cooling LAND ROVER DEFENDER 1999 User Guide
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DEFENDER, Model: LAND ROVER DEFENDER 1999Pages: 667, PDF Size: 8.76 MB
Page 110 of 667
ENGINE
25
DESCRIPTION AND OPERATION CYLINDER HEAD COMPONENTS
The cylinder head components are described below:
Cylinder head
The cylinder head is of aluminium construction. It is not possible to reface the cylinder head if it becomes worn or
damaged. An alloy camshaft carrier is bolted directly to the upper surface of the cylinder head. Two dowels are
included in the cylinder head upper face for correct location of the camshaft carrier.
The EU3 cylinder head has a single internal fuel rail for delivering fuel to the injectors and an external fuel pipe for
returning spill fuel back to the fuel connector block. Therefore, pre EU3 and EU3 cylinder heads are not
interchangeable.
CAUTION: The cylinder head incorporates drillings for the fuel injection system, any
contamination which enters these drillings could cause engine running problems or injector
failure. It is therefore, essential that absolute cleanliness is maintained when carrying out work on
the cylinder head.
The camshaft carrier and cylinder head assembly is attached to the cylinder block by twelve cylinder head
retaining bolts which pass through the camshaft carrier and the cylinder head to secure the assembly to the
cylinder block.
CAUTION: The valve heads, tips of the injectors and glow plugs protrude below the face of the
cylinder head and will be damaged if the cylinder head is stored face down.
The camshaft is located between the cylinder head and the camshaft carrier, and the bearing journals are line
bored between the two components to form a matched pair.
CAUTION: Always fit plugs to open connections to prevent contamination.
The valve guides and valve seat inserts are sintered components which are an interference fit to the cylinder
head. The cylinder head machining also provide the locations for the electronic unit injectors, glow plugs, hydraulic
lash adjusters, finger followers and low pressure fuel rail.
Cooling to the cylinder head is provided by coolant flow through a water jacket machined into the cylinder head.
Drillings through the block provide lubrication channels for pressurised oil supply to cylinder head components
such as the lash adjusters, finger followers, rocker arms and camshaft bearings.
A coolant outlet elbow is fitted to the front LH side of the cylinder head to allow flow of coolant from the cylinder
head back to the radiator. A metal gasket is used to seal the joint between the water outlet elbow and the cylinder
head. A coolant temperature sensor is located in a port in the side of the water outlet elbow for monitoring coolant
temperature.
A stub pipe is connected at the front RH side of the cylinder block above the timing cover which connects a pipe to
supply oil to the vacuum pump. The timing chain tensioner adjuster is screwed in a thread in the cylinder head at a
location on the front RH side of the engine below the oil feed port for the vacuum pump.
An access hole for the camshaft gear is included at the front of the cylinder head which is sealed with a plastic
plug and rubber’O’ring. A press-fit core plug for the chain chest is located on the front face of the cylinder head.
A press-fit core plug for the cylinder head water jacket is located at the rear of the cylinder head and a threaded
brass plug for the water jacket is located on the LH side of the cylinder head beneath the exhaust manifold
assembly.
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ENGINE
35
DESCRIPTION AND OPERATION 1.To cylinder block main gallery (from rear of oil cooler housing)
2.Oil cooler housing
3.Oil pressure switch
4.Full-flow filter
5.Centrifuge filter
6.Return to sump
7.Flow from oil pump (via cylinder block)
8.Oil cooler matrix
When the engine temperature is below 74°C, the thermostat in the full-flow filter adaptor housing is closed and a
proportion of the oil flow to the main oil gallery is diverted to the oil cooler to supply an oil feed to the turbocharger
bearings. Oil passes through the oil cooler to the front gallery in the oil cooler housing where there is a tapping to
connect the feed pipe to the turbocharger. Oil used by the turbocharger bearings is returned to the sump through
an oil drain pipe which connects to a port in the LH side of the cylinder block.
The remainder of the oil flow leaving the full-flow filter outlet is passed into the cylinder block via a port at the rear
of oil cooler rear gallery.
