engine coolant 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 98 of 667
ENGINE
13
DESCRIPTION AND OPERATION CYLINDER BLOCK
The cylinders and crankcase are contained in a single cast iron construction. The cylinders are direct bored and
plateau honed with lubrication oil supplied via lubrication jets for piston and gudgeon pin lubrication and cooling. It
is not possible to rebore the cylinder block if the cylinders become worn or damaged. Three metal core plugs are
fitted to the three centre cylinders on the right hand side of the cylinder block.
Lubrication oil is distributed throughout the block via the main oil gallery to critical moving parts through channels
bored in the block which divert oil to the main and big-end bearings via oil holes machined into the crankshaft. Oil
is also supplied from the cylinder block main gallery to the five lubrication jets which cool and lubricate the piston
and gudgeon pins. Plugs are used to seal both ends of the main oil gallery at front and rear of the engine block.
An oil cooler is fitted to the LH side of the engine block; ports in the oil cooler assembly mate with ports in the
cylinder block to facilitate coolant flow. Oil is diverted through the oil cooler, centrifuge filter and full-flow filter
before supplying the main oil gallery. A tapping in the oil filter housing provides a lubrication source for the
turbocharger bearings and an oil pressure switch is included in a tapping in the oil cooler housing which
determines whether sufficient oil pressure is available to provide engine lubrication and cooling.
Cylinder cooling is achieved by water circulating through chambers in the engine block casting. A threaded coolant
jacket plug is located at the front RH side of the cylinder block.
Cast brackets are bolted to both sides of the engine block for mounting the engine to the chassis on the LH and
RH hydramount studs.
The gearbox bolts directly to the engine block; a gearbox shim plate is located between the adjoining faces of the
gearbox and the flywheel side of the engine block and is fixed to the rear of the engine block by two bolts. Two
hollow metal dowels locate the rear of the cylinder block to the shim plate. The gearbox casing provides the
mounting for the starter motor.
A port is included at the rear left hand side of the cylinder block which connects to the turbocharger oil drain pipe
to return lubrication oil to the sump. A plug sealing the lubrication cross-drilling gallery is located at the front right
hand side of the cylinder block and plugs for the main lubrication gallery are located at the front and rear of the
cylinder block. Two plastic dowels are used to locate the cylinder head to the cylinder block and must be replaced
every time the cylinder head is removed from the cylinder block.
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12ENGINE
16
DESCRIPTION AND OPERATION Oil cooler
1.Front oil gallery - full-flow filter to oil cooler matrix
2.Full-flow filter adaptor outlet port to oil cooler
(opens at 74°C)
3.Full-flow filter inlet port
4.Oil cooler housing
5.Full-flow filter outlet port to cylinder block
6.Coolant inlet port
7.Oil cooler banjo bolt seals (2 off)
8.Banjo bolts (2 off)
9.Banjo bolt oil holes - to oil cooler matrix
10.Rear oil gallery - full-flow filter / oil cooler outlet
to cylinder block11.Centre oil gallery - from pump to full-flow filter
12.Inlet port to centrifuge filter
13.Sealing ring - centrifuge filter housing to oil
cooler housing
14.Port - oil cooler matrix
15.Oil cooler matrix
16.Inlet port from pump via cylinder block to oil
cooler housing
17.Outlet port from oil cooler housing to cylinder
block
18.Rear view of oil cooler housing
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Page 102 of 667
ENGINE
17
DESCRIPTION AND OPERATION The engine oil cooler assembly is located on the left hand side of the engine block behind the oil centrifuge and oil
filter. The housing is bolted to the engine block by seven bolts. A matrix is included in the oil cooler housing which
acts as a heat exchanger. Coolant flow circulates through the oil cooler housing under pressure from the coolant
pump and distributes the flow evenly around the matrix fins and then along the block into three core holes for
cylinder cooling. Coolant enters the oil cooler through a pipe with a rubber hose extension at the rear side of the
engine. The coolant hose is attached to the stub pipe of the oil cooler by a spring clip.
