engine LAND ROVER DEFENDER 1999 Workshop Manual

12ENGINE
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OVERHAUL Refit
1.Clean mating faces of oil pump, stiffener plate
assembly and cylinder block; ensure bolt and
dowel holes are clean and dry.
2.Lubricate a new’O’ring with engine oil and fit to
oil pump housing outlet.
3.Position oil pump and stiffener plate assembly
on to cylinder block ensuring 2 dowels are
correctly located.
4.Fit new bolts and using sequence shown, tighten
to13 Nm (10 lbf.ft).
5.Lubricate a new’O’ring with engine oil and fit to
oil pick-up strainer.
6.Clean threads of oil pick-up strainer Torx screws
and apply Loctite 242 to threads.
7.Fit oil pick-up strainer, fit Torx screws and
tighten to10 Nm (8 lbf.ft).
8.Position oil pump drive sprocket to chain and oil
pump ensuring that the’D’shape on the drive
sprocket is located on the flat on the oil pump
drive shaft.
9.Clean threads of oil pump drive sprocket
retaining bolt and apply Loctite 242 to threads.
10.Fit oil pump drive sprocket bolt and tighten to25
Nm (18 lbf.ft).
11.Fit sump gasket.See this Section.TIMING CHAIN AND SPROCKETS
Service repair no - 12.65.13.01
Remove
1.Remove cylinder head gasket.See this
Section.
CAUTION: If timing chain tensioner is to
be replaced, ensure tensioner is correct
for engine. Tensioner bodies are colour
coded as follows:- Engine Serial No. Prefixes 10P
to 14P - BLACK with, additionally, on later
engines, YELLOW on tensioner hex. head. Engine
Serial No. Prefixes 15P to 19P:- Body is coloured
YELLOW. Later tensioners may be fitted to early
engines provided that the modified adjustable
guide is also fitted.
2.Remove 3 bolts securing crankshaft damper to
pulley, remove damper.
3.PositionLRT-51-003to crankshaft pulley and
secure with 2 bolts.
4.Using assistance, restrain engine and remove
crankshaft pulley bolt; discard bolt.
WARNING: CRANKSHAFT BOLT IS
TIGHTENED TO 460 Nm (340 lbf.ft),
ENSURE THAT ENGINE IS ADEQUATELY
RESTRAINED.
5.Remove crankshaft pulley, remove bolts and
tool.
6.Remove sump gasket.See this Section.
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OVERHAUL
7.Noting their fitted positions, remove 8 bolts
securing timing chain cover.
8.Remove timing chain cover.
NOTE: Dowel located.
9.Remove bolt securing oil pump drive sprocket.
10.Remove oil pump drive sprocket.
11.Remove camshaft and crankshaft sprockets
together with timing and oil pump drive chains.
12.Remove Woodruff key from crankshaft.
13.Remove 2 bolts and remove timing chain fixed
guide.
14.Remove bolt and remove timing chain adjustable
guide.
15.Remove bolt and remove timing chain lubrication
jet.
16.Using toolLRT-12-092, remove and discard oil
seal from timing cover.
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12ENGINE
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OVERHAUL Inspection
1.Clean all components.
2.Check condition of timing chain running surfaces
on adjustable and fixed guides.
CAUTION: Adjustable guide fitted to
Engine Serial No. Prefixes 15P to 19P may
be fitted to Engine Serial No. Prefixes 10P
to 14P provided that timing chain tensioner having
a YELLOW colour coded body is also fitted.
3.Check timing chains and sprockets for signs of
wear.
CAUTION: Timing chains and sprockets
fitted to Engine Serial No. Prefixes 15P to
19P may be fitted to Engine Serial No.
Prefixes 10P to 14P as an assembly only, oil pump
sprockets are interchangeable. Timing chains
fitted to Engine Serial No. Prefixes 15P to 19P
have BRONZE coloured timing links.
4.Check that drilling in timing chain lubrication jet
is clear.
5.Clean oil seal recess in timing cover and oil seal
running surface on crankshaft.
6.Remove all traces of sealant from mating faces
of timing cover and cylinder block using suitable
solvent.
CAUTION: Do not use metal scrapers.
7.Ensure bolt and dowel holes are clean and dry.
8.Clean oil pump sprocket bolt threads.Refit
1.Fit timing chain lubrication jet.
