Land Rover Defender 1990 User Manual

GED

DEFENDER

90

WORKSHOP MANUAL SUPPLEMENT

Publication

Number

110

SLR

621

130

EN

WS

1

Published by the

Technical Publications Department

@

Copyright Land Rover

1990

of

Land Rover

West Midlands,

Lode Land

Sol

ihul

892

8NW

England

I

.

CONTENTS

...

.....

-

..

;,TI

,::-...$,.

......

........

,..

,.

.....

'U

.

..I-',

Section

Number

01

:

L

04

INTRODUCTION

-

General information

-

Poisonous substances

-

Fuel Handling

-

Sealants

-

Disposal

-

Abbreviations and symbols

-

Special tools

-

Vehicle identification numbers

-

Copyright

G

E

N

-

Tdi engine data

-

Fuel

-

Cooling system

-

Clutch

of

ERAL

system

oil

and fluids

SPECIFICATION

Page

DATA

9-12

9

9

9

05

06

109

L

12

E

N

G

I

N

E

T

U

N

I

N

G

DATA

T

O

R

Q

U

E

WRENCH

I

RECOMMENED LUBRICANTS, FLUIDS AND CAPACITIES

-

Tdi engine lubricants

-

Capacities

-

Anti-freeze

SETTING

ENGINE

-

Camshaft - remove and refit - including front cover

-

Power steering pump bracket - remove and

-

Cylinder head - remove and refit

-

Camshaft timing belt - renew

-

Tdi engine - overhaul

refit

oil

seals/timing belt and gears

17

-

18

17

-

ia

17 - 18

30
31

32

34

35

..:r

...

,

_

,.

5..

19

1

FUEL SYSTEM

-

Fuel

injection pump - remove and refit

-

Air cleaner - remove and refit

-

-

~ur-bo charger- remove and retit

-

Intercooler - remove and refit

:i'

.

,.

-

..

81

84

a5

86

Section

Number

26

I

C

O

O

L

I

N

G

SYSTEM

Page

e

..

-7

30

157

86

>

-

Engine protection

-

Drain and

-

Fan cowl - remove and refit

-

Fan and coupling - remove and refit

-

Radiator - remove and refit

-

Water pump - remove and refit

I

MANIFOLDS

I

STEERING

ELECTRICAL EQUIPMENT

refill

AND

EXHAUST

87

87

a8

88

89

90

..

-

-

a

DEFENDER

INTRODUCTION

01

-

.I

INTRODUCTION

This Workshop Manual Supplement
maintenance

Individuals who undertake their own repairs should have some skill and training, and limit repairs to
components which could not affect the safety
safety critical items such as steering, brakes, or suspension should be carried out by a Land Rover
Dealer. Repairs to such items should

WARNINGS and CAUTIONS are given throughout this Supplement

WARNING: Procedures which must

CAUTION: This calls attention to procedures which must be followed to avoid damage

NOTE: This calls attention to methods which make a job easier to perform.

REFERENCES

References to the left

unless otherwise stated. With the engine and gearbox assembly removed, the water pump end

is

referred to as the front.

To

reduce repetition, some operations covered in this Manual do not include reference to testing the vehicle

after repair. It

of

the vehicle is carried out particularly where safety related items are concerned.

of

Land

Rover

vehicles.

or

right hand side in the supplement are made when viewing the vehicle from the rear

is

essential that work is inspected and tested after completion and

is

designed to assist skilled technicians in the efficient repair and

of

the vehicle

NEVER

be

be attempted by untrained individuals.

followed precisely to avoid the possibility

or

its passengers. Any repairs required to

in

the following form:

of

personal injury.

to

components.

if

necessary a road test

of

the engine

DIMENSIONS

to

The dimensions quoted are
brackets following the dimensions, have been converted from the original specification.

REPAIRS AND REPLACEMENTS

When replacement parts are required it
Attention
and accessories: Safety features embodied in the vehicle may be impaired
fitted. In certain territories, legislation prohibits the fitting
specification. Torque wrench values given in the Workshop Manual supplement must
Locking devices, where specified, must be fitted.
removal it must
specified in the Workshop Manual Supplement.

PO

Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances
be consumed and should be kept away from open wounds. These substances among others include
anti-freeze, brake fluid,
adhesives.

AS

B

IS

0 N 0

EST0

is

particularly drawn

be

replaced with a new one. Certain fasteners must not be re-used. These fasteners are

US SUBSTANCES

fuel,

S

design engineering specification. Alternative unit equivalents, shown in

is

essential that genuine Land

to

the following points concerning repairs and the fitting

of

parts not to the vehicle manufacturer's

If

the efficiency

windscreen washer additives, air conditioning refrigerant, lubricants and various

Rover

parts are

if

other than Land Rover parts are

of

a locking device

used.

of

replacement parts

be

strictly adhered

is

impaired during

to.

WARNING: Some components on the vehicle, such as gaskets and friction surfaces (brake linings, clutch

discs) may contain asbestos. inhaling asbestos dust

essential precautions must

1.

Work out

2.

Dust found on the vehicle
and not by blowing.

3.

Dust waste should

4.

If

any cutting, drilling etc.,

and

of

doors

on1 hand tools

be

observed:

or

in a well ventilated area and wear a protective mask.

or

produced during work on the vehicle should be removed by vacuuming

be

dampened, placed in a sealed container and marked

is

attempted on materials containing asbestos the item should be dampened

or

low speed power tools used.

is

dangerous to your health and the following

to

ensure safe disposal.

1

101

I

INTRODUCTION

FUEL HANDLING PRECAUTIONS

e

DEFENDER

The following information provides basic precautions which must

also outlines the other areas

This

information

of

made

Fuel vapour is highly flammable and in confined spaces
When fuel evaporates it produces
a readily ignitable mixture. The vapour

be

dangerous.

Always have a

or

WARNING:

the battery terminal could ignite

BEFORE

when fuel systems are being dismantled all forms
head

NO
HAVING HAD SPECIALIST TRAINING.

HOT

your local fire station.

distributed throughout a workshop by air current, consequently, even a small spillage

when dismantling fuel systems and in areas where fuel containers are stored.

carrying out work on a fuel system. Whenever fuel

-

lamps used must be flameproof and kept clear

ONE

SHOULD BE PERMWrED

FUEL HANDLING

is

issued

fire

extinguisher containing

It

is

imperative that the battery

of

risk which must not

for

basic guidance only, and in any

150

times its own volume in vapour, which when diluted with air becomes

is

heavier than air and will always fall to the lowest level. It can readily

FOAM

fuel vapour in the atmosphere. Always disconnect the vehicle battery

TO

REPAIR COMPONENTS ASSOCIATED

be

CO

is

not disconnected during fuel system repairs as arcing at

ignored.

is

also

GAS,

of

ignition must be extinguished

of

spillage.

be

observed

case

of

doubt, appropriate enquiries should be

very

explosive and toxic.

or

POWDER

is

being handled, transferred

if

close at hand when handling fuel,

WITH

fuel is to be handled safely. It

of

fuel

is very

or

or

removed, any

FUEL

WITHOUT

stored,

or

FIRST

Before

be adhered to.

i

FUEL TRANSFER

WARNING:

The transfer

transfer tank must
including attention

FUEL TANK REMOVAL

A

FUEL TANK REPAIR

Under

commencing any operation requiring fuel drainage from fuel tanks, the following procedures should

1.

Allow sufficient time for the fuel to

2.

Vent system by removing the fuel cap in a
drainage.

Fuel

must not be extracted or drained from any vehicle while it is standing over a pit.

of

fuel from the vehicle

be

used according to the transfer tank manufacturef s instructions and local regulations,

to

grounding

fuel vapour label should be attached to the fuel tank upon removal from the vehicle.

no

circumstances should a repair to any tank be attempted.

of

cool,

thus avoiding contact with hot fuels.

well

ventilated area. Replace cap until commencement

fuel

tank must be carried out in a well ventilated area. An approved

tanks.

of

tank

p

i.

..

:’”

3

e

DEFENDER

INTRODUCTION

101

-

<,,

.

RECOMMENDED

A

number

work. These items include:

COMPOUND.

obtaining supplies, contact one

Marston Lubricants Limited

Hylo

Cale Lane, New Springs

Wigan, WN2

Tel: [phone]

Fax: [phone]

Telex: 67230

USED ENGINE

Prolonged and repeated contact with engine

-skin, leading to dryness, irritation and dermatitis. In addition,

contaminants which may cause skin cancer. Adequate means
be provided.

Health Protection Precautions

of

House

SEALANTS

branded products are recommended in this Supplement

HYLOMAR GASKET AND JOINTING COMPOUND

They should be available locally from garage equipment suppliers.

of

the following companies

IJR

OIL

HANDLING PRECAUTIONS

or

motor

for

Northern Adhesives Limited

Prudhoe
Northumberland
NE42 6NP

Tel:

0661

Fax:

0661 35839

oil

will result in the removal

used

of

for

use during maintenance and repair

advice and the address

32014

engine

skin protection and washing facilities should

oil

and

HYLOSIL

If

there

of

of

natural fats from the

contains potentially harmful

RN

SILICON

is

any problem

the nearest stockist.

1. Avoid prolonged and repeated contact with

2. Wear protective clothing, including impervious gloves where applicable.

3. Do not put oily rags in pockets.

4. Avoid contaminating clothes, particularly

5.

Overalls must be cleaned regularly. Discard unwashable clothing and

6.

First aid treatment must be obtained immediately for open cuts and wounds.

7.

Use barrier creams, before each work period, to help the removal

8.

