service LAND ROVER DEFENDER 1999 Service Manual

12ENGINE
2
OVERHAUL GASKET - EXHAUST MANIFOLD
Service repair no - 30.15.12.01
Remove
NOTE: The following procedure covers
both EU3 and non EU3 engines
NOTE: EU3 engine illustrated.
1.Remove 3 bolts securing heater pipe to cylinder
head and turbocharger heat shield.
2.Remove heater pipe.
3.Remove bolt and remove turbocharger heat
shield.
4.Remove and discard 2 Allen screws securing
EGR pipe to exhaust manifold.
5.Remove banjo bolt securing oil feed pipe to
turbocharger and discard sealing washers.
6.Loosen turbocharger drain hose union at
cylinder block.
7.Remove 10 nuts and remove exhaust manifold
and turbocharger.
8.Remove manifold gasket.Refit
1.Clean exhaust manifold mating faces.
2.Position exhaust manifold to cylinder head using
new gasket and fit manifold nuts.
3.Working from the centre outwards, fit and tighten
nuts to25 Nm (18 lbf.ft).
4.Clean turbocharger drain and feed hose unions.
5.Fit turbocharger oil drain hose to cylinder block
and tighten union to48 Nm (35 lbf.ft).
6.Fit new sealing washers to turbocharger oil feed
pipe, fit banjo bolt and tighten to25 Nm (18
lbf.ft).
7.Position EGR pipe to exhaust manifold. Fit new
Allen screws and tighten to10 Nm (7 lbf.ft).
8.Position turbocharger heat shield.
9.Position heater pipe to cylinder head and tighten
bolts to25 Nm (18 lbf.ft).
10.Position exhaust manifold heatshield and tighten
M6 bolts to9 Nm (7 lbf.ft)and M8 bolt to25
Nm (18 lbf.ft).
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ENGINE
3
OVERHAUL GASKET - CYLINDER HEAD
Service repair no - 12.29.02.01
Remove
CAUTION: The following procedures
should only be carried out when cylinder
head is to be overhauled; for replacement
of cylinder head gasket only, see Repairs section -
Gasket - Cylinder head.
NOTE: The following procedure covers
both EU3 and non EU3 engines
1.Remove exhaust manifold gasket.See
MANIFOLD AND EXHAUST SYSTEM, Repair.
2.Remove inlet manifold gasket.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
3. Models with EGR cooler:Remove and discard
2 Allen screws securing EGR pipe to cooler.
4.Progressively loosen then remove 13 bolts
securing camshaft cover, remove cover; remove
and discard gasket.
5.Remove isolators and sealing washers from
cover.
6.Disconnect injector multiplug from camshaft
carrier.
7.Disconnect multiplug from ECT sensor.
8.Remove bolt securing alternator strap bracket to
cylinder head.
9.Set engine to TDC firing - No. 1 cylinder -
coloured links on timing chain are aligned with
timing mark on camshaft sprocket.
10.Fit timing pinLRT-12-058into slot in camshaft.
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12ENGINE
8
OVERHAUL CYLINDER HEAD - OVERHAUL
Service repair no - 12.29.19.01
Dismantling
1.Remove cylinder head gasket.See this
Section.
CAUTION: Due to the design of the
cylinder head which incorporates drillings
for the fuel injection system, it is important
that absolute cleanliness is adhered to when
carrying out overhaul procedures.
2.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
CAUTION: If new pistons, connecting rods
or crankshaft are fitted, it will be
necessary to determine thickness of
gasket required.See this Section.
3.Remove 4 glow plugs.
4.Disconnect multiplugs from EUI’s and remove
harness from camshaft carrier. Remove and
discard’O’ring from harness multiplug.
5.Loosen lock nuts and fully unscrew rocker
adjusting screws; discard locknuts and screws.
6.Remove and discard 6 bolts securing rocker
shaft, remove shaft.
NOTE: Dowel located.
7.Using sequence shown, progressively loosen 13
bolts securing camshaft carrier to cylinder head
until valve spring pressure is released; remove
bolts.
CAUTION: Do not discard bolts at this
stage.
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12ENGINE
20
OVERHAUL GASKET - ENGINE SUMP
Service repair no - 12.60.38.01
Remove
1.Remove 2 bolts securing centrifuge oil drain pipe
to sump, remove and discard gasket.
2.Using sequence shown and noting their fitted
positions, remove 20 bolts securing sump to
cylinder block.
3.Remove sump, remove and discard gasket.
CAUTION: Do not lever between sump and
cylinder block.Refit
1.Clean sump and mating faces, ensure bolt holes
in cylinder block are clean and dry.
2.Using suitable solvent, remove all traces of
sealant from joint faces of timing chain cover and
crankshaft rear oil seal housing.
3.Clean centrifugal filter oil drain pipe and mating
faces.
4.Apply a bead of sealant, Part No. STC 3254 to
joint faces of timing chain cover and crankshaft
rear oil seal housing.
CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
5.Position new sump gasket.
CAUTION: Gasket must be fitted dry.
6.Position sump, fit and lightly tighten bolts
ensuring they are in their original fitted positions.
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ENGINE
21
OVERHAUL
7.Using sequence shown, tighten sump bolts to25
Nm (18 lbf.ft).
8.Fit new centrifuge oil drain pipe gasket.
CAUTION: Gasket must be fitted dry.
9.Fit centrifuge oil drain pipe, fit bolts and tighten
to10 Nm (7 lbf.ft).SEAL - CRANKSHAFT - REAR
Service repair no - 12.21.20.01
Remove
1.Remove flywheel.See Repair.
2.Remove sump gasket.See this Section.
3.Remove 5 bolts securing crankshaft rear oil seal
housing to cylinder block.
4.Remove and discard crankshaft rear oil seal and
housing.
NOTE: Dowel located.
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12ENGINE
22
OVERHAUL Refit
1.Clean crankshaft rear oil seal housing mating
face on cylinder block, ensure bolt and dowel
holes are clean and dry. Remove all traces of oil
from oil seal running surface on crankshaft.
2.Position seal protectorLRT-12-061over
crankshaft boss. Fit new seal and housing,
removeLRT-12-061.
CAUTION: Oil seal must be fitted dry.
3.Fit oil seal housing bolts and using sequence
shown, tighten to9 Nm (7 lbf.ft).
4.Fit sump gasket.See this Section.
5.Fit flywheel.See Repair.STARTER RING GEAR
Service repair no - 12.53.19
Remove.
1.Remove flywheel.See Repair.
2.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
3.Apply a cold chisel to root of teeth, break ring
gear and remove from flywheel.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
Refit
1.Heat ring gear evenly to 350°C, indicated by
light blue colour.
2.Locate ring gear on flywheel and press on to
flange.
WARNING: Handle hot ring gear with care.
3.Allow ring gear to air cool.
4.Fit flywheel.See Repair.
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ENGINE
23
OVERHAUL PUMP - OIL
Service repair no - 12.60.26.02
Remove
1.Remove sump gasket.See this Section.
2.Remove bolt securing oil pump drive sprocket.
3.Release drive sprocket from chain, remove
sprocket.
4.Remove 3 Torx screws securing oil pick-up
strainer, remove strainer.
5.Remove and discard’O’ring.
6.Using sequence shown, remove and discard 22
bolts securing oil pump and stiffener plate
assembly to cylinder block.
7.Remove oil pump and stiffener plate assembly.
NOTE: Dowel located.
8.Remove and discard’O’ring from oil pump
housing outlet.
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12ENGINE
26
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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12ENGINE
30
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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12ENGINE
32
OVERHAUL
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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