2.Fit bolt securing lubrication jet and tighten to10
Nm (7 lbf.ft).
3.If crankshaft has been rotated, check that No. 1
piston is at TDC using the following procedures:
4.Temporarily fit and lightly tighten a new
crankshaft pulley bolt.
5.Assemble a magnetic base DTI to cylinder block
top face, position stylus to cylinder block top face
and zero gauge.
6.Using crankshaft pulley bolt, rotate crankshaft
clockwise until No. 1 piston is at top of its stroke
and Woodruff key slot in crankshaft is at 12
o’clock position.
7.Position stylus of DTI to No. 1 piston crown and
rotate crankshaft until highest reading is
indicated on DTI.
8.Check that Woodruff key slot in crankshaft is still
at 12 o’clock position indicating No. 1 piston is at
TDC firing.
9.Remove DTI.
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ENGINE
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OVERHAUL 10.Remove crankshaft pulley bolt.
11.Fit Woodruff key to crankshaft.
12.Fit oil pump drive chain to rear row of teeth on
crankshaft sprocket i.e. teeth furthest away from
timing mark on sprocket.
13.Fit sprocket to crankshaft ensuring that timing
mark on sprocket is facing towards front end of
crankshaft.
14.Fit oil pump drive sprocket to oil pump and drive
chain ensuring that’D’shape on sprocket is
located on flat on oil pump drive shaft.
15.Apply Loctite 242 to threads of oil pump drive
sprocket bolt, fit bolt and tighten to25 Nm (18
lbf.ft).
16.Fit timing chain fixed guide, fit bolts and tighten
to:
M6 bolt -10 Nm (7 lbf.ft)
M10 bolt -45 Nm (34 lbf.ft)
17.Fit timing chain adjustable guide, fit bolt and
tighten to25 Nm (18 lbf.ft).
18.Fit camshaft sprocket to timing chain with timing
mark on sprocket between the 2 coloured links,
suitably retain sprocket to chain.
19.Fit timing chain to crankshaft sprocket aligning
coloured link to timing mark on sprocket.
CAUTION: Ensure timing marks are
positioned as shown - No. 1 piston at TDC
firing.
20.Apply an even film film of sealant, Part No. STC
4600 to mating face of 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.
21.Fit timing cover, fit bolts in their original fitted
positions and working from the centre outwards,
tighten progressively to27 Nm (20 lbf.ft).
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OVERHAUL
22.Fit oil seal guide, from seal kit, over end of
crankshaft.
23.Fit new oil seal into timing cover using
LRT-12-156.
CAUTION: Oil seal must be fitted dry.
24.RemoveLRT-12-156and oil seal guide.
25.Fit crankshaft pulley, fit crankshaft pulley bolt.
26.FitLRT-51-003to crankshaft pulley and secure
with 2 bolts.
27.Using assistance, restrain engine and using a
torque multiplier, tighten crankshaft bolt to460
Nm (340 lbf.ft).
WARNING: DUE TO THE HIGH TORQUE
LOADING REQUIRED, IT IS ESSENTIAL
THAT ENGINE IS ADEQUATELY
RESTRAINED.
28.RemoveLRT-51-003.
29.Position damper to crankshaft pulley, fit 3 bolts
and tighten to80 Nm (60 lbf.ft).
30.Fit sump gasket.See this Section.
31.Fit cylinder head gasket.See this Section.BEARINGS - CONNECTING RODS
Service repair no - 12.17.16.01
Remove
1.Remove oil pump.See this Section.
2.Mark cylinder reference number on each
connecting rod big-end bearing cap.
3.Make suitable alignment marks between each
big-end bearing cap and connecting rod.
CAUTION: Due to the’fracture split’
method of manufacturing connecting rods
and bearing caps, incorrect fitting of cap
to connecting rod will damage mating faces and
necessitate replacement of connecting rod
assembly.
4.Rotate crankshaft clockwise until No. 1 big-end
is at BDC.
5.Remove and discard 2 bolts securing No. 1
big-end bearing cap.
6.Remove bearing cap, remove and discard
big-end bearing shell.
7.Push connecting rod up cylinder bore until rod is
clear of crankshaft journal.
CAUTION: Ensure that connecting rod
does not contact cylinder bore or oil squirt
jet and piston does not contact the valves
or EUI’s if the cylinder head is fitted.