Wash with soap and water

Preparations containing lanolin replace the natural skin

D

O

9.

10.

11.

12. Where there is a

DISPOSING

Environmental protection precaution

It

is

Dispose

S

P E CI FICATIO N

not use petrol, kerosene, diesel fuel,

If

skin disorders develop, obtain medical advice.

Where practicable, degrease components prior to handling.

risk

shields; in addition an

OF

USED

OILS

illegal to pour used

of

used

oil

oil

through authorised waste disposal contractors.

to

ensure all

of

eye

contact,

eye

wash facility should be provided.

AND FLUIDS

and other fluids onto the ground, down sewers or drains,

eye

oils,

particularly used engine

underwear, with

oil

is

removed (skin cleansers and nail brushes

gas

oil,

thinners

oil.

oils

which have been removed.

or

solvents

.

protection should be worn, for example, goggles

oils.

oil

impregnated footwear.

of

oil

from the skin.

for

washing the skin.

or

will

help).

or

face

into waterways.

..

Purchasers are advised that the specification details set out in this Supplement apply to a range
and not
The Manufacturers
in such manner
Manufacturer's policy

While every
Manufacturer
any inaccuracy

to

any one.

effort

For

the specification

resetve the right to vary their specifications with

as

they think fit. Major

of

constant product improvement.

is

made to ensure the accuracy

or

Dealer, by whom this Supplement is supplied, shall in any circumstances be held liable for

or

the consequences thereof.

of

a particular vehicle, purchasers should contact their Dealer.

or

without notice, and at such times and

as

well

as

minor changes may be involved in accordance with the

of

the particulars contained in this Supplement, neither

of

vehicles

the

3

INTRODUCTION

01

COPYRIGHT

Q

Rover Group Ltd

All

rights reserved.

any form, electronic, mechanical, photocopying, recording

Rover

Group Ltd.

1990

No

part

of

this publication may be produced, stored

in

a

or

other means without

e

retrieval system or transmitted

prior

DEFENDER

written permission

in

of

SPECIAL

The use
carried out efficiently, and safely. Where the
be used to avoid the possibility

ACCESSORIES AND CONVERSIONS

Land
should be carried out to any vehicle produced by Land Rover which could affect the safety
its passengers.

T

Land
Before fitting any accessory
accessory

WARNING:

vehicle. Land Rover

may occur as
conversions to Land

SERVICE

of

approved special service tools is important.

Rover

vehicles are designed and constructed for a

Rover

has

or

TOOLS

of

personal injury

tested and approved a large number

or

commencing any conversion work to any Land Rover vehicle,

conversion

DO

NOT

a

direct result

is

approved by Land

FIT

unapproved accessories

will

not accept any liability

of

fitment

Rover

vehicles.

of

They

are essential

use

of

special service tools i specified, only these tools should

or

damage

of

Rover.

or

conversions, as

for

death, personal

non-approved accessories

to

components.

variety

accessories and conversions, suitable for this vehicle.

of uses but no alterations

if

service operations are to be

they

could affect the safety

injury

or

damage to property which

or

the carrying out

or

conversions

of

the vehicle or

CHECK

of

non-approved

that

of

the

the

4

DEFENDER

INTRODUCTION

n

01

,-

'

..

.

.-

.

a:.;

,;.:

.:..,*-:.

'

I:

.I

%

1.

.

..

.:,

,I

.....

..

...

.....

..

ABBREVIATIONS AND SYMBOLS

Across flats (bolt size)

After bottom dead centre
After top dead centre
Alternating current

Ampere
Ampere hour

Before
Before

Bottom dead centre
Brake horse power bhP

British Standards
Carbon monoxide
Centimetre
Centigrade (Celsuis)
Cubic centimetre
Cubic inch
Degree (angle)

.

Degree (temperature)
Diameter
Direct current
Electronic Control Unit

Electronic Fuel Injection
Fahrenheit
Feet
Feet
Fifth
First
Fluid ounce
Foot pounds (torque)
Fourth

Gramme
Gramme (mass)
Gallons gal

Gallons (US)
High tension (electrical)
Internal diameter

Inches

Inches
Kilogramme

Kilogramme (mass.) kg
Kilogramme centimetre (torque)

Kilogramme per square millimetre
Kilogramme per square centimetre
Kilogramme metres (torque)
Kilometres
Kilometres per hour

Kilovolts
Left-hand steering
Left-hand thread
Litres

..............................................................

.................................................

bottom dead centre

top dead centre

..........................................................

............................................................

...........................................

.............................................................

.....................................................

...............................................................

.......................................................................

per

minute

...............................................

.....................................................................

......................................................................

.......................................................

..................................................................

(force)

.....................................................

......................................................

................................................................

..................................................

of

mercury

....................................................................

(force)

...........................................................

................................................................

...................................................................

..........................................

..............................

.....................................

..............................................

............................

...................................

.........................................

............................................

...................................................

..............................................

..............................................

................................................

.................................

...................................

...................................

........................................

....................................

................................................

..........................................

..............................................

..............................................

...................

...............

..............

...........................

.........................................

..........................................

............................................

ABDC
ATDC

a.c.

amp

amp hr

BBDC

BTDC

BDC

CO

cm3

deg or
deg

or

dia.

d.c.

E.C.U.

E.F.I.

ft/min

5th

fl

ft

4th

US gal

H.T.

I.D.

in. Hg

kg

kgf.cm

kgf/mm2

kgf/cm2

kgf.m

km

km/h

LHStg

LHThd

litre

AF

BS

cm

C

in3

O

O

F

ft

1st

oz

Ib

g

f

g

in

f

kV

Low tension
Maximum
Metre
Millilitre
Millimetre

Miles per gallon

Miles per hour
Minute (angle)

Minus
Negative (electrical)
Newton meters (torque)

Number
Ohms
Ounces
Ounces
Ounce inch (torque)
Outside diameter
Part number
Percentage

.....................................................................

Pints Pt
Pints (US)

Plus (tolerance)

Positive (electrical)

Pound

Pounds inch (torque)
Pound
Pounds per square inch
Ratio

........................................................................

Reference
Revolution per minute
Right-hand
Second (angle)
Second (numerical order)
Specific gravity
Square centimetres
Square inches
Standard wire gauge

Synchroniser/Synchromesh

Third

...................................................................

Top dead centre

United Kingdom
Vehicle Identification Number
Volts

......................................................................

Watts

....................................................................

SCREW TH READS

American Standard Taper Pipe
British Standard Pipe
Unified Coarse

Unified Fine

..........................................................

.........................................................

.....................................................................

................................................................

...........................................................

.................................................

...................................................

.........................................................

(of

tolerance)

...............................................

................................................

....................................

..............................................................

...............................................................

(force)
(mass)

....................................................

......................................................

......................................

.............................................

.................................................

............................................................

........................................................

.....................................................

................................................

(force)

.......................................................

......................................

(mass)

.........................................................

....................................

...........................................................

.....................................

...........................................................

.......................................................

...................................

................................................

.............................................

.......................................................

.......................................

.........................

................................................

..................................................

............................

..........................

...........................................

.................................................

.......................................................

1.t.

ma.

mi

mm

mpg
mPh

Nm

No.

ohm

ozf

oz

ozf.in.

O.D.

Part

No.

US pt

Ibf

in.lbf.

P.S.I.

ref.

r.p.m

RH

2nd

sp.gr.

cm2

in2

s.w.~.

synchro.

3rd

TDC

UK

VIN

W

NPTF

BSP

UNC

UNF

m

'

-

-

%

+
+

Ib

:

I'

v

5

loll

INTRODUCTION

e

DEFENDER

Special

The use
carried out efficiently, and safely. Where special tools are specificed,

avoid the possibility

they save can

Every special

which has not been tested and approved by us. New tools are only introduced where an operation cannot

satisfactorily carried out using existing tools or standard equipment. The user

is

necessary and that it wilt perform accurately, efficiently and safely.

Special tools bulletins

All

should be placed with the local
distributor may order direct from

The tools recommended in this Workshop Manual Supplement are listed in a multi-language illustrated

catalogue obtainable from Messers. V. L. Churchill at the above address under publication number VLC

23721187

Erdington, Birmingham, 624

of

approved special service tools

of

personal injury

be

considerable.

tool

is

designed with the

will

be

issued periodically giving details

orders and enquiries from the United Kingdom should be sent direct to

V.

L. Churchill distributor, where one exists. Countries where there

V.

or

from Land

Rover

Merchandising Service, quoting publication number SMR

OQ5.

is

or

close

L.

Churchill Limited,

Service

important. They are essential

damage to the components.

co-operation

PO

Tools

only these

of

Land Rover, and

of

new tools

Box

3,

Daventry, Northants, England,

if

service

Also

as

V.

operations are to

tools

should be used to

the amount

no

tools

is

therefore assured that the

they are introduced.

L.

Churchill. Overseas orders

of

is

put into production

681

MI,

be

time which

is

no

NNI

1

4NF.

PO

Box

534,

be

tool

6

DEFENDER

LOCATION

OF

VEHICLE IDENTIFICATION & UNIT NUMBERS

101

..

~.,..

..

.I

).

.

b: : ..,

..

...

,.

...

..

..

.

..

.

VEHICLE IDENTIFICATION NUMBER (VIN)

The Vehicle Identification Number and the
recommended maximum vehicle weights are

of

stamped on a plate riveted to the top

box

behind the brake servo

The number

of

the chassis forward

is

also stamped on the right-hand

of

the spring mounting turret.

the pedal

Always quote this number when writing to Land
Rover.

side

E

F

ST3067M

The Vehicle Identification Number identifies the
manufacturer, model range, wheel
engine, steering, transmission, model name and
place

of

the coding process.