When the oil temperature rises above 74°C the thermostat in the full-flow filter housing begins to open to allow a
proportion of the oil from the full-flow filter to pass through the oil cooler before it reaches the main oil gallery in the
cylinder block. In this instance, oil supply to the turbocharger bearings is fed directly from the full-flow filter without
first passing through the oil cooler. Between 74°C and 88°C the thermostat valve plunger opens by about 9 mm
(0.3 in) to allow proportionally more oil to flow through the oil cooler before being passed to the cylinder block main
oil delivery gallery. Above 88°C the thermostat valve continues to open by about 1mm (0.03 in) for every 10°C
increase in temperature until the valve is fully open, when all the oil flow to the cylinder block is forced to pass to
the cylinder block via the oil cooler.
An oil pressure switch is located in a port in the rear gallery of the oil cooler housing to sense the oil pressure level
before flow enters the main oil gallery in the engine block. A warning lamp in the instrument cluster is switched on
if the oil pressure is detected as being too low.
Drillings from the cylinder block main oil gallery direct oil to the crankshaft main bearings and cross drillings in the
crankshaft direct oil to the big-end bearings. An additional five drillings in the cylinder block supply oil at reduced
pressure to the oil squirt jets for piston cooling and gudgeon pin lubrication.
Oil supply from the cylinder block is then passed to the cylinder head galleries through a non-return valve which is
included as an integral item in the lower face of the cylinder head.
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Page 128 of 667
ENGINE
3
REPAIR
25.Using sequence shown, progressively tighten
bolts to25 Nm (18 lbf.ft).
26.Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
27.Fit rocker shaft ensuring it is located on dowel, fit
new bolts and working from the centre outwards,
tighten bolts progressively to32 Nm (24 lbf.ft).
28.Fit new’O’ring to injector harness multiplug, fit
harness and connect injector multiplugs.
29.Fit cylinder head gasket.See this Section.
30.Before refitting the camshaft cover the fuel
injector rockers must be adjusted.
31.Rotate engine clockwise until No. 1 injector lobe
is at full lift.
32.Rotate rocker adjusting screw clockwise until the
injector plunger is felt to bottom out.
33.Rotate rocker adjusting screw anti-clockwise 1
complete turn to give plunger the required bump
clearance and tighten rocker adjusting screw
locknut to16 Nm (12 lbf.ft).
34.Carry out above procedure for the remaining 4
rockers.
35.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no injectors are bottoming
out on their plungers.PULLEY - CRANKSHAFT
Service repair no - 12.21.01
Remove
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Remove radiator.See COOLING SYSTEM,
Repair.
3.Using a 15 mm ring spanner release the
auxiliary drive belt tensioner.
4.Remove auxiliary drive belt.
5.Remove 3 bolts and remove crankshaft damper.
6.PositionLRT-51-003to crankshaft pulley and
secure with 2 bolts.
7.Remove and discard crankshaft pulley bolt.
Remove crankshaft pulley.
8.Remove 2 bolts and removeLRT-51-003.
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12ENGINE
4
REPAIR Refit
9.Position new crankshaft pulley to vice.
10.Remove 3 bolts and remove damper from
crankshaft pulley.
11.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
12.Fit crankshaft pulley.
13.FitLRT-51-003to crankshaft pulley and secure
with 2 bolts.
14.Fit new crankshaft pulley bolt and tighten to460
Nm (340 lbf.ft).
NOTE: It is recommended that a torque
multiplier is used to tighten crankshaft
pulley bolt.
15.Remove 2 bolts and removeLRT-51-003from
crankshaft pulley.
16.Fit damper to crankshaft pulley, fit bolts and
tighten to80 Nm (60 lbf.ft).
17.Fit auxiliary drive belt.
18.Fit radiator.See COOLING SYSTEM, Repair.
19.Fit underbelly panel.See CHASSIS AND
BODY, Repair.OIL SEAL - CRANKSHAFT - REAR
Service repair no - 12.21.20
Remove
1.Remove flywheel.See this Section.
2.Remove sump gasket.See this Section.
3.Remove 5 bolts securing oil seal housing to
cylinder block.
4.Remove seal housing.
Refit
5.Clean seal housing mating face on cylinder
block.
6.Position seal protector,LRT-12-061over
crankshaft boss. Fit new seal and housing
assembly and remove toolLRT-12-061.
CAUTION: Oil seal must be fitted dry.
