shaft LAND ROVER DEFENDER 1999 Manual PDF

ENGINE
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OVERHAUL
8.Gently tap camshaft carrier upwards to break
sealant bond, remove carrier.
NOTE: Dowel located.
9.Remove camshaft.
10.Remove and discard camshaft rear oil seal.
11.Remove finger followers and lash adjusters.
CAUTION: Store lash adjusters and finger
followers in their fitted order and store
lash adjusters upright. Maintain absolute
cleanliness when handling components.
12.Remove and discard 5 bolts securing EUI
retainers.
13.Using toolLRT-12-154/1remove EUI units from
cylinder head and collect retainers. Remove
reaction posts and keep in their fitted order.
14.Using toolLRT-12-154/4, remove and discard
sealing washer and’O’ring from each EUI unit.
15.Support cylinder head clear of valves, use a
hollow drift and tap each valve spring cap to free
collets.
16.Using toolLRT-12-034, compress valve spring.
17.Remove 2 collets from valve stem using a stick
magnet.
18.Remove toolLRT-12-034.
19.Remove valve spring cap, valve spring and
valve.
CAUTION: Keep components in their fitted
order.
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ENGINE
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OVERHAUL
23.Remove 3 bolts and remove fuel connector
block from cylinder head.
24.Remove and discard gasket,’O’ring and fuel
filter.
25.Remove spacer block and gasket (if fitted).Cylinder head and camshaft carrier - cleaning
1.Thoroughly clean cylinder head mating faces,
ensure oil and coolant passages are clear and
bolt holes are clean and dry.
CAUTION: Take care to ensure that EUI
drillings are clear.
2.Using suitable solvent, remove all traces of
sealant and gasket material.
CAUTION: Do not use metal scrapers.
3.Remove all traces of oil from camshaft bearings
and journals.
4.Clean glow plug threads.
Cylinder head - Inspection
1.Check core plugs for signs of leakage and
corrosion, seal replacement plugs with Loctite
243.
2.Check cylinder head for warping across centre
and from corner to corner.
Maximum cylinder head warp =0.1 mm (0.004
in).
CAUTION: Cylinder heads may not be
refaced, replace the head assembly if
warping exceeds the limit given.
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12ENGINE
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OVERHAUL Lash adjusters and finger followers - Inspection
1.Check lash adjuster bores for scoring and signs
of wear or damage.
2.Check lash adjusters for signs of wear, scoring
and overheating, replace as necessary. Ensure
oil hole in each lash adjuster is clear.
CAUTION: Store lash adjusters upright
and in their fitted order.
3.Check finger followers for wear and that rollers
are free to rotate.
CAUTION: Store finger followers in their
fitted order.
Camshaft - Inspection
1.Check camshaft lobes and bearing journals for
signs of scoring and wear.
2.Check bearing surfaces in cylinder head and
camshaft carrier for signs of scoring and wear.
CAUTION: Cylinder head and camshaft
carrier are machined together as an
assembly, if bearing surfaces in either
component are damaged, both components must
be replaced as an assembly.Camshaft - Check end-float
1.Position camshaft in camshaft carrier.
2.Check end-float of camshaft using a DTI.
Camshaft end-float =0.06 to 0.16 mm (0.002 to
0.006 in).
3.Renew components as necessary to achieve
correct end-float.
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ENGINE
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OVERHAUL Camshaft bearings - check clearance
1.Position camshaft in cylinder head.
2.Place a piece of Plastigage along the centre line
of each camshaft bearing journal.
3.Carefully fit the camshaft carrier ensuring it is
located on dowels.
CAUTION: Do not rotate camshaft.
4.Fit original camshaft carrier retaining bolts and
tighten in sequence shown to25 Nm (18 lbf.ft).
5.Using sequence shown, loosen then remove
camshaft carrier retaining bolts.
CAUTION: Do not discard bolts at this
stage.
6.Carefully remove camshaft carrier.
7.Measure and record widest portion of Plastigage
on each camshaft bearing journal.
8.Compare figures obtained with camshaft bearing
clearance.
Camshaft bearing clearance =0.04 to 0.10
mm (0.002 to 0.004 in).
9.If any bearing clearance is found to exceed
figures given, repeat the above procedure using
a new camshaft.
CAUTION: If, after repeating the bearing
clearance check with a new camshaft the
bearing clearances are still excessive, a
new cylinder head and camshaft carrier assembly
must be fitted.
10.Remove all traces of Plastigage using an oily
cloth, do not use a scraper.
11.Discard camshaft carrier bolts.
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ENGINE
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OVERHAUL Valves - Lapping-in
1.Lap each valve to its seat using grinding paste.
2.Apply Prussian Blue to valve seat, insert valve
into guide and press it firmly, without rotating on
to seat.
3.Remove valve and check that a continuous,
even line of Prussian Blue has been transferred
on to valve face.
NOTE: Line does not have to be across
whole width of valve face.
4.Remove all traces of grinding paste on
completion.