SAL World manufacturer identifier

LD Land Rover

C

Class

V

Class

H

Class

A

Basic

B

2door

M 4door

H High Capacity

F

Tdi or

8

5

speed LHD or

7

5

speed RHD

H

1991

A

Solihull site

PAINT

0

TRIM

base,

body type,

manufacture. The following example shows

100

inch

90

inch

110

inch

MY

..

Key

to

Veh

iicle

ldentiiication Number Plate

A.

Type approval

B.

VIN

(minimum

of

17

digits)
C. Maximum permitted laden weight

D. Maximum vehicle and trailer weight

E.

Maximum road weight - front axle

F.

Maximum road weight - rear axle

for

\

vehicle

ENGINE SERIAL NUMBER - Tdi ENGINE

The engine number

block on the right hand side

is

stamped on the cylinder

of

the engine above
the camshaft front cover plate. Commencing Serial
Number

IIL

00001.

7

L

01

LOCATION

OF

VEHICLE IDENTIFICATION & UNIT NUMBERS

e

DEFENDER

MAIN GEARBOX

The serial number
bottom right hand side

RR1513M

.

TRANSFER GEARBOX

The serial number

of

the gearbox casing

bearing housing adjacent

LT77

is

1'

is

-

5

SPEED

stamped on a cast pad on the

of

the gearbox.

-------

LT230

stamped on the

below

the mainshaft rear

to

the bottom cover.

left

hand side

FRONT AND REAR AXLES

Serial number

axle tube.

is

stamped on top

of

the

left

hand

e

Tdi

Type
Number

Bore

Stroke
Capacity

Compression ratio
Valve operation
Turbo charger

Crankshaft

DEFENDER

ENGINE

.................................................................................

of

cylinders

..................................................................................

...............................................................................

............................................................................

...................................................................

.........................................................

............................................................

................................................................

G

ENE

RA

L

S

P

E

C

IFI

C

A

T

ION

D

A

Direct injection, turbocharged, intercooled
4

90,47 mm (3.562 in)

97,OO mm (3.822 in)

2495 cc

19.5:l

O.H.V. pushrod operated
Carrett T25

+

-

0.5:l

T

A

n

I04

I

Main journal diameter

Regrind dimensions

Crankpin journal diameter

Regrind dimensions

1

Crankshaft end thrust
Crankshaft end float

Main bearings

Number and type
Diametrical clearance

Connecting rods

Length between centres
Diametrical clearance (big-end bearings)
End float on crankpin

Pistons

Type

.................................................................................

Skirt

diametrical clearance
(at right angle to gudgeon pin
Maximum height above combustion face

......................................................

..........................................................

................................................

..........................................................

.......................................................

.........................................................

.............................................................

........................................................

...................................................

..........................

.......................................................

.........................................

........................

63,475 - 63,487 mm (2.499 - 2.4993 in)
63,2333 . 63,246 mm (2.4895 - 2.490 in)

0.010'in U/S bearings

Use

58,725 - 58,744

58,4708 . 58,49985 mm (2.30200 . 2.30275

Use

0.010

Taken on thrust washers

0,05 . 0,15 mm (0.002 - 0.006 in)

5 halved shells with
0,0792 - 0,0307

175,38 - 175,43 mm (6.905 - 6.907 in)

0,025 . 0,075 mm (0.001 . 0.003 in)

0,15 - 0,356 mm (0.006

Aluminium alloy, combustion chamber in crown

0,025 . 0,05

0,8 mm (0.031 in)

mm

(2.312 - 2.31275 in)

in U/S bearings

of

oil

grooves

mm

(0.0031 - 0.0012 in)

.

mm

(0.001 . 0.002 in)

centre main bearing

0.01

4 in)

in)

Gudgeon pins

.................................................................................

Type

Fit

in piston
Diameter
Clearance in connecting rod

Pistons rings

Type

.

Top

-

Second

.

Oil

control

Cap in

-

Top

-

Second

-

Oil

control

-:.

:.,a:

i.

I

:

,

'

Clearance in piston grooves:

.

Top

.

Second

.

Oil

control

......................................................................

...........................................................................

............................................

................................................................................

...........................................................................

.....................................................................

bore:

................................................................................

...........................................................................

.....................................................................

................................................................................

...........................................................................

.....................................................................

Floating

Hand push in
30,1564 - 30,1625 mm
0,0036 - 0,0196 mm (0.00014 - 0.00077 in)

Chamfered friction edge, chrome plated

Taper faced

Expander ands rails

0,40 . 0,65
0,30
0,3 - 0,6 mm (0.011

0,167 . 0,232 mm (0.0065 - 0.0091 in)

0,05 . 0,08 mm (0.0019 . 0.0031 in)

0,05

mm

(0.0157 . 0.0255 in)

-

0,50

mm (0.0118 - 0.0196 in)

.

0,08

mm

(0.0019 . 0.0031 in)

.

0.023

(1.1

8726

in)

-

7.1

8750 in)

9

04

GENERAL

SPECIFICATION

DATA

e

DEFENDER

Camshaft

Timing Belt

Location
End float
Number

Material

Valves

Tappet clearance:

.

Inlet and exhaust

Seat angle:

.

Inlet

-

Exhaust

Head diameter:

.

Inlet

.

Exhaust

Stem diameter:

-

.

Inlet

-

Exhaust

Valve lift:

.

Inlet

.

Exhaust

Cam lift

.

Inlet

.

Exhaust

Valve head stand down

-

Inlet and exhaust

Valve spring length fitted

lubrication

.......................................................................

...........................................................................

...........................................................................

of

bearings

............................................................................

................................................................................

...........................................................................

................................................................................

...........................................................................

................................................................................

...........................................................................

................................................................................

...........................................................................

................................................................................

...........................................................................

.........................................................

............................................................

............................................................

.................................................

30 mm (1.2 in dry toothed belt

Right hand side (thrust side)

0,l - 0,2 mm (0.004 - 0.008 in)

4
Steel shell, white metal lined

0,20 mm (0.008 in)

30"

45

O

39,35 - 39,65 mm (1.549 - 1.560 in)
36,35 - 36,65 mm (1.431 - 1.443 in)

7,960 - 7,975 mm (0.313 - 0.314 in)

-

7,940

9,93 mm (0.401 in)
10,26 mm (0.404 in)

6,81 mm (0.268 in)
7,06 mm (0,278 in)

0,9

40,4 mm (1.590 in) at pressure

7,960 mm (0.212 - 0.313 in)

-

1,l

mm (0.035 - 0.040 in)

of

29.5 kg (65

.

Ib)

......

(-?$

........

..

.- .

.-

System
Pressure, engine warm at
normal operating speeds

Oil

-

-

-

-

-

Oil
Relief

-

-

Oil

Engine

..............................................................................

..................................................

pump:

Type

...............................................................................

Drive

..............................................................................

End float
Radial clearance
Backlash

pressure

Full length

Compressed length at 2.58 kg (5.7 Ib) load

filter

of

both gears

or

gears

relief

valve spring:

of

valve

..................................................

gears

................................................

...........................................................

....................................................

......................................................................

............................................................................

oil

cooler

..............................................................

..................

Wet sump, pressure fed

25- 55

Double gear 10 teeth, sintered iron gears
Splined shaft from camshaft skew gear
0,026
0,025

0,l

Non-adjustable

67,82 mm (2.670 in)
61,23 mm (2.450 in)

Screw
Combined with coolant radiator and intercooler

p.s.i.

(1.76 - 3.86 kgf/cm2)

-

0,135 mm (0.0009 - 0.0045 in)

-

0,075 mm (0,0034 - 0.0067 in)

-

0,2 mm (0.0034 - 0,0067 in)

-

on disposable canister

10

<..,

i..-

5,.

....

.

.

,

..*:;,:;

......

....

._.

........

'-

.

~.,.

,

48B

DEFENDER

FUEL

3

"'

I

SYSTEM - Tdi Engine

injection pump type

.........................................................

injection pump timing
injectors
Heater plugs
Fuel lift pump type

...........................................................................

.....................................................................

...........................................................

Fuel lift pump pressure
Fuel filter

Air

Turbo charger

..........................................................................

cleaner

........................................................................

...................................................................

......................................................

.....................................................

GENERAL

Bosch rotary

see

section

see

section

see

section

SPECIFICATION

VE4/11

05
05

05

F

(see section

05)

Mechanical with hand primer

42 - 55

kpa at

1800

rpm

Paper element in disposable canister
Paper element type
Carrett T25 (see section

05)

DAT

A

n

04

COOLING

System type

SYSTEM - Tdi engine

......................................................................

Pressurised, spill return, thermostatically controlled

water and anti freeze mixture. Pump assisted
thermosyphon. Coolant radiator combined with

cooler

Cooling fan

%

Pump type

Thermostat opening

Expansion tank cap pressure

CLUTCH

Type

.................................................................................

Centre plate diameter
Facing material
Number
Damper spring colour

Eelease bearing

......................................................................

........................................................................

.........................................................

............................................

-

Tdi engine

......................................................

..................................................................

of

damper springs

..............................................

......................................................

................................................................

7

ratio. Viscous coupling.
Centrifugal, impellor, belt driven.

88°C

15

Valeo iaphragm spring

235 mm

Verto F202 grooved

8

2

2

4

Ball journal

and turbo intercooler.

blade axial flow

395

mm diameter.

p.s.i. (system pressure)

(9.25

in)

off

white/green - suffix 'C'

off

pigeon blue - suffix

off

ruby

red

-

suffix

'B'

1.1:l

'A'

oil

drive

11

p.