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12ENGINE
6
REPAIR GASKET - CYLINDER HEAD
Service repair no - 12.29.02
Remove
NOTE: The following procedures cover
engines fitted with or without an EGR
cooler. The EGR cooler is bolted to the
front of the cylinder head.
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain cooling system.See COOLING
SYSTEM, Adjustment.
3.Remove camshaft cover gasket.See this
Section.
4.Remove cooling fan.See COOLING SYSTEM,
Repair.
5.Release clips and disconnect air flow meter from
air filter.
6.Disconnect multiplug from air flow meter.
7.Loosen clip and remove air inlet hose from
turbocharger.
8.Remove 3 bolts and remove exhaust manifold
heat shield.
9.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
10.Remove 3 nuts, release turbocharger from
exhaust manifold, discard gasket and tie
turbocharger aside.
11.Remove 2 bolts securing engine harness to
camshaft carrier.
12.Disconnect fuel injector, coolant and compressor
sensors.
13.Disconnect 4 heater plug connectors.
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Page 136 of 667
ENGINE
11
REPAIR 63. Pre EU3 model:-Fit bolt, EGR valve pipe to
cylinder head and tighten to25 Nm (18 lbf.ft).
64. EU3 model:-Connect coolant hoses to EGR
cooler and secure with clips.
65.Position air intake hose to EGR valve and
tighten clip screw.
66.Disconnect fuel hose from connector block and
connect to fuel cooler.
67.Connect fuel hoses to fuel cooler and connector
block on cylinder head.
68.Connect coolant hoses to fuel cooler and secure
clips.
69.Connect vacuum hose to EGR valve.
70.Position engine harness and connect multiplugs
and heater plug connectors.
71.Fit and tighten bolts, engine harness to camshaft
carrier.
72.Clean exhaust manifold and mating face.
73.Fit new gasket to exhaust manifold, position
turbocharger and tighten nuts to30 Nm (22 lbf.
ft).
74.Clean turbocharger feed hose bolt.
75.Position feed hose using new sealing washers,
tighten bolt to25 Nm (18 lbf.ft).
76.Position exhaust manifold heat shield, and
tighten M6 bolts to10 Nm (7 lbf.ft)and M8 bolt
to25 Nm (18 lbf.ft).
77.Position air inlet hose to turbocharger and
tighten clip screw.
78.Connect air flow meter to air filter and secure
clips.
79.Connect air flow meter multiplug.
80.Fit cooling fan.See COOLING SYSTEM,
Repair.
81.Fit camshaft cover gasket.See this Section.
82.Refill cooling system.See COOLING SYSTEM,
Adjustment.
83.Fit underbelly panel.See CHASSIS AND
BODY, Repair.ROCKER SHAFT ASSEMBLY
Service repair no - 12.29.29
Remove
1.Remove cooling fan.See COOLING SYSTEM,
Repair.
2.Remove camshaft cover gasket.See this
Section.
3.Loosen lock nuts and fully retract rocker
adjusting screws to prevent damage on
reassembly.
4.Rotate engine clockwise, until camshaft gear
and timing chain marks are aligned and fit
LRT-12-058through camshaft carrier to lock
camshaft.
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Page 138 of 667
ENGINE
13
REPAIR 11.Before refitting the camshaft cover, the fuel
injector rockers must be adjusted.
12.RemoveLRT-12-058.
13.Rotate engine clockwise until No. 1 injector lobe
is at full lift.
14.Rotate rocker adjusting screw clockwise until the
injector plunger is felt to bottom out.
15.Rotate rocker adjusting screw anti-clockwise 1
complete turn to give the 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.
16.Carry out above procedure for the remaining 4
rockers.
17.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no injectors are bottoming
out on their plungers.
18.Fit camshaft cover gasket.See this Section.
19.Fit cooling fan.See COOLING SYSTEM,
Repair.GASKET - COVER - CAMSHAFT
Service repair no - 12.29.40
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Release clip and disconnect breather hose from
camshaft cover.
5.Remove 13 bolts, spacers and sealing washers
from camshaft cover.
6.Remove camshaft cover and gasket.
Refit
7.Clean camshaft cover and mating face.
8.Renew sealing washers and spacers as
necessary.
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Page 139 of 667
12ENGINE
14
REPAIR
9. Not EU3 model:-Apply two 3 mm diameter
beads of sealant, Part No.STC 5433 to areas’A’
shown on illustration.