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OVERHAUL 8.Remove and discard big-end bearing shell from
connecting rod.
CAUTION: Engine Serial No. Prefixes 10P
to 14P:- The’sputter type’connecting rod
bearings fitted to these engines, identified
by them having a slightly darker colour than the
bearing cap shells should be replaced with the
’plain type’bearing shells fitted to Engine Serial
No. Prefixes 15P to 19P.
9.Repeat above procedures for remaining big-end
bearings.
CAUTION: Keep bearing caps in their fitted
order.
Inspection
NOTE: If crankshaft is to be removed,
big-end bearing journals should be
checked when crankshaft is inspected.
1.Check each big-end bearing journal for scoring,
wear and ovality, make 3 checks at 120°intervals
in centre of journal:
Big-end journal diameter =
54.000±0.01 mm (2.125±0.0004 in)
CAUTION: Big-end journals may not be
reground undersize,only one size of
big-end bearing shell is available and if
journals are found to be scored, oval or worn,
crankshaft must be replaced. Big-end bearing
shells must be replaced whenever they have been
removed.Refit
1.Clean connecting rod journals and bearing shell
locations.
2.Lubricate new big-end bearing shells with engine
oil and fit to connecting rods and bearing caps
ensuring that the’sputter bearings’are fitted to
the connecting rods.
NOTE:’Sputter type’bearing shells can be
identified by them by having a slightly
darker colour.
3.Rotate crankshaft until No. 1 big-end bearing
journal is at BDC.
4.Taking care not to damage oil squirt jet or to
displace bearing shell, pull connecting rod on to
crankshaft journal.
5.Check that bearing shell is correctly located in
big-end bearing cap.
6.Fit No. 1 big-end bearing cap ensuring that
reference marks are aligned.
7.Lightly oil threads of new big-end bearing cap
bolts, fit bolts and tighten to:
Stage 1 -20 Nm (15 lbf.ft)
Stage 2 -Further 80
°
CAUTION: Do not carry out stages 1 and 2
in one operation.
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8.Carefully move connecting rod to one side of
journal and using feeler gauges, measure
end-float of connecting rod on journal:
Connecting rod end-float =0.2 to 0.5 mm
(0.008 to 0.021 in).
CAUTION: If end-float exceeds limits
given, replace connecting rod and repeat
end-float check - See pistons, connecting
rods and cylinder bores.
9.Repeat above procedures for remaining big-end
bearings.
10.Fit oil pump.See this Section.PISTONS, CONNECTING RODS AND CYLINDER
BORES
Service repair no - 12.17.02.01
Remove
1.Remove cylinder head gasket.See this
Section.
2.Remove connecting rod bearings.See this
Section.
3.Remove ridge of carbon from top of cylinder
bore.
4.Suitably identify each piston and connecting rod
assembly to its respective cylinder bore.
5.Carefully push connecting rod to top of cylinder
bore taking care that connecting rod does not
contact oil squirt jet or cylinder wall, remove
each piston and connecting rod assembly in
turn.
6.Using a suitable expander, remove and discard
piston rings from pistons.
7.Using a squared off end of an old piston ring,
clean carbon from ring grooves.
8.Clean carbon from piston crown and skirt.
CAUTION: Do not use abrasives on
graphited area of piston skirt, do not use a
wire brush or scraper on any part of the
pistons.
9.Secure connecting rod in a soft jawed vice.
10.Suitably identify each piston to its connecting rod
and fitted position of piston on rod.
11.Using suitable circlip pliers, remove and discard
2 circlips securing gudgeon pin.
12.Push gudgeon pin out of piston and connecting
rod; remove piston.
13.Suitably identify each gudgeon pin to its
respective piston.
14.Repeat above procedures for each piston.
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OVERHAUL Cylinder bores - Inspection
1.Check cylinder bores for scoring.
2.Measure cylinder bore wear and ovality at a
point 70 mm (2.75 in) from top of each cylinder
bore:
Cylinder bore diameter =84.460 to 84.442 mm
(3.325 to 3.324 in)
CAUTION: Measurement must be taken
from side to side and front to rear of bore:
CAUTION: Cylinder bore diameter and
ovality must be within limits given above,
no reboring, honing or glaze busting of
cylinder bores is permissible; cylinder block must
be replaced if bores are worn or excessively
scored.
Pistons and connecting rods - Inspection
1.Check each piston for cracks, burning and
damage.