.-..

:

.!:.

.d

.

..I

e

DEFENDER

ENGINE

TUNING

DATA

105

.

.

i-.

1..

....

3

ENGINE

Firing order

.......................................................................

injection pump timing
Timing marks:
Valve timing

......................................................................

injection timing

Tappet clearances inlet and exhaust
Valve timing: inlet Exhaust

.

Opens

.

Closes

.

Peak

.

Lift

............................................................................

............................................................................

...............................................................................

..................................................................................

Maximum governed speeds:

.

Full load (speed cut-off starts)

.

No

load (flight

..

Idle

speed

INJECTION PUMP

Makeltype

Direction

......................................................................

.........................................................................

of

rotation

Advance box (single stage)

Peak

pumping pressure

Tdi ENGINE TUNING

......................................................

................................................................

.................................

.......................................

speed)

....................................................

........................................................

..............................................

....................................................

DATA

1-3-4-2
1,54 mm lift at T.D.C.

Slot

for

peg in flywheel and TDC mark on front
pulley
Statically timed with special tool inserted in Bosch
pump hub

0,20 mm

16" B.T.D.C.

42" A.B.D.C.

(0.008

in) cold

51
13

"

"

B.B.D.C.

A.T.D.C.

103" A.T.D.C. 109" B.T.D.C.

9,93

mm

(0.401 in)

10,26 mm (0.404 in)

3800 r.p.m.

4100

.

4260 r.p.m.

780 . 800

Bosch rotary

rpm

VE

411

1

F

1900R 347-1 Type with boost

control and negative mechanical torque control.
Two speed mechanical governor with speed
advance and solenoid electrical shut

proof

sealing

on

flight speed and fuel adjustment

-

off. Tamper

screws
Clockwise, viewed from drive end
9" advance (7.38 mm)

650

bar

. ...

,.

I.

.

..

,

INJECTORS

Makeltype

Nozzle

.........................................................................

sizeltype

Nozzle holder
Opening pressure (working pressure)

.

,

injector pipe type
Injector pipe size

HEATER PLUGS

Makeltype

Time

TURBOCHARGER

Makeltype

.........................................................................

to

reach operating temperature

.........................................................................

Maximum boost pressure

Fuel specification

...............................................................

...................................................................

..............................

.............................................................

..............................................................

of

850°C

...............

.................................................

..............................................................

Bosch

two

spring (04321 93879 assembly number)

DSLA 145P208

KBEL

98 P52

initial pressure 200 atmospheres
Secondary 280 atmospheres

Guido high pressure

1,8

mm dia. Length 490 mm

Probe type, Beru

8

seconds

11

cold

volts

drawn steel

Carrett T25

0.82 bar (12 P.S.I.C.) measured at wastegate
actuator

Diesel 852869 (certain levels down

'T'

piece

to

45 with

adjustment

13

.

n

e

Tdi

Bearing cap
Camshaft thrust plate
Clutch cover plate to flywheel
Connecting rod
Dipstick tube assembly
Dipstick mounting bracket to
Earthing strap stud to cylinder block
Engine mounting

Housing flywheel to cylinder block

Flywheel to crankshaft

Ladderframe

Oil

Oil

Oil

Oil

Oil

Oil
Oil

*

Oil
Plug - blanking
Plug - drain
Plug . drain cylinder block
Plug - drain flywheel housing
Plug
Side
Starter motor
Sump to ladderframe

Sump
Sump
Support brackets

-

Vacuum pump

Vertical drive shaft gear to cylinder block

Alternator and heat shield to mounting bracket
Adjusting link
Adjusting link

Cylinder head

Breather cylcone
Engine lifting bracket

Electrical hamess clip

Exhaust manifold

Glow plug terminal

Glow

Heater stud (water)
Injector clamp stud to cylinder head
Injector clamp to injector
Inlet manifold to cylinder head

Rocker

Rocker
Tappet adjusting nut
Thermostat housing
Water outlet to thermostat housing

water temperature

Cowl mounting bracket to front cover

Fan assembly

Front

Front

Front

injector pump to front cover

Injector pump stud

DEFENDER

ENGINE

to

cylinder block

to

cylinder block

to

cap

.............................................

to

foot

to

cylinder block

..............................................

to

cylinder block

filter

adaptor
pressure switch
pump
pump
pump

pump strainer to
squirt

strainer to mounting bracket

exhaust manifold

cover

relief

to

jet

.

inlet

cover

to

ladderframekylinder block

to

cylinder blocUfront cover

plug

cover

shaft to cylinder head

cover

cover

cover

to

cylinder block

...................................................

to pump body

valve plug

cylinder block

oil

pump

assembly

oil

oil

sump

manifold (boost take-off)

to cylinder block

to

to

cylinder block

gallery

.........................................

................................................

flywheel

housing

................................................

to

cylinder block

to

cylinder block

to

alternator

to

pas pump plate

to

cylinder block
to

rocker

to

cylinder head

to

cylinder head

to

cylinder head

nut

............................................

to

cylinder head

to

cylinder head

nut

to cylinder head

.................................................

to

cylinder head

switch

to

water pump hub

plate to cylinder block

plate to front cover

to

cylinder block

to

front

...................................

....................

.................................

cylinder block

inlet

.................

manifold

............

........................

...................

..........................

..................................

...........................

................................

........................................

......................................

.................................

..................

..............................

........................................

...................................

.......................

.....................................

............................

.........................

..........................

........................

..............................

................

.......................................

..............................

...............................

cover

.............................

.....................

.....................

...........................

......................................

........................

........................

...................................

................................

..................................

...................................

.......................

.........................

to

thermestat

heusing

.....................

............................

..........................

...............................

...................................

...................................

cover

............................

.......

....

TOR

139

See

3, 5

Q

Nm

130

.136

7-10

30 .38
56 .62
22 .28

7-10

21

.30

80

.90

40

.50

.153

22 .28
40 .50
15

.19

20 .28
27 .33
22 .28

40

.50

14 .20
22 .28

32 .42
40 .50

25

10

.14

23 .27
23 .30
40 .50
22 .28
22 .28
20 .24

22 .28

22 .28

22 .28
22 .28
22 .28
22 .28

section

7-10

22 .28

22 .28'

20 .26

3-5

15

.30

15

.30

6-10

20

.25

20 .26

.

4,

.32

28
22 .26
22 .28

7

.10

75

.73

.

28

22
22 . 28
22 . 28
22 . 28
22

.

28

22

.

28

-

10

6

5

U

E

12

W

R

E

N

C

H

SE~TINGS

106

I

15

Tdi

ENGINE

Injector pump to support bracket

(continued)

............................

Tensioner (timing belt) to cylinder block
Timing pulley to camshaft
Timing pulley to injector pump hub

lV

damper pulley to crankshaft
Water pump to cylinder block
Water pump to cylinder block - stud
Water pump to front cover

Oil

drain adaptor to cylinder block - Turbo

Oil

drain pump to turbo

Oil

feed

pipe

adaptor to cylinder block . Turbo

Oil

feed

pipe

to turbo

Outlet elbow to turbo - nut

Outlet elbow to turbo - stud
Turbocharger to exhaust manifold

........................................

.........................

................................

..................................

.......................

......................................

...........................................

..............................................

.....................................

...................................

...........................

Belt tensioner assembly

to front cover plate compressor
Compressor to mounting bracket

-

Compressor mounting bracket
to front cover and plate
Banjo bolt - fuel pump
Banjo bolt - boost pipe
Banjo bolt - spill rail
Banjo bolt - fuel filter

...........................................

.............................................

............................................

.................................................

...............................................

Banjo bolt - injector spill rail
Fuel lift pump to fuel

filer

Fuel lift pump to cylinder block

...............................

............................

....................................

unions

.............................

...............................

Injector pipes to injectors and injector pump

P.A.S.

pump to mounting plate

P.A.S.

pump mounting plate to front

P.A.S.

pump pulley

to

hub

Tappet guide retaining screw

................................

cover

.......................................

...................................

.................

..............

......

..........

.............

Nm

22 .28

40 .50
40

.50

22 .28

333

.350

23

.30

23

.30

22 .28
22 .28

32

.48

22 .28

15

.22

21 .26
22 .28
21 .26

14

.16

40

.50

40 .50

10

.14

8

.

12

20

.30

14

.20

2

10

.14

22 .28
22 .25

14

.16

22 .28

14

.16

13

.15

(!?:

....

.....

.....

...%

i

&.~

::

.

Y

16

e

DEFENDER

RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES

109

I

.<-

.

.,..

,:;-

,

..~._

,....,.

.

,..

,w>;:.

-+-

-

.~

;:.!!

81'1

..

ENGINE OIL - Tdi ENGINES

The minimum performance level
specifications BLS 22.0L.09 and CCMC

oil

The engine

below,

can be obtained by the

of

Oils

Agip Superdiesel

BP

Caltex
Castrol Syntron
Century Superb
Duckhams

Esso

Super
Gulf Super Diesel
Mobil Delvac Super, Mobil

1

Kuwait Q8 Auto-4
Shell Rimula

Texaco Dieseltex

or

the

oils

to

BLS

Vanellus C3

RPM Delo 400*

Superlube

Oil

Formula 15Wl50

and filter must be changed every 10,000 km

clearly marked as meeting the required specification, should be used. Superior engine protection

use

meeting the above specifications are listed below:

22.OL.09tCCMC PD1

or

Sint Turbo Diesel

or

Visco

Diesel

X,

TXT,

Dynamax

QXR

or

Hypergrade

EX

2,

Superlube

or

Engine

or

Q8

Auto-7

X

or

Rotella

MTX

oil

required for satisfactory engine performance and protection

of

Super High Performance Diesel (SHPD)

or

GTX

+,

Ultra

Oil

T

1

Rally Formula or Mobil

PD1.

