engine oil LAND ROVER DEFENDER 1999 Manual Online

12ENGINE
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OVERHAUL
4.Assemble valves, springs and valve spring caps
ensuring that they are in their original fitted
order.
5.Compress valve springs using toolLRT-12-034,
fit collets.
6.Using a wooden dowel and mallet, tap each
spring cap lightly to seat collets.
7.Lubricate new injector’O’rings with engine oil.
8.Using toolLRT-12-154/2, fit’O’ring to each
injector.
9.Using toolLRT-12-154/3, fit new sealing washer
to each injector.
10.Support each end of cylinder head on blocks of
wood.
CAUTION: Ensure blocks are clear of
valves.
11.Position reaction posts in their original fitted
order.
12.Carefully fit EUI’s, ensuring they are in their
original fitted order and that each retainer is
located on its dowel.
CAUTION: If new EUI’s are fitted, ensure
replacements are correct. Engine Serial
No. Prefixes 10P to 14 - Push rod bushes
are coloured BLACK or BLUE. Engine Serial No.
Prefixes 15P to 19P - Push rod bushes are
coloured GREEN.
13.Fit new retainer bolts and tighten to32 Nm (24
lbf.ft).
CAUTION: If new injectors are fitted they
must be programmed for use with the ECM
using Testbook.
14.Lubricate lash adjusters and bores with engine
oil.
15.Fit lash adjusters ensuring they are in their
original fitted order.
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ENGINE
19
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
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
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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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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
24
OVERHAUL Inspection
CAUTION: Inspection/overhaul procedures
for the oil pump are limited to carrying out
dimensional checks. In the event of wear
or damage being found, a replacement pump and
stiffener plate assembly must be fitted.
Oil pump
1.Remove and discard 5 screws securing cover to
oil pump, remove cover.
2.Using a felt tipped pen, make suitable alignment
marks between inner and outer rotors and pump
body.
3.Remove inner and outer rotors.
4.Check rotors, cover and pump body for signs of
scoring and wear.
5.Fit rotors ensuring that reference marks are
aligned and identification mark on inner rotor is
facing outwards.
6.Using feeler gauges, check pump body to outer
rotor clearance:
Pump body to outer rotor clearance =0.295
to 0.375 mm (0.012 to 0.015 in)
7.Using feeler gauges, check clearance of inner to
outer rotor in 2 positions, both clearances must
be within limit given:
Inner to outer rotor clearance =0.13 mm (0.05
in)
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ENGINE
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OVERHAUL
8.Place a straight edge across pump body and
using feeler gauges, measure end-float of outer
rotor:
Outer rotor end-float =0.038 to 0.075 mm
(0.001 to 0.003 in)
9.Check drive shaft bush in pump cover for signs
of scoring and wear.
10.Renew oil pump and stiffener plate assembly if
excessive scoring exists or clearances exceed
limits given.
11.Lubricate pump rotors and drive shaft bush with
engine oil.
12.Fit rotors ensuring reference marks are aligned
and identification mark on inner rotor is facing
forwards.
13.Fit cover to pump, fit 5 new screws and tighten
by diagonal selection to6 Nm (4.5 lbf.ft).
14.Check that pump rotors rotate freely.Oil pressure relief valve
1.Remove and discard oil pressure relief valve
plug.
2.Remove spring and relief valve plunger.
3.Clean valve plunger and spring.
4.Check valve plunger and relief valve bore for
scoring and corrosion.
NOTE: Light scoring and corrosion may be
removed using grade 600 emery cloth
soaked in oil.
5.Check spring for distortion, check free length of
spring:
Spring free length =42.00 mm (1.65 in)
CAUTION: Renew relief valve as an
assembly.
6.Lubricate valve plunger and seating.
7.Fit valve plunger and spring to oil pump.
8.Apply Loctite 243 sealant to threads of a new
plug.
CAUTION: Do not attempt to fit original
plug.
9.Fit plug and tighten to23 Nm (17 lbf.ft).
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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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ENGINE
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OVERHAUL
7.Noting their fitted positions, remove 8 bolts
securing timing chain cover.
8.Remove timing chain cover.
NOTE: Dowel located.
9.Remove bolt securing oil pump drive sprocket.
10.Remove oil pump drive sprocket.
11.Remove camshaft and crankshaft sprockets
together with timing and oil pump drive chains.
12.Remove Woodruff key from crankshaft.
13.Remove 2 bolts and remove timing chain fixed
guide.
14.Remove bolt and remove timing chain adjustable
guide.
15.Remove bolt and remove timing chain lubrication
jet.
16.Using toolLRT-12-092, remove and discard oil
seal from timing cover.
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