioning only
4.Remove auxiliary drive belt.See
ELECTRICAL, Repair.
5.Remove 4 bolts securing compressor and move
to one side.
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ENGINE
31
REPAIR All Models
6.Remove 3 bolts securing centrifuge to engine oil
cooler.
7.Remove centrifuge and discard’O’ring.
8.Remove 2 bolts, remove drain pipe from
centrifuge and discard gasket.Refit
9.Clean mating faces of centrifuge, oil cooler and
sump.
10.Position drain pipe to centrifuge using new
gasket and tighten bolts to10 Nm (7 lbf.ft).
11.Position new’O’ring to oil cooler.
12.Position centrifuge and tighten bolts to25 Nm
(18 lbf.ft).
13.Align drain pipe to sump, fit new gasket and
tighten bolts to10 Nm (7 lbf.ft)
Models with air conditioning only
14.Position compressor and tighten bolts to25 Nm
(18 lbf.ft).
15.Fit auxiliary drive belt.See ELECTRICAL,
Repair.
All Models
16.Fit turbocharger.See FUEL SYSTEM, Repair.
17.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
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12ENGINE
32
REPAIR ROTOR - CENTRIFUGE
Service repair no - 12.60.91
Remove
1.Remove 2 bolts and remove centrifuge cover.
2.Remove and discard’O’ring and rotor
Refit
3.Clean centrifuge body and cover.
4.Fit new rotor.
5.Fit centrifuge cover using new’O’ring and
tighten bolts to9 Nm (7 lbf.ft).OIL SEAL - TIMING COVER
Service repair no - 12.65.05
Remove
1.Remove crankshaft pulley.See this Section.
2.PositionLRT-12-092into crankshaft front oil seal
and discard seal.
Refit
3.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
4.Position new seal into timing chain housing. Drift
seal into place usingLRT-12-156.
5.RemoveLRT-12-156.
6.Fit crankshaft pulley.See this Section.
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ENGINE
33
REPAIR TIMING CHAIN AND SPROCKETS
Service repair no - 12.65.13
Remove
1.Remove crankshaft front oil seal.See this
Section.
2.Remove cylinder head gasket.See this
Section.
3.Remove sump gasket.See this Section.
4.Release clip securing vacuum pump drain hose
to timing chain cover.
5.Remove 8 bolts securing timing chain cover.
6.Remove cover.
7.Remove timing chain and camshaft sprocket.
8.Remove 2 bolts and remove timing chain fixed
guide.
9.Remove bolt and remove timing chain adjustable
guide.
10.Remove bolt securing oil pump drive sprocket.
11.Remove crankshaft sprocket, oil pump drive
chain and sprocket.
12.Remove bolt and remove timing chain lubrication
jet.
Refit
13.Clean timing chain lubrication jet.
14.Fit lubrication jet and tighten bolt to10 Nm (7
lbf.ft).
15.Clean oil pump drive sprocket bolt threads.
16.Clean timing sprockets and chain guides.
17.Ensure that crankshaft is set to TDC firing No. 1
cylinder.
18.Fit oil pump drive chain to crankshaft sprocket
and fit sprocket to crankshaft.
19.Fit sprocket to oil pump.
20.Apply Loctite 242 to oil pump sprocket bolt
threads and tighten bolt to25 Nm (18 lbf.ft).
21.Fit timing chain fixed guide and tighten M10 bolt
to45 Nm (34 lbf.ft)and M6 bolt to10 Nm (7
lbf.ft).
22.Fit timing chain adjustable guide and tighten bolt
to25 Nm (18 lbf.ft).
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12ENGINE
34
REPAIR
23.Fit camshaft sprocket to timing chain with timing
mark between the 2 bluelinks.
24.Fit timing chain to crankshaft sprocket aligning
blue link to timing mark.
25.Clean timing cover and mating face.
26.Apply an even film of sealant, Part No. STC
4600 to timing cover and spread to an even film
using a roller.
CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
27.With assistance, fit timing cover, connect
vacuum pump drain hose and working
progressively, tighten bolts to27 Nm (20 lbf.ft).
28.Secure vacuum hose clip.
29.Fit cylinder head gasket.See this Section.
30.Fit sump gasket.See this Section.
31.Fit crankshaft front oil seal.See this Section.
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ENGINE
1
OVERHAUL GASKET - INLET MANIFOLD
Service repair no - 30.15.08.01
Remove
NOTE: The following procedure covers
both EU3 and non EU3 engines
NOTE: EU3 Engine in main illustration, Pre
EU3 condition shown in inset.
1.Remove and discard 2 Allen screws securing
EGR pipe or EGR cooler to exhaust manifold.
2.Remove bolt securing EGR pipe to cylinder
head, (if fitted)
3.Disconnect multiplug from IAT and MAP sensor.
4.Remove 4 bolts securing fuel cooler to inlet
manifold. and remove cooler.
5.Remove bolt securing engine dipstick tube to
camshaft carrier.
6.Release and remove engine dipstick tube.
7.Remove’O’ring from dip stick tube.
8.Disconnect 4 leads from glow plugs.
9.Remove 2 nuts and 8 bolts and remove inlet
manifold.
10.Remove manifold gasket.Refit
1.Clean inlet manifold and mating face, clean
mating faces of EGR pipe, exhaust manifold and
EGR cooler (if fitted).
2.Fit new gasket.
3.Position inlet manifold and working from the
centre outwards, fit inlet manifold nuts and bolts
and tighten to25 Nm (18 lbf.ft).
4.Connect glow plug leads.
5.Clean engine dipstick tube.
6.Fit new’O’ring to dipstick tube.
7.Fit engine dipstick tube to camshaft carrier and
tighten bolt to10 Nm (7 lbf.ft).
8.Position fuel cooler and tighten bolts to25 Nm
(18 lbf.ft).
9.Connect multiplug to IAT and MAP sensor.
10.Position EGR pipe or EGR cooler to exhaust
manifold and using new Allen screws tighten to
10 Nm (7 lbf.ft).
11.Fit EGR pipe clamp to cylinder head, (if fitted)
and tighten bolt to10 Nm (7 lbf.ft).
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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).
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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.
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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.
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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.
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