Oil

or

is

defined by

(6000

miles) and it

oils

-

SHPD

Agip Sigma Turbo

BP

Castrol Turbomax
Century Centurion

Caltex

Duckhams Fleetmaster SHPD or Fleetmaster Extra

Elf

Esso

Fina Kappa LDO
Gulf Superfleet Special
Mobil Delvac 1400 Super
Texaco Ursa Super TD
Shell
Total Rubia
Silkolene Turbolene

oils

to CCMC

Vanellus C3 Extra

RPM

Delo 450

Multiperformance 4D

Super Diesel

Myrina

TIR

is

important that only

to specification CCMC D3. Some

D3

Oil

TD or Special Diesel

or

Total Diesel

D

oils

Oil

listed

In markets where

Under severe operating conditions, eg.
ambient temperatures above 40°C
not exceed
requires a monthly
instructions may result

Oil

Viscosity - Ambient Temperatures Applications Chart

SPECIFICATION

Oils must meet

BLS.22.OL. 09

or

CCMC PD1

or

CCMC D3

oils

to the above specifications are not available use products to MIL-L-2104D

5000

km (3000 miles). Continuous

oil

and filter change. Failure to adhere to the recommended

in

premature engine wear

I

!jAE

v'scos'Ty

5Wf30
5Wi40
5Wt50

1

10Wi40
10W150

15Wl40
15Wt50

off

road in mud, airborne sand, dust, operating at high speeds in high

or

continual stoptstart operation, the

off

or

I

I

)

1

Owl30

)
)

)

)

or

API CD.

oil

and filter change period should

road operation in mud, dust and wading conditions

damage.

-30"

-20"

service

AMBIENT TEMPERATURE "C

-10"

0"

10

"

and operating

20

"

30

"

40

"

50

I

"

20Wf40

)

17

CAPACITIES

The following capacity figures are approximate and are provided

or

using the dipstick

Engine sump

oil

level plugs

................................................................

Extra when filling following new filter

Transfer box

Cooling system

Anti-freeze

oil

................................................................

................................................................

as

applicable.

..............................

6,OO litres (10.56 pints)

0,85

2,30 litres

11,lO

as

a guide only.

litres (1.50 pints)

(4

pints)

litres (20 pints)

All

oil

levels

must be set

Ethylene Glycol based anti-freeze (containing no methanol) with non-phosphate corrosion inhibitors only are
suitable
inhibitors should

for

use

in

Tdi engines to ensure protection

be

used. Only anti-freeze, summer and winter even in climates where anti-freeze is not

of

the cooling system against frost and corrosion.

necessary.

One part anti

~

See cooling system section 26

-

freeze, one

part

water,

i.e.

50%

anti-freeze in coolant. Complete protection below -36°C.

for

engine protection information.

No

18

...

..

I.,

;:,:;i

. . - ...

,

.

.

e

1’

.

.

,

,

DEFENDER

ENGINE

11

2

I

~I

:,

.

..

...

.,..

...

..._

.

..

ST3121

M

19

12

ENGINE

_I

CLUTCH AND FLYWHEEL HOUSING
COMPONENTS
LAND ROVER Tdi engine

I

. Clutch housing

2.

Bell

housing stud (9)

3.

Starter motor stud

4.

Allen bolts

5.

Plug

(2)

ST3066M

(4)

6. Screw housing to block

7.

Washer (6)

8.

Bolt housing to block

9. Spring washer

10.

Bracket

11.

Harness clip

12.

Oil

seal

(2)

(2)

(2)

-

(1)

(6)

(2)

13. Flywheel

14. Starter ring

15. Reinforcing plate

Bolt

16.

flywheel to crank

17. Clutch cover

18.

Clutch plate

19. Dowel

20. Screw

21. Spring washer

e

DEFENDER

$"'!

...

..,

-->"d

2n

.

DEFENDER

ENGINE

12

ST3066M

3

21

12

ENGINE

DEFENDER

SUMP

LAND

AND

OIL

ROVER

1.

Sump

2.

Drain plug

3.

Joint washer

4.

Flange bolt M8x20

5.

Flange bolt M8x60

Oil

6.

7.

Oil

8. Dowel

9.

Oil

10.

Spindle

11.

Screw

12. Spring washer

13.

Support bracket

14. Screw

15.

Lock washer

16.

Casket

17.

Filter

18. 0 ring

19. Lock washer

20. Screw

21. Spring washer

22. Plain washer

23. Drive shaft

24.

Oil

25. Spring

26. Joint washer

27.

Oil

Tdi

pump housing lower
pump housing upper

pump gears

relief

plunger

relief

plug

PUMP

engine

COMPONENTS

(8)

(1

2)

ST3065M

-

22

.-:.:.

<

,.

.

.

,..

,+

' . :

,,.,x2.;:,,

,I.

..

,1:

.,~.

..

_

..

...

.

.

.,

-DEFENDER

16

ENGINE

n

12

ST3065M

24

\

4

4

5

23

e

DEFENDER

FRONT COVER COMPONENTS ST3064M
ROVER Tdi

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

-

17.

7

8.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

Viscous unit

Fan
Bolt
Plain washer

Pulley
Screw
Spring washer
Water pump assembly
Gasket
Flange
Flange bolt

Flange screw
Stud
Flange nut
By pass hose
Hose
Crank pulley
Flange bolts
Crank pulley bolt
Washer
Torsional vibration damper
Inspection plate
Gasket
Flange screw
Front cover plate
Gasket
Cover plate seal
Flange screw
Flange bolt
Flange bolt
Flange bolt
Flange bolt
Front
Front cover gasket
Front
Front cover dowel
Flange screw
Flange
Crankshaft
Camshaft
Gasket
Gasket

Plug

Timing belt
Timing belt tensioner assembly
Slotted washer

Flange bolt

Tensioner pivot pin
Crankshaft gear wheel
Camshaft gear wheel

Bolt

engine

assemb!y

(4)

(4)

(4)

(4)

bolt

M8x85 (2)
M8x75

M8

M8

M8x35

(1)

(3)

clip

(4)

M6x20

M8x25 (3)
M8x100 (2)
M8x70
M8x75 (3)
M8x50

(3)

(2)

(1)

cover

covedwater inlet gasket

M8x20 (2)

bolt

M8x65

oil

seal

oil

seal

-

centre bolt

-

block front

M10x70

face

-

LAND

52.

Washer

53.

0

ring

54.

Retaining plate

0

55.

56.

57.

58.

59.

60.

61.

ring
Injection pump timing gear
Flange screw

(3)

Retaining plate
Nut

Spring washer

(3)

Stud injection pump to front cover

(3)

24

DEFENDER

.

ENGINE

11

2

25

12

ENGINE

a

DEFENDER

CYLINDER BLOCK COMPONENTS ST3063M

LAND

.

ROVER

Oil

1.

Oil filter adaptor

2.

Gasket

3.

Screw

4.

Spring washer

5.

Oil

6.

Thermostat bulb

7.

0

ring

8.

Spring

9.

Washer

10.

Screw

11.

Washer

12.

Oil pressure switch

13.

Copper washer

14.

Blanking plug

15.

Skew gear

16.

Dowel pin

17.

Bush

18.

Locking screw

19.

20.

0

ring

Snap ring

21.

Deep groove bearing

22.

Snap ring

23.

0

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

ring - bearinghousifig
Bearing housing
Rear

Casket

Dowel

Socket screw
Washer

Flange bolts

Froct side cover breather

Gasket

Baffle plate
Screw
Flange bolt
Flange screw
Cylinder block

Pushrod

Tappet slide

Roller

Tappet guide

Set bolt

Washer
Camshaft

Locking plate

Screw
Spring washer
Camshaft bearing
Camshaft bearing - interhear
Camshaft

Tdi

engine

filter

element

(2)

cooler

adaptor

(2)

(2)

-

external

-

internal

side

cover

-

flywheel housing

(2)

(2)

(6)

No.6

(2)

M8x40

M8x25

follower

(2)

key

(2)

(2)

-

(2)

(1)

(5)

front

(3)

-

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

. 63.

64.

65.

66.

67.

68.

69.

70.

71.

72.

73.

74.

75.

76.

77.

78.

79.

80.

81.

82.

83.

84.

85.

86.

87.

88.

89.

90.

91.

92.

93.

Piston

Piston rings
Gudgeon pin
Circlip

(8)

Connecting rod

Gudgeon pin bush

Connecting rod bolt
Big end bearing
Big end bearing cap

Connecting rod

nut

Crankshaft

Crankshaft main bearing
Main bearing cap - rear
Main bearing cap - centre

Thrust washers

Main bearing cap

(3)

Main bearing cap bolt
Crankshaft

key

Crankshaft dowel

Crankshaft bush

Packing strip

let adaptor

joint washer

Dowel

Joint washer

Relief

vaive assembly

Drain plug

joint washer

Dipstick tube
Dipstick
Oil gallery plug
cup plug

(5)

cup plug
Oil

gallery plug
Camshaft
Ring dowel

Oil

Oil

oil

feed plug

(2)

feed adaptor

drain adaptor

(3)

Ladder frame
Flange bolt
Flange bolt
Flange screw

M8x125
M8x60

M8x30 (3)

(3)

(4)

-.

