oil LAND ROVER DEFENDER 1999 Manual Online

12ENGINE
34
REPAIR
23.Fit camshaft sprocket to timing chain with timing
mark between the 2 bluelinks.
24.Fit timing chain to crankshaft sprocket aligning
blue link to timing mark.
25.Clean timing cover and mating face.
26.Apply an even film of sealant, Part No. STC
4600 to timing cover and spread to an even film
using a roller.
CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
27.With assistance, fit timing cover, connect
vacuum pump drain hose and working
progressively, tighten bolts to27 Nm (20 lbf.ft).
28.Secure vacuum hose clip.
29.Fit cylinder head gasket.See this Section.
30.Fit sump gasket.See this Section.
31.Fit crankshaft front oil seal.See this Section.
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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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12ENGINE
4
OVERHAUL
11.Disconnect alternator/vacuum pump oil feed pipe
union from cylinder head, remove and discard
’O’ring.
12.Remove camshaft sprocket access plug from
front of cylinder head, remove and discard’O’
ring.
13.Remove timing chain fixed guide Allen screw.
14.Remove timing chain tensioner, remove and
discard sealing washer.
15.Remove and discard 3 bolts securing camshaft
sprocket to camshaft; release sprocket from
camshaft.
16.Remove bolt and nut securing front of cylinder
head to timing chain cover.
17.Using sequence shown, progressively loosen
then remove 12 cylinder head bolts; discard
bolts together with their captive washers.
18.Using assistance, remove cylinder head and
place on 2 wooden blocks.
CAUTION: Cylinder head is dowel located,
do not tap it sideways to free it from
cylinder block. Support both ends of
cylinder head on blocks of wood. With the
camshaft carrier bolted down, the injector nozzles
and some of the valves will protrude from the face
of the cylinder head.
19.Remove the cylinder head gasket.
20.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of the cylinder head.
CAUTION: If new pistons, connecting rods
or crankshaft are fitted, it will be
necessary to measure piston stand proud
in order to determine thickness of gasket
required.See this Section.
21.Remove and discard 2 plastic locating dowels
from cylinder block.
22.Carry out cylinder head overhaul procedures.
See this Section.
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ENGINE
5
OVERHAUL Refit
1.Thoroughly clean cylinder block and cylinder
head mating faces.
2.Ensure coolant and oil passageways are clear
and bolt holes are clean and dry.
3.Ensure locating dowel holes in cylinder block are
clean and dry.
4.Fit new plastic locating dowels in cylinder block.
5.Fit new cylinder head gasket of the correct
thickness with the word’TOP’uppermost.
CAUTION: Gasket must be fitted dry.
6.Ensure that camshaft timing pinLRT-12-158is
still in position and using assistance, fit cylinder
head.
7.Carefully enter new cylinder head bolts together
with their captive washers,DO NOT DROP.
Lightly tighten bolts.
CAUTION: Cylinder head bolts are
pre-lubricated and do not require
additional lubrication.
8.Using sequence shown, tighten cylinder head
bolts to:
Stage 1 -30 Nm (23 lbf.ft)
Stage 2 -65 Nm (48 lbf.ft)
Stage 3 -90
°
Stage 4 -Further 180°
Stage 5 -Further 45°
CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages. Do not tighten bolts 315°in one
operation.9.Fit cylinder head to timing chain cover nut and
bolt and tighten to25 Nm (18 lbf.ft).
10.Clean camshaft sprocket and mating face on
camshaft.
11.Ensure engine is set to TDC firing - No.1
cylinder.
12.Check that mark on camshaft sprocket is
positioned between the 2 coloured links on
timing chain.
13.Position sprocket to camshaft, fit and lightly
tighten 3 new bolts then loosen bolts half a turn.
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12ENGINE
6
OVERHAUL 14.Clean fixed guide Allen screw and apply Loctite
242 to screw threads.
15.Fit fixed timing chain guide Allen screw and
tighten to25 Nm (18 lbf.ft).
16.Clean timing chain tensioner and fit new sealing
washer.
17.Fit timing chain tensioner and tighten to45 Nm
(33 lbf.ft).
18.Tighten camshaft sprocket bolts to36 Nm (27
lbf.ft).
19.Remove toolLRT-12-058from camshaft.
20.Lubricate a new’O’ring with engine oil and fit to
camshaft sprocket access plug.
21.Fit camshaft sprocket access plug.
22.Clean alternator/vacuum pump oil feed hose
union.
23.Lubricate a new’O’ring with engine oil and fit to
alternator/vacuum pump hose union.
24.Fit and tighten alternator/vacuum pump oil hose
union to10 Nm (7 lbf.ft).
25.Fit bolt securing alternator strap bracket to
cylinder head and tighten to25 Nm (18 lbf.ft).
26.Connect multiplugs to ECT sensor and EUIs.
CAUTION: Following cylinder head
overhaul, it will be necessary, before
fitting the camshaft cover, to adjust the
fuel injector rockers using the following
procedures:
27.Rotate engine clockwise until No. 1 EUI lobe is
at full lift.
28.Tighten No.1 rocker adjusting screw until the EUI
plunger is felt to’bottom out’.
29.Loosen rocker adjusting screw 1 complete turn
to give EUI 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.30.Carry out above procedures for the remaining 4
rocker arms.
31.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no EUI’s are bottoming out
on their plungers.
32.Clean camshaft cover and mating face.
33.Fit new sealing washers and isolators as
necessary to camshaft cover.
34.Fit new camshaft cover gasket to cover.
CAUTION: Gasket must be fitted dry.
35.Fit camshaft cover to camshaft carrier, fit bolts
and working from the centre outwards, tighten
bolts to10 Nm (7 lbf.ft).
36.Fit inlet manifold gasket.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
37.Fit exhaust manifold gasket.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
38. EGR cooler fitted:-Position EGR pipe to cooler,
fit new Allen screws and tighten to10 Nm (7
lbf.ft).
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ENGINE
9
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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12ENGINE
10
OVERHAUL
20.Using toolLRT-12-071, remove and discard
valve stem oil seal.
21.Repeat above operations to remove remaining
valves.
22. Engine Serial No. Prefixes 15P to 19P:-
Disconnect spill return pipe from cylinder head
and fuel connector block, remove and discard’O’
rings.
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ENGINE
11
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
12
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
13
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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