lock LAND ROVER DEFENDER 1999 Service Manual

ENGINE
33
DESCRIPTION AND OPERATION 1.Oil squirt jets (5 off)
2.Main oil delivery gallery
3.Inflow from oil cooler housing
4.Flow to oil cooler / filters (from oil pump via cylinder block)
5.Sump
6.Oil pick-up pipe
7.Flow from oil pump (relief-valve in housing)
8.Oil pump
9.Cross-drilling supply to main and crankshaft bearings
10.To cylinder head
Oil from the sump is drawn up through a two-piece plastic pick-up which contains a mesh to siphon any relatively
large pieces of material which could cause damage to the pump. The head of the pick-up is centrally immersed in
the sump oil and oil is delivered to the inlet side of the eccentric rotor pump through a gallery in the stiffener plate.
Pressurised oil from the pump is passed through to the cylinder block where it is delivered to the centrifuge filter
and full-flow filter via a port in the RH cylinder block which interfaces with a port in the centre gallery of the oil
cooler housing. The oil pump contains an oil pressure relief valve which opens to allow oil to be recirculated back
around the pump if the oil pressure increases to a high enough level.
10% of the oil flow from the pump is diverted through the centrifuge filter and returned to the sump via the
centrifuge filter drain tube. The remaining 90% of the oil passes through the standard full-flow filter to the main oil
gallery in the cylinder block.
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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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12ENGINE
36
DESCRIPTION AND OPERATION CYLINDER HEAD FLOW
1.Cast-in groove between cylinder head and
camshaft carrier
2.Rocker shaft flow
3.Lash adjuster supply channels (10 off)
4.Non-return valve
5.Chain lubrication jet supply6.Oil return from vacuum pump
7.Oil supply to timing chain tensioner adjuster
8.Oil supply to vacuum pump
9.Oil supply hole to camshaft sprocket and timing
chain
Oil passes to the cylinder head from the cylinder block via a non-return valve which is included to prevent oil
draining away from the lash adjusters when the engine is switched off.
Oil is passed to a cast-in groove between the top of the cylinder head and the camshaft carrier. The part of the
channel on the top left hand side of the cylinder head has ten cross-drillings which supply oil to the hydraulic lash
adjusters and finger followers. Lubrication oil fed to the lash adjusters passes up through the lash adjuster body
and into the socket of the finger followers. The oil exits the finger followers through a small hole to lubricate the
surfaces between the camshaft lobes and rollers.
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ENGINE
1
REPAIR CAMSHAFT
Service repair no - 12.13.02
Remove
1.Remove cylinder head gasket.See this
Section.
2.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
3.Disconnect multiplug from injector units and
remove harness from camshaft carrier.
4.Remove and discard multiplug’O’ring.
5.Loosen lock nuts and fully retract rocker
adjusting screws.
6.Progressively loosen then remove and discard 6
bolts securing rocker shaft, remove shaft.
7.Using sequence shown, progressively loosen
then remove 13 bolts securing camshaft carrier
to cylinder head.
8.Gently tap the camshaft carrier upwards to break
the sealant bond and remove carrier noting it is
located by 2 dowels.
9.Remove camshaft.
10.Remove and discard camshaft rear oil seal.
11.Remove and discard lock nuts and rocker
adjusting screws.
12.Check bearing surfaces in cylinder head and
camshaft carrier for signs of scoring and wear.
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12ENGINE
2
REPAIR
13.Position camshaft in camshaft carrier.
14.Check end-float of camshaft using a DTI.
Camshaft end-float = 0.06 to 0.16 mm (0.002 to
0.006in).
15.Renew components as necessary to achieve
correct end-float.
CAUTION: Cylinder head and camshaft
carrier are machined together as an
assembly. If bearing surfaces in either
component are found to be damaged, complete
assembly must be replaced.
NOTE: The procedure for checking
camshaft bearing clearances is covered in
Td5 Engine Overhaul section - Cylinder
head - overhaul.Refit
16.Using a suitable cleaning solvent, clean mating
faces of cylinder head and camshaft carrier.
17.Blow out all oilways and waterways.
18.Ensure threaded holes in cylinder head and
camshaft carrier are clean and dry.
CAUTION: Support each end of the
cylinder head on blocks of wood. With
camshaft carrier bolted down some valves
and the injector nozzles will protrude from the
face of cylinder head.
19.Fit new adjusting screws fully into rocker arms.
Fit new lock nuts to screws but do tighten.
CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P
to 19P have a centre punch mark adjacent to the
adjusting screw slot. These screws are not
interchangeable with those fitted to Engine Serial
No. Prefixes 10P to 14P.
20.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with clean engine oil.
21.Position camshaft in cylinder head with the
timing pin hole in the vertical position.
22.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face as shown and
spread to an even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate
camshaft bearings. Assembly and bolt
tightening must be completed within 20 minutes
of applying sealant.
23.Fit camshaft carrier ensuring that it is correctly
located on dowels.
24.Fit and lightly tighten camshaft carrier bolts.
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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
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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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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ENGINE
9
REPAIR
30.Remove timing chain tensioner and discard
sealing washer.
31.Remove timing chain fixed guide Allen screw
from front of cylinder head.
32.Lever out camshaft sprocket access plug from
front of cylinder head and discard’O’ring.
33.Remove 3 bolts and release sprocket from
camshaft; discard bolts.
34.Using sequence shown, progressively loosen
then remove and discard 12 cylinder head bolts
together with their captive washers.
35.Using suitable lifting chains andLRT-12-138
carefully remove cylinder head and place on
wooden blocks or stands.
CAUTION: The tips of the injectors, heater
plugs and valves protrude below the face
of the cylinder head and could be
damaged if the cylinder head is placed face down
on a work bench.
36.Remove cylinder head gasket.
37.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
38.Remove and discard dowels from cylinder block.
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