2.Check connecting rods for alignment.
CAUTION: Do not attempt to straighten
misaligned connecting rods.
3.Ensure small-end oil feed holes in connecting
rods are clear.
4.Measure and record diameter of each piston at
right angles to gudgeon pin axis and 46 mm
(1.81 in) from bottom of skirt:
Piston diameter =84.262 mm±0.009 mm
(3.317 in±0.0003 in)
CAUTION: Measurement point must be on
the graphited area of the piston.
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5.Starting with No. 1 piston, invert piston and with
arrow on piston crown pointing towards REAR of
cylinder block, insert piston into No. 1 cylinder
bore.
6.Position piston with bottom of skirt 25 mm (1.0
in) from top of cylinder bore.
7.Using feeler gauges, measure and record
clearance between piston skirt and LEFT HAND
side of cylinder bore 60 mm (2.4 in) from top of
bore:
Piston to cylinder bore clearance =0.171 to
0.207 mm (0.007 to 0.008 in)
8.Repeat above procedures for remaining pistons.
CAUTION: Oversize pistons are not
available, if piston to cylinder bore
clearance exceeds limits given, repeat
check using a new piston; if clearances are still
excessive, replace cylinder block.
Piston and 1st compression rings fitted to Engine
Serial No. Prefixes 15P to 19P may be fitted to
Engine Serial No. Prefixes 10P to 14P in engine
sets only. Oil control and 2nd compression rings
are interchangeable between all engines.
9.Check fit of each gudgeon pin in its piston. Pin
must be a tight, sliding fit with no perceptible
side play.
10.Measure gudgeon pin diameter at each end and
centre of pin. Renew gudgeon pin and piston as
an assembly if diameters are less than specified
or if excessive pin to piston side play is evident.
Gudgeon pin diameter =29.995 to 30.000 mm
(1.180 to 1.181 in)
11.Check connecting rod small-end bushes for
wear, check that gudgeon pin is a sliding fit in
the bush with no perceptible side play.
CAUTION: Small-end bushes cannot be
replaced, a new connecting rod must be
fitted.
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ENGINE
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OVERHAUL Piston ring gaps - Checking
1.Insert new compression and oil control piston
rings in turn into No. 1 cylinder bore 30 mm (1.25
in) from top of bore and check ring fitted gaps;
ensure rings are kept square to bore when
checking gaps.
1st compression ring fitted gap =0.30 to 0.40
mm (0.012 to 0.016 in)
2nd compression ring fitted gap =0.40 to 0.60
mm (0.016 to 0.024 in)
Oil control ring fitted gap =0.25 to 0.50 mm
(0.01 to 0.02 in)
Repeat for each cylinder bore in turn.
CAUTION: Ensure rings are suitably
identified with the cylinder bore in which
they were checked and are fitted to the
piston for that bore.
2.Fit oil control expander and ring to piston.
3.Fit 2nd compression ring with’TOP’marking
upwards.
4.Fit 1st compression ring with’TOP’marking
upwards.
5.Check piston ring to groove clearance:
1st compression ring -Not measured
2nd compression ring =0.050 to 0.082 mm
(0.02 to 0.003 in)
Oil control ring =0.050 to 0.082 mm (0.02 to
0.003 in)
Pistons and connecting rods - Assembling
1.Lubricate gudgeon pin, gudgeon pin holes in
piston and small-end bush with engine oil.
2.Position piston to its respective connecting rod
with arrow on piston crown on the same side as
the cast boss on the connecting rod.
3.Fit gudgeon pin to its respective piston and
connecting rod; secure with new circlips.
CAUTION: Ensure circlips are fully seated
in their grooves.
4.Repeat above procedures for remaining pistons.
5.Lubricate piston rings and cylinder bores with
engine oil.
6.Check that rings are free to rotate, position ring
gaps at 120°to each other and away from the
thrust - LH side of piston - viewed from front of
piston.
7.Using a suitable piston ring clamp, compress
piston rings.
8.Insert connecting rod and piston into its
respective cylinder bore, ensuring that the arrow
on piston crown and the cast boss on connecting
rod are facing towards the front of the cylinder
block.
CAUTION: Ensure that connecting rod
does not contact cylinder bore or oil squirt
jet. Do not pull connecting rod fully down
cylinder bore at this stage.
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