0

I.

..

..

.

26

e

DEFENDER

ENGINE

-

12

ST3063M

27

ENGINE

12

Y

CYLINDER HEAD COMPONENTS ST3062M - LAND
ROVER Tdi

1.

3

-.

3.

4.

Washer

5.

6.

7.

8.

9.

10.

11.

12.

13.

Tappet adjuster screw

14.

15.

16.

-

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

Oil

Rocker

Rocker
Flange headed bolt

Sealing washer
Breather cyclone
Flange headed screw

Rocker

Rocker
Rocker

Rocker arm

Rocker

Locknut

Rocker

Rocker

Rocker

Rocker
Rocker

Exhaust manifold
Manifold stud

Self

Plair; washer

Stud turbocharger mounting
Inlet manifold
Manifold stud

Flarlge nut

Manifold gasket
Engine lifting brackets
Cylinder head
Cylinder head gasket
Head bolts
Head bolts

Head bolts

Adaptor cooling system

Ring dowel
Valve
Valve seat insert
Valve
Valve seat insert
Valve guide
Valve stem seal
Valve spring seat
Valve spring
Valve spring cup

Split cotters

Injector

Injector clamp

Injector clamp nut

engine

filler

cap

cover

cover

shaft bolt
shaft bolt

arm

RH

LH

arm bush

shaft
shaft spacer
shaft spring
shaft clamp
shaft seal

locking nut

M12

M12

M10

-

inlet

-

exhaust

gasket

(3)
(2)

-

exhaust

-

inlet

short
long

(4)

(4)

(10)

51.

Injector clamp stud

52.

Injector clamp dowel

53.

Injector sealing washer

54.

Spill return pipe

55.

Banjo bolt

56.

Copper washers

57.

Glow plug

58.

Glow plug cable

59.

Nut and washer

60.

Thermostat housing

61.

Casket

62.

Flange screw

63.

Thermostat

64.

Gasket

65.

Thermostat housing cover

66.

Flange bolt

67.

Thermal transmitter

68.

Joint washer

69.

Flange bolt

70.

Cup plug

71.

Cup plug

6mm

(3)

M6x40 (3)

(1)

(2)

e

DEFENDER

28

6Z

c

121

ENGINE

a

DEFENDER

The following list

of

sections

the

of

operations can be carried out with the engine installed using the appropriate

ENGINE

OPERATION
Cylinder Head

Heater plugs
injectors
Rocker

cover

Rocker shaft

Removing cylinder head

Front cover

oil

seals/timing beltlcamshaft

Water pump
Front cover plate

or

seal
Front pulley damper
Front cover

plate

Removing timing belt
Removing timing belt gears
Removing injection pump
Removing front cover

Vacuum

Fuel pump and

pump/skew gear/bush/oil filter adaptor

side

cover
Front side cover plate
Cam followers
Removing camshaft

Sump and

Removing

oil

oil

pump

pump

OVERHAUL PROCEDURE.

Remove Overhaul Refit

Page Page Page

41

44

38
38
38
39

39
40
40
40
40
40
41

-

43

44
44

-

46
46
46
47
48
48

42

45

72

78

66

63

70

76

62

63

-

80
80
79
78
76

-

70
66

69

69
68
66

67
66

-

65
65
62
62
72
72

77

66

64

The foregoing list

vehicle. Cross reference, where necessary,
procedure

12.41.05.

publication SMR

of

remove and refit operations are those which can

is

made

to

thr relevant instructions in the engine overhaul

Each operation

670

EN

RT

A91.

is

numbered with the appropriate Repair Operation Time Contained in

be

carried-out with the engine in the

OPERATION Number Page

Cams haft

Power steering pump bracket

Cylinder head

Fuel

injection pump

Air

cleaner

Turbo charger

Inter Cooler
Cooling system
Fan cowl
Fan and coupling
Radiator

Water pump

Exhaust and inlet manifolds
Power steering pump

Altemator

12.1 3.02

72.35.22

12.29.02

19.30.07

19.10.01

19.42.01

19.42.1 5

0.01

26.1

26.25.1

26.25.1 9

26.40.01

26.50.01

30.1 5.01

57.20.14

86.1 0.02

1

30
31
32
81
84
35
86
87
88
88
89
90
91
93
94

30

e

DEFENDER

ENGINE

12

-

.:'

?:

,i

.,.

.!.-.

.....

.

+_I._

-

:

.

.

U

..

.

.

.,..

CAMSHAFT

Service Repair

No.

12.13.02.

Remove and refit

1.

Remove the bonnet and disconnect the
battery.

2. Disconnect the radiator bottom hose and allow
the coolant to drain and reconnect the hose.

3.

Remove the radiator top coolant hose,

4. Remove the fan and viscous coupling

assembly,

operation 26.25.1

9.

instructions

see

4 to 7.

5. Remove the fan cowl.

6. Remove the radiator, see operation 26.40.01.

3

instructions

7.

Remove the air cleaner,

19.1

0.01.

to 5 and 7 to

instructions 1 to 5.

8. Remove the alternator,

instruction

5

to 9.

9. Remove the power assisted steering pump
bracket,

see

operation 12.25.22 instructions

to 9.

10. Remove the air conditioning compressor,

8.

see

operation

see

operation 86.10.02.

11.

Remove the exhaust and inlet manifolds, see

operation 30.15.01 instructions 4 to 15.

12. Remove the cylinder head, see operation

12.29.02 instructions 6

4

13. Now follow the instructions in ENGINE

OVERHAUL

section 12.

to

SEE

7

and 9 to

INDEX:

-

17.

Operations with engine installed in vehicle

where fitted, and the mounting bracket

together with the platform secured by four
socket headed bolts. Note that the hoses must
not be removed from the compressor but it

should

be

carefully secured to one

side.

.

Refitting

14.

Follow the instructions for fitting the camshaft

of

and assembly
the

rocker

cover, crankshaft damper and

the engine up to the fitting

of

pulley.

15.

Fit the inlet and exhaust manifolds

see

operation 30.15.01 instructions 16 to 24 and

27.

...

Fit the power assisted steering pump bracket

16.
and secure and the four bolts.

17.

Fit the power steering pump to the bracket

with the single pivot bolt and clamp bolts.

Leave the bolts slack at this stage.

18.

Fit the alternator to the common bracket, see
operation

19.

Where applicable, fit the air conditioning

compressor and tension the drive belt

86,10.02 instructions 10 to

15.

as

follows:- Move the compressor clockwise

about the pivot bolts

(do

not use a lever

against the pump) until the belt deflects 12

mm (0.5ins.I at the

mid

point

of

the run
between the compressor and crankshaft
pulleys

Mme the

contact with the belt
belt and tighten the damper

.

Tighten the pivot and clamp bolts.

drive

belt

dampei

or

so

that

1,Omm clear

is

is

of

bolts.

jiisi

the

iii

31

L

12

ENGINE

a

DEFENDER

POWER STEERING PUMP

Service Repair

Remove and refit

1.

Disconnect the battery.

2.

Remove the air cleaner, see operation

19.1

0.01.

3.

Remove the alternator, instructions 2 to

operation 86.1 0.02.

4. Remove the steering pump
clamp bolts and remove the drive belt.

5.

Remove the single pivot bolt.

\\

20. Fit and tension the power steering pump drive
belt,

see

operation 57.20.14 instruction 10.

Take note

of

the

CAUTION

when tensioning

the belt.

21. Fit the air
instructions

22. Fit the radiator,
instructions 9 to 15.

23. Fit the fan cowl in position but do not secure

clemer,

12

to 14.

see

see operation 19.10.01

operation 26.40.01

ST3026M

6.

Move the pump aside with the
attached to gain access

to the radiator. retaining bolts.

24. Fit the fan and coupling assembly, see
operation 26.25.19 instructions

25.

Fill

the cooling system,

instructions 5 to

8.

see

8

to

11.

operation 26.10.01

7.

Remove the single
cylinder

8.

Remove the single bolt frpm the front into the
cylinder block.

No.

12.25.22

block

into the bracket.

BRACKET

two

II

to

the bracket

long

bolt through the

adjustment

\y

4

two

hoses still

9

c

four

32

Continued

I-

.

.

-.

~

I

.I,

.J

-.

I.

DEFENDER

9.

Remove the
the front cover and remove the bracket and

triangle shaped packing plate.

.

Refitting

10.

Fit the bracket to the cylinder block with the

four

bolts, reversing instructions 7 to

11.

Loosely

the three

12.

Fit and tension the drive belt.

CAUTION:- Do not apply any pressure
against the pump casing when tensioning
the drive belt since it will damage the
casing, permanently, beyond repair.

Tighten the

13.
bol. The belt is correctly tensioned when the
belt can be deflected by thumb pressure 12

mm (0.5ins.)

14.

Fit the alternator and tension the drive belt,

see operation 86.10.02.
Fit the air cleaner.

15.

Connect the battery, run the engine at a fast

16.

idle

for

Stop the engine and check the drive belt
tensions.

two

bolts inside the bracket into

secure the pump

bolts.

two

clamp bolts and single pivot

to

approximately three

the bracket with

to

five minutes.

9.

ENGINE

CYLINDER HEAD
Service Repair No.
Remove and refit

1.

Remove the bonnet and disconnect the
battery.

2.

Drain the coolant.

3.

Remove the radiator top hose.

4.

Remove the exhaust and inlet manifolds,

complete with turbo charger

30.29.02.

5.

Remove the heater rail.
Remove the thermostat to waterpump hose.