Oil, drawn from the sump by the oil pump, passes through the oil cooler via the cylinder block. The flow of coolant
around the exterior surface of the oil cooler matrix cools a proportion of the engine oil flow as it passes through the
oil cooler.
The oil cooler is sealed to the cylinder block by a gasket which must be replaced every time the oil cooler housing
is removed.
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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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Page 131 of 667
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 132 of 667
ENGINE
7
REPAIR
14.Disconnect MAP sensor multiplug from inlet
manifold.
15.Position engine harness clear of inlet manifold.
16.Disconnect vacuum hose from EGR valve.
17.Loosen clip screw and disconnect air intake
hose from EGR valve.
18.Release 3 clips and disconnect coolant hoses
from fuel cooler.
19.Disconnect fuel hoses, tank to fuel cooler and
connector block on cylinder head.
CAUTION: Plug the connections.
20.Disconnect fuel hose from fuel cooler and secure
to connector block on cylinder head. This is to
prevent contamination of the fuel injection
system.
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Page 133 of 667
12ENGINE
8
REPAIR
NOTE: Non EU3 model illustrated.
21.Loosen vacuum pipe union from cylinder head
and discard’O’ring.
22.Loosen 2 bolts and release alternator support
bracket from cylinder head.
23. Pre EU3 model:-Remove bolt securing EGR
valve pipe to cylinder head.
24. EU3 model:-Release the clips and disconnect
the coolant hoses from the EGR cooler.
25.Release clips and disconnect top hose, heater
hose and heater feed hose.
26.Remove the nut and bolt securing the cuylinder
head to the timing chain cover.
27.Rotate engine clockwise to align mark on
camshaft sprocket between coloured links on
timing chain.
28.PositionLRT-12-058through camshaft carrier to
lock camshaft.
29.PositionLRT-12-158through gearbox bell
housing to lock crankshaft.
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Page 135 of 667
12ENGINE
10
REPAIR Refit
39.Clean mating faces of cylinder head and cylinder
block.
40.Check cylinder head for warping, across centre
and from corner to corner:
Maximum warp = 0.10 mm (0.004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head assembly if
warping exceeds figure given.
41.Ensure coolant and oil passages are clean.
42.Clean dowel holes and fit new dowels.
43.Fit new cylinder head gasket of the correct
thickness with the word’TOP’uppermost.
44.Using assistance, fit cylinder head and locate on
to dowels.
45.Carefully enter new cylinder head bolts together
with their captive washers,DO NOT DROP.
Lightly tighten bolts.
46.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.
47.Fit nut and bolt securing cylinder head to timing
chain cover and tighten to25 Nm (18 lbf.ft).
48.Clean camshaft sprocket and mating face on
camshaft.
49.Ensure engine is set to TDC No. 1 cylinder and
mark on camshaft sprocket is positioned
between the 2 coloured links.
50.Position camshaft sprocket to camshaft, fit and
lightly tighten new bolts then loosen bolts half a
turn.
51.Clean fixed guide retaining pin and apply Loctite
242 to threads.
52.Fit and tighten fixed guide retaining pin to25 Nm
(18 lbf.ft).
53.Clean timing chain tensioner and fit new sealing
washer.
54.Fit timing chain tensioner and tighten to45 Nm
(33 lbf.ft).
55.Tighten camshaft sprocket retaining bolts to36
Nm (27 lbf.ft).
56.RemoveLRT-12-058from camshaft.
57.RemoveLRT-12-158from gearbox bell housing.
58.Clean access plug recess in cylinder head and
fit new’O’ring. Fit access plug.
59.Clean vacuum pump union.
60.Tighten vacuum pipe union to10 Nm (7lbf.ft).
61.Fit bolts securing alternator bracket to cylinder
head and tighten to25 Nm (18 lbf.ft).
62.Connect top hose, heater hoses and secure with
clips.
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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 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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