5.Check valve head stand-down.See this
Section.
Valve head stand down
1.Insert each valve into its respective guide.
2.Using a straight edge and feeler gauges, check
and record stand down of each valve head.
3.Compare figures obtained with figures given
below.
Valve head stand down:
Inlet valveA= 0.555 to 0.825 mm (0.022 to
0.032 in)
Exhaust valveB= 0.545 to 1.35 mm (0.021 to
0.053 in)
CAUTION: If any valve has a stand down
greater than specified, repeat check using
a new valve. If, after checking with a new
valve, stand down is still excessive, cylinder head
assembly must be replaced. It is not possible to
replace valve seat inserts.Rocker shaft - Dismantling
1.Suitably identify each rocker arm to its fitted
position.
CAUTION: Identify type of rocker arm
fitted. Engine Serial No. Prefixes 10P to
14P - Type A rocker arms. Engine Serial
No. Prefixes 15P to 19P - Type B rocker arms.
Type B rocker arms and type B rocker shaft may
be fitted to Engine Serial No. Prefixes 10P to 14P
as an assembly.
2.Remove and discard spring ring retaining rocker
arm on shaft.
3.Remove rocker arm.
4.Remove and discard 2nd spring ring.
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12ENGINE
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OVERHAUL 5.Repeat above procedures for remaining rocker
arms.
CAUTION: Keep rocker arms in their fitted
order.Rocker arms and shaft - Inspection
1.Clean rocker arms and shaft, ensure oilways are
clear.
CAUTION: Identify type of rocker shaft
fitted. Engine Serial No. Prefixes 10P to
14P - Type A rocker shaft. Engine Serial
No. Prefixes 15P to 19P - Type B rocker shaft.
Type B rocker arms and shaft may be fitted to
Engine Serial No. Prefixes 10P to 14P as an
assembly.
2.Check diameter of each rocker arm journal on
shaft, take 2 measurements at 180°in centre of
journal.
Journal diameter =26.971 to 26.998 mm
(1.062 to 1.063 in)
CAUTION: Any ovality must be within
limits given.
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ENGINE
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OVERHAUL
3.Using a vernier, check internal diameter of each
rocker arm, take 2 measurements at 180°.
Rocker arm internal diameter =27.0 to 27.013
mm (1.102 to 1.103 in)
CAUTION: Any ovality must be within
limits given.Rocker shaft - Assembling
1.Fit new spring ring to groove in rocker shaft.
2.Lubricate rocker shaft journals and rocker arms
with engine oil.
3.Fit rocker arm to shaft ensuring that it is in its
original fitted order.
4.Fit new spring ring to retain rocker arm.
5.Repeat above procedures for remaining rocker
arms ensuring they are in their original fitted
order.
6.Fit new rocker adjusting screws and locknuts to
rocker arms; do not tighten screws fully into
arms at this stage.
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 slot. These screws are not
interchangeable with those fitted to Engine Serial
No. Prefixes 10P to 14P.
Cylinder head - Assembling
1.Lubricate new valve stem oil seals with engine
oil.
2.Using toolLRT-12-071, fit valve stem oil seals.
3.Lubricate valve guides, valve stems, valve
spring caps and springs with engine oil.
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ENGINE
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OVERHAUL 16.Lubricate finger followers with engine oil.
17.Fit finger followers ensuring they are in their
original fitted order.
18.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
19.Position camshaft in cylinder head with the
timing pin hole in the vertical position.
20.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face 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.
21.Fit camshaft carrier ensuring it is correctly
located on dowels.
22.Fit and lightly tighten new camshaft carrier bolts.
23.Using sequence shown, progressively tighten
bolts to25 Nm (18 lbf.ft).
24.Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
25.Position rocker shaft on camshaft carrier,
ensuring rocker shaft is located on dowel.
26.Fit new rocker shaft retaining bolts and working
from the centre outwards, tighten bolts
progressively to32 Nm (24 lbf.ft).27.Lubricate a new’O’ring with engine oil and fit to
injector harness multiplug.
28.Fit injector harness and connect multiplugs.
29.Clean fuel connector block and mating face.
30.Lubricate a new fuel filter’O’ring with engine oil.
31.Fit new fuel filter,’O’ring and gasket.
CAUTION: Gasket must be fitted dry.
32.Fit fuel connector block spacer and gasket (if
fitted).
33.Fit fuel connector block, fit bolts and tighten to
25 Nm (18 lbf.ft).
34.Clean glow plugs.
35.Fit glow plugs to cylinder head and tighten to16
Nm (12 lbf.ft).
36. Engine Serial No. Prefixes 15P to 19P:-
Lubricate new’O’rings with engine oil and fit to
spill return pipe; fit pipe and tighten connectors
to20 Nm (15 lbf.ft).
37.Fit new cylinder head gasket.See this Section.
CAUTION: Ensure that the fuel injector
rockers are adjusted following the
procedures given in Gasket - Cylinder
head - Refit.
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12ENGINE
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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
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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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