6.

7.

Disconnect the electrical leads fromthe

thermostat housing sensors.

Disconnect the harness from the alternator.

8.
Remove the heater hose from the cylinder

9.

head.

10.

Remove the axle breather pipe bracket from
the rear

11.

Remove the fuel pipes from the injectors and

of

injector pump.

12.

Remove the spill return pipes from the
injectors.
Remove the injectors and washers and place in

13.
a clean,

14.

Remove the electrical leads from the heater

sealable container,

plugs.
Remove the heater plugs and store in a safe

15.

place.
Remove the hose from the breather valve.

16.

Follow the instructions in the

17.

OVERHAUL

Operations with engine installed in vehicle.

12.29.02.

the cylinder head.

for

section 12.

SEE

INDEX:

see

operation

safe keeping.

ENGINE

-

11

2

Continued

33

121

_I

Refitting

ENGINE

a

DEFENDER

18. Follow the instructions in ENGINE
from "fitting cylinder head" and continue until
the

rocker

19. Fit the heater plugs and connect the electrical
leads.

insulation to touch the cylinder head when
fitted.

20. Fit the injectors

21. Fit the spill retum pipes to the injectors.

22. Fit the supply pipes

23.

Fit the hose to the breather valve.

24. Fit the axle breather bracket.

25. Fit the heater hose

26.

Connect the hamess to the altemator.

27. Fit the waterpump to thermostat hose.

28. Connect the leads to the

29. Fit the inlet and exhaust manifolds and heater

-

rail.

30.

Fit the radiator top hose.

Fill

31.

32. Fit the bonnet.

the cooling system, see operation 26.10.01.

cover

is

fitted.

Do

not allow any part

-

see ENGINE

to

of

the lead

OVERHAUL.

to

the injectors and pump.

cylinder head.

thermostat sensors.

OVERHAUL

or

f-;

....

..,

.

.'

.

34

.

DEFENDER

.I

ENGINE

n

12

m

I

-,

CAMSHAfl

Service Repair
Renew

1.

Disconnect the battery.

2. Remove the fan and viscous coupling
assembly,

3.

Slacken and remove the power steering pump
drive belt,

4. Slacken and remove the air conditioning
compressor drive belt.

5.

Remove the air conditioning compressor from
the mounting bracket but do not detach the
fluid hoses from the compressor. Move the
compressor aside taking care not to strain the

hoses.

6.

Remove the compressor mounting bracket

7.

Using an
socket headed bolts that secure the
compressor bracket mounting
front cover and

8.

Remove the water pump and alternator drive
belt, see operation 86.10.02 insturctions 4 to

7.

9. Remove the hoses from the water pump.

NOTE: From this stage onwards reference
should
ENGINE

Operations

These

point when the timing belt has been fitted and
the engine and injector pump are correctly
timed.

TIMING BELT

No.

12.65.18

see

operation 26.25.19.

see

operation 57.20.14.

8,O

mm Allen Key, remove the four

platform to the

cover

plate.

be

made to the instructions in the

OVERHAUL

with

imtructi~ns

section 12.

engine installed in vehicle.

shnu!d

be !c!lcwed

SEE INDEX:

-

the

Assembling

10.

Fit the front cover plate using a new gasket
and a new gasket washer on the centre bolt
boss.

11.

Secure the cover with the various length bolts
tightening evenly to the correct torque.
to the bolt length chart in ENGINE

12. Using a new gasket
instructions 9 to 12 operation 26.50.01.

13. Connect the hoses

14. Fit the air conditioning compressor bracket
mounting platform and secure with the

socket headed bolts.

15.

Fit the compressor mounting U bracket.

16.

Refer

to ENGINE

of

method

17. Fit the pulley to the damper and evenly tighten

the four bolts to the correct torque.

18. Fit the water pump pulley and secure with the
four bolts. Use a
provided to restrain the pulley while tightening
the bolts.

19. Fit and tension the water
belt.

20. Fit and tension the compressor drive belt. SEE

OPERATION 12.13.02

21. Fit and tension the

bel.

22.

Fit

the fan cowl into position but do not

secure to the radiator until the fan

23. Fit the fan and viscous coupling assembly

the water pump spindle. Tighten the left hand
thread to the
bar in the hole provided in the fan pulley
restrain the coupling.

24. Secure the fan

two

nuts and fit the top hose.

fitting the crank shaft damper.

correct

fit

the water pump,

to

the water pump.

OVERHAUL

tommy bar in the hole

power

torque using a tommy

cowl

to the radiator with the

for

the correct

pump/alternator drive

steering pump drive

Refer

OVERHAUL

see

four

is

fitted.

to

to

35

J

12

ENGINE

DEFENDER

ENGINE

Service Repair
Special service

Handle set, seat cutter

Pilot, seat cutter
Valve seat cutter
Cylinder head bolt degree plate
Adaptor, crankshaft rear seal
Crankshaft rear seal saver
Valve spring compressor
Drift, valve guide removal
Distance piece, valve guide fitting
Drift, valve guide fitting
Mandrel, clutch plate
Replace, crankshaft front seal
Remover.
Replace, camshaft

_1

Flywheel timing pin
Crankshaft damper restraining tool
Rear main cap
Crankshaft damper tool
injection pump timing pin

-

part

OVERHAUL PROCEDURE.

No.

12.41.05

tools

crankshaftkamshaft gear

oil

seal

sea1 guide

of

LST129 pump remover tool

MS76B

MS150-8

MS621

LSTI 22

18G134-I

18C1344

MS1519A

R0274400

R0605774A

R0605022

18C1456
18C1464
18C1482

LSTI

1

LSTI 30

LSTl28

LSTI 27

270304

LSTI 36

2912

Die. Range

18G.

134

-

11

28.5”

-

44

mm

15

~

b

45

MS.768

Dia

7.9

mm

S

W5M

186.1344

-@

MS.

1519A

-

8.5

mm

1

11

36

e

1

R0.27-

DEFENDER

1BG.

LST.

1482

128

ENGINE

12

I

18G

18G.

1456

1464

I

I

I
I

I

!

1

LST.

127

.,

,:_:i

...

,

..

::..:

..

.

I

1

ST2344M

37

72

LST136

E

N

G

I

N

E

DEFENDER

ST2677M

CAUTION

Note that where the
specified, only these tools should
the possibility
components.

WARNING.

recommended, it is absolutely essential to follow

the stand manufactures instructions to ensure safe
and effective

in the intrests

the engine to an engine stand recognised by the
garage repair trade. Drain and discared the sump
whilst strictly observing the the handling and
disposal instructions in the Introduction section

AND

WARNING

use

of

special

of

personal injury and

Where the use

use

of

the equipment.

of

safety and efficient working, secure

of

service

be

used to avoid

or

damage

an engine stand

tools

is

is

to

01.

oil

Remove the following ancillary equipment

to dismantling the engine.

Air

conditioning compressor-where fitted

Power steering pump and alternator.

Starter motor

Engine electrical harness.

Air

Inlet manifold.

Exhaust manifold and turbo charger.

Whilst dismantling, make

of

miscellaneous brackets, clips, hamess, pipes, and
hoses, that are removed at the same time, and any
non standard items,

a

note

of

to

facilitate assembly.

the the position

prior

.

DEFENDER

ENGINE

12

CYLINDER

HEAD

REMOVE.

.-.I

._...

.

..

..

I..

39

121

ENGINE

Rocker

See

cover remove.

1.

Release

connections, evenly slacken and remove the

three

fitting

the crankcase ventilation hose

bolts then

rocker

lift-off

cover

the

rocker

cover.

a

4.

Having removed the rocker shaft, lift-out the
push rods and insert them through holes in a
piece

of

card marked from 1 to 8 to ensure

assembly to their original locations.

5.

Remove the cap from each valve stem.

See

fitting

rocker

shaft

DEFENDER

ST2948M

Rocker

shaft remove.

2.

Evenly release the five
bolts but do not remove the bolts from the
shaft, especialy the
the assembly from falling apart when removed

from the cylinder head.

rocker

two

end ones,

shaft retaining

to

prevent

ST294CM

40

e

Removing cylinder head

See cylinder head overhaul or see fitting cylinder
head

DEFENDER

8.

Evenly slacken and remove the eighteen bolts
retaining the cylinder head and lift the cylinder
head from the cylinder block and remove the
gasket.

ST2952M

Front cover plate or seal remove

Front pulley and damper.

5.

Release the

crankshaft pulley from the damper.

four

bolts and remove the

ENGINE

n

12

ST2951 M

Note:- If..necessary, at this stage the cam
followers may be removed for inspection.
See Cam follower removal

FRONT COVER

BE

LT/CAM

See radiator removehefit

Water pump remove.

1.

If

necessary remove the viscous coupling

.

.I

.,

.,..

"

..

complete, with the fan, from the water pump
spindle, using a cranked open-ended spanner,
noting that it has a left-handed thread.

2.

Remove the

from the water pump hub.

3.

If

necessary release the

remove the by

4.

Evenly release and remove the six bolts and
one nut to remove the water pump from the
front cover plate.

See water pump inspection and fitting.

S

HA

OIL

SEALS/TIMINC

fi

four

screws, to release the pulley

-

pass hose.

two

Jubilee clips and

1.

41

12

ENGINE

a

DEFENDER

6.

To

remove the crankshaft damper retaining

bolt use pecial service tool

o

restrain the damper and a 30" socket to

remove the special bolt.

ST3125M

7.

