service LAND ROVER DEFENDER 1999 Owner's Manual

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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ENGINE
5
REPAIR
7.Fit oil seal housing bolts and using sequence
shown, tighten to9 Nm (7 lbf.ft).
8.Fit sump gasket.See this Section.
9.Fit flywheel.See this Section.BEARING - SPIGOT - CRANKSHAFT
Service repair no - 12.21.45
Remove
1.Remove clutch assembly.See CLUTCH,
Repair.
2.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
3.Fit extractor to spigot bush.
4.Remove spigot bush from crankshaft.
Refit
5.Clean spigot bush and mating face in rear of
crankshaft.
6.Fit new spigot bush to crankshaft using a
suitable drift.
7.Fit clutch assembly.See CLUTCH, Repair.
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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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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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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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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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ENGINE
19
REPAIR 70.Connect coolant hoses to fuel cooler and coolant
rail and secure clips.
71.Fit air intake hose to intake elbow and tighten
clip screw.
72.Fit starter motor.See ELECTRICAL, Repair.
73.Fit turbocharger.See FUEL SYSTEM, Repair.
74.Fit radiator.See COOLING SYSTEM, Repair.
75.Fit air filter.See FUEL SYSTEM, Repair.
76.Fill engine with oil.
77.Fit underbelly panel.See CHASSIS AND
BODY, Repair.MOUNTING - FRONT - LH
Service repair no - 12.45.01
Remove
1.Remove centrifuge assembly.See this
Section.
2.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3.Fit suitable lifting chains to support engine.
4.Remove 2 nuts securing engine mounting to
chassis.
5.Remove 4 bolts securing engine mounting
bracket to cylinder block.
6.Remove nut securing mounting to mounting
bracket.
7.Remove mounting and mounting bracket.
8.Remove mounting shield.
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12ENGINE
20
REPAIR Refit
9.Fit shield to mounting ensuring cut-away portion
is correctly aligned.
10.Fit mounting and mounting bracket.
11.Fit mounting bracket to cylinder block bolts and
tighten to48 Nm (35 lbf.ft).
12.Fit nuts securing mounting to chassis and tighten
to85 Nm (63 lbf.ft).
13.Fit mounting to mounting bracket nut and tighten
to85 Nm (63 lbf.ft).
14.Remove engine support chains.
15.Clean oil filter adaptor housing and mating face.
16.Fit oil filter adaptor housing using a new gasket
and tighten bolts to25 Nm (18 lbf.ft).
17.Fit centrifuge assembly.See this Section.MOUNTING - FRONT - RH
Service repair no - 12.45.03
Remove
1.Remove engine acoustic cover.See this
Section.
2.Remove fixings, remove battery cover.
3.Disconnect battery negative lead.
4.Raise front of vehicle.
WARNING: Support on safety stands.
5.Remove 4 bolts, move fuel cooler to one side.
6.Fit suitable lifting chains to support engine.
7.Remove 2 nuts securing engine mounting to
chassis.
8.Remove 4 bolts securing engine mounting
bracket to cylinder block.
9.Remove nut securing mounting to mounting
bracket.
10.Remove mounting and mounting bracket.
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ENGINE
21
REPAIR Refit
11.Fit mounting and mounting bracket.
12.Fit mounting bracket to cylinder block bolts and
tighten to48 Nm (35 lbf.ft).
13.Fit nuts securing mounting to chassis and tighten
to85 Nm (63 lbf. ft).
14.Fit mounting to mounting bracket nut and tighten
to85 Nm (63 lbf.ft).
15.Remove engine support chains.
16.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
17.Remove stand(s) and lower vehicle.
18.Reconnect battery negative lead.
19.Fit engine acoustic cover.See this Section.MOUNTING - GEARBOX - REAR - LH
Service repair no - 12.45.07
Remove
1.Raise vehicle on ramp.
2.Position jack to support gearbox.
3.Remove 4 bolts securing mounting bracket to
transfer gearbox.
4.Remove 2 nuts, remove mounting and mounting
bracket.
5.Remove heat shield from mounting.
Refit
6.Clean mounting and mating faces.
7.Position heat shield to mounting.
8.Position mounting and mounting bracket and
tighten nuts to48 Nm (35 lbf.ft)and bolts to85
Nm (63 lbf. ft).
9.Lower support jack.
10.Lower vehicle.
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