CAUTION: Excessive use of sealant could
result in blockage of oil drain hole,
arrowed’B’in illustration.
10.Fit new gasket to camshaft cover. fit cover and
tighten bolts to10 Nm (7 lbf.ft).
11.Position breather hose and secure clip.
12.Fit engine acoustic cover.
13.Reconnect battery negative lead.
14.Fit battery cover.ENGINE AND ANCILLARIES
Service repair no - 12.41.01.99
Remove
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain engine oil.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Remove turbocharger.See FUEL SYSTEM,
Repair.
5.Remove starter motor.See ELECTRICAL,
Repair.
6.Remove air filter.See FUEL SYSTEM, Repair.
7.Loosen clip screw and release air intake hose
from intake elbow.
8.Release clips and disconnect coolant hoses
from fuel cooler and coolant rail.
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Page 140 of 667
ENGINE
15
REPAIR
NOTE: Non EU3 model illustrated.
9.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Plug the connections.
10.Disconnect fuel hose from fuel cooler and secure
to connector block on cylinder head. This to
prevent contamination of the fuel system.
11.Release servo vacuum pipe, remove 4 bolts and
remove fuel cooler.
12.Release servo vacuum pipe from engine rear
cover clips and vacuum pump.
NOTE: Non EU3 model illustrated.
13.Disconnect vacuum hose from EGR valve.
14.Release EGR vacuum hose from vacuum pipe.
15.Disconnect multiplug from condensor cooling
fan.
NOTE: Non EU3 model illustrated.
16.Disconnect multiplugs from EGR solenoid, inlet
manifold sensor and injector harness.
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Page 143 of 667
12ENGINE
18
REPAIR
35.Remove 2 bolts and remove acoustic cover from
rear of cylinder head.
36.FitLRT-12-138to suitable lifting chains and
connect to lifting eyes on engine.
37.Remove 2 nuts from RH and LH front engine
mountings.
38.Fit trolley jack to support gearbox.
39.With assistance raise chains and remove engine
from vehicle.Refit
40.With assistance, raise engine from bench and
position in vehicle.
41.With assistance, align engine to gearbox input
shaft.
42.Position 2 upper bolts securing gearbox housing
to engine and tighten to50 Nm (37 lbf.ft).
43.Lower engine onto mountings and tighten nuts to
85 Nm (63 lbf.ft).
44.RemoveLRT-12-138from engine.
45.Fit and tighten bolt securing engine closing panel
to gearbox.
46.Raise vehicle on ramp.
47.Fit bolts securing gearbox housing to engine and
tighten to50 Nm (37 lbf.ft).
48.Lower ramp.
49.Fit acoustic cover to rear of cylinder head and
tighten bolts.
50.Position coolant hose to engine oil cooler and
secure clip.
51.Position PAS pump and tighten bolts to25 Nm
(18 lbf.ft).
52.Position PAS pulley and tighten bolts to25 Nm
(18 lbf.ft).
53.Position A/C compressor and tighten bolts to25
Nm (18 lbf.ft).
54.Route engine harness beneath inlet manifold
and connect multiplugs to oil pressure switch,
A/C compressor, and ECT sensor.
55.Fit and tighten bolts securing engine harness to
camshaft carrier.
56.Connect multiplug to alternator.
57.Connect battery lead to alternator and tighten
nut.
58.Clean CKP sensor and mating face.
CAUTION: If originally fitted:- Fit spacer to
CKP sensor.
59.Using a new’O’ring, fit CKP sensor, tighten bolt
to10 Nm (7 lbf.ft).
60.Connect CKP sensor multiplug.
61.Connect multiplugs to EGR solenoid, inlet
manifold sensor, injector harness, fuel
temperature sensor and CKP sensor.
62.Connect glow plug leads.
63.Connect multiplug to condensor cooling fan.
64.Connect vacuum hose to EGR valve.
65.Connect EGR vacuum hose to vacuum pipe.
66.Position pipe to vacuum pump and secure pipe
to acoustic cover clips.
67.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
68.Disconnect fuel hose from connector block and
connect to fuel cooler.
69.Connect fuel hoses to fuel cooler and connector
block on cylinder head.
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