Fit the pressure button 18G1464/5 to the end

of

the crankshaft and using

136, extract the damper

See fitting front damper and pulley

FR

I01 tor

service

as

illustrated.

tool

LST

LST

127

Removing front cover plate.

9.

Unscrew the
the cover plate.

See fitting front

STZ

91

8M

Removing timing belt

11

bolts and one nut to

cover

plate

75"

release

1. Use the xstraining tool

crankshaft in a clockwise direction to
that the valves
closed with number four cylinder valves on the

"

rock

"

and the crankshaft key aligned with the
arrow cast into the front cover
the crankshaft

TDC

do not turn it back but continue on

round until the above conditions are achieved.

of

is

turned inadvertently beyond

LST

127

to

turn the

TDC

number one cylinder are

as

illustrated.

so

If

e.

Q,

..

'J/

A3

I

.:!.

c.

*.

DEFENDER

2.

Now screw the body

128

into the flywheel housing and check that

be

the pin can
slot in the flywheel periphery. Note that there
are

two

slots in the flywheel one being wider

than the othe. The narrowest

TDC

for

this engine and it

important that the correct slot is used.

inserted in to the appropriate

of

the timing pin tool LST

slot

determines

is

therefore

ENGINE

4.

To

lock

the pump, Slacken the locking screw

anticlockwise and remove the inhibiting plate.
Turn the screw clockwise to
shaft. Remove the timing pin from the flywheel
housing.

lock

the pump

11

2

1

a*

ST2954M

3.

Remove the three screws to
injection pump access cover from the front

cover

plate and insert the locking pin LST129/2
through the
hub and into the hole in the pump body. This

will confirm that the injection pump
timed in relation to the valves and crankshaft
and can
the pin in position in the pump.

"U"

be

locked ready

shaped cut-out in the pump

release

the

is

for

removing. Leave

correctly

0

CAUTION:

once the injection pump has been locked

no attempt must be made to rotate it.
Therefore take care not
crankshaft to be turned until the pump has
been removed.

It is important to ensure that

to

allow the

NOTE:-

or gears (with the cylinder head fitted) and
there
will need to be rotated after removal
timing belt, it would be advisable to remove
the rocker shaft. This will prevent the
pistons contacting the valves as the
crankshaft is turned.
rocker shaft removal.

..

...I

.:

..

..

-

.

.,...

If

renewing the timing belt,oil seals

is

any possibility that the crankshaft

If

necessary,

See

of

the

43

E[

ENGINE

e

DEFENDER

5.

To

verify any timing error, check that the

timing marks inside the front cover line-up

with the gear wheels.

6.

If

necessary temporarily fit the damper and
restrain the crankshaft with service tool
while the three screws securing the pump

to

timing gear
gear wheel retaining bolt is being slackened.

7.

Remove the single bolt, special washer and
remove the tensioner.

8.

If

the original belt
direction
removing

the pump hub and the camshaft

is

to be re-fitted, mark its

of

rotation with

it.

soft

chalk before

FR

101

Removing timing

9.

If

the crankshaft gear wheel cannot be

removed by hand,

1462-2

Assemble the tool and withdraw the gear
wheel

ST2960M

as

belt

gears

use

special service tool

and pressure button

illustrated.

18G

18G 1464-5.

1464-2

18C

\\\

ST2959M/

NOTE:-

pattern relative to the driving loads and its
direction
re

-

used it must
continues to operate in the original
direction.

S

ee

fitting Timing gears and belt.

1

A

used drive belt develops a wear
of

rotation.

be

If

the belt is to be

refitted

so

that it

10.

Remove the camshaft gear wheel retaining bolt

assembly to enable the gear to be removed.

Use

special service tool
button
withdraw the the gear.

ST2960M

The camshaft and crankshaft

renewed at this stage with the engine in the vehicle

without removing the front cover.

See

fitting front cover seals

18G 1464-6.

18G 1462-2

Assemble

18G

1464-2

oil

seals may be

and

as

shown and

\\?--.

44

DEFENDER

ENGINE

n

12

I

*

.I

Removing injection pump

11.

Release the injection pump from the rear
support bracket.

Removing front cover

13.

To

remove the front cover,release the three

bolts securing it

face

and the three bolts that pass up through
the sump and ladder frame into lower
the cover.

See

fitting front cover timing

to

the cylinder block front

belt

face

and gears

of

12.

Remove the three nuts securing the pump
flange to the front cover and withdraw the
pump and gasket complete with hub and
timing pin.

Removing vacuum pump

14.

Mark the position
pump with relation

a

6mm Allen key remove the three screws and

-

out the pump.

lift

See fitting vacuum pump

of

to

the brake servo vacuum

the cylinder block. Using

45

112)

ENGINE

DEFENDER

Removing skew gear

During normal operation

and skew gear teeth develop a mated a wear

is

pattern. It
gear

is

teeth on the gear and camshaft engage in the

original running position.

15.

To

turn the camshaft
aligned with the
and mark the position
relation to the one
securing the vacuum pump.
skew gear housing flange to the same bolt
hole.

therefore important that

to

be

re-used it should be fitted

ensure orininal re-engagement

of

the engine the camshaft

if

the skew

so

of

the gears

so

that the camshaft key

oil

groove in the thrust plate

of

the skew gear in

of

the three bolt holes

Also

mark the

that the

is

for

16.

To

remove the skew gear assembly, tap the
flange round
cylinder block, then tap the flange upwards
enable the skew gear assembly to be lifted
out.

If

necessary the

removed at this stage

so

that the edge overlaps the

oil

pump drive shaft may be

to

Removing skew gear

17.

Unscrew the
using a strap wrench. Dispose

18. Release the
adaptor and gasket from the engine.

19.

Using a 6 mm alien key remove the retaining

screw and bush.

bush

oil

filter cartridge, anti-clockwise,

of

the

two

bolts and remove the

oil

oil

safely,

filter

46

a

DEFENDER

ENGINE

12

Removing fuel pump and side cover

20.

Use

a

6

mm allen

pump to gain access
retaining bolts.

21.

Release

plate.

See fitting

Remove front side cover plate

Release

22.
cover

ventilation pipe.

the

lift

pump.

the

plate complete with the crankcase

key

to release the fuel lift

to

the side cover

six

bolts and remove the cover

six

bolts and remove the front side

1. Slacken back the guide locating screw

of

the end is below the bore

x

'

i'

2.

Using a length

lift-out the slide.

3.

With the same piece

4.

Remove the guide locating screw and lift-out

the guide.

6.

As

each assembly

one to eight,

location.

See

fitting cam followers

of

thin wire with a hooked end

of

is

removed number it, from

for

refitting to its original

the guide.

wire remove the roller

n

so

that

I

ST3003

M

Remove camfollowers

See

cylinder head remove

CAUTION:

held in position against the cam by a slide
inside a
before the roller, it
roller can fall behind the camshaft and
become jammed. Furthermore the roller
could slip past the cam and fall into the
crankcase.

the following procedure for removal.

The camfollers are solid rollers

fixed

guide.

It

is therefore important to adopt

111

If

the guide

is

possible that the

is

removed

47

ENGINE

12

Removing the camshaft.

1.

Release

camshaft thrust plate.

2.

Carefully Withdraw the camshaft taking care
not

the bearings

See fitting camshaft

the

two

to

allow the end

as

screws and remove the

of

the shaft

it

is

removed.

to

drop

on

to

e

Removing flywheel housing.

DEFENDER

ST2552M

Removing Clutch and Flywheel housing

engine unit removal

See

1.

Mark the relationship
flywheel to ensure original balance
maintained.

2.

Evenly slacken and remove the six retaining
bolts and washers and remove the assembly
complete with the friction plate.

fitting clutch

See
Removing flywheel

1.

In the intrests
into the clutch bolt holes, diametrically
opposite, to
flywheel

2.

temporarily fit the the crankshaft damper and
use special service
crankshaft while slackening the flywheel eight

retaining bolts. Remove the bolts and

reinforcing plate and lift

See

overhaul and fitting flywheel

of

use

off

the crankshaft.

of

the cover to the

safety, fit

as

handles

tool

FR

-

off the flywheel.

two

long 8mm bolts

for

lifting the

101

to restrain the

1.

Remove the eight internal and
and five ladder frame securing bolts, then ease
the flywheel housing from the
dowels and crankshaft.

See

fitting rear main

is

ST2972M

oil

seal

two

external

two

locating

to

flywheel housing.

i

A8

e

DEFENDER

ENGINE

n

12

Removing sump and

1.

If

necessary drain the engine
working with the engine on a work stand,
invert the cylinder block
uppermost. Remove the screws and ease the
sump from the ladder frame to reveal the

Pump.

I

I

...

ST2553M

Note: After removing the

is

engine

two

the cylinder
the ladder frame cylinder block joint seal.

See

fitting sump

in the vehicle, refit and tighten

of

the retaining bolts to the left side of

block

oil

pump

oil.

When

so

that the sump

1

oil

sump when the

to

maintain pressure on

oil

is

2

Removing ladder frame

Note: The ladder frame and flywheel
housing are secured by
inaccessable with the gearbox
fitted. Therefore
the ladder frame when the engine

vehicle without first removing the gearbox

or

engine unit, flywheel flywheel housing,

engine sump and

3.

With the engine removed,
remaining ten bolts and separate the ladder
frame from the crankcase by gently tapping
break the seal.

See

fitting ladder frame

it

five

bolts which are

bell

housing

is

not possible to remove

is

oil

pump

release

the

in the

to

3

oil

Removing

2.

Two

crankcase.
require the use

joint. Removal

pump to be withdrawn.

See fitting oil pump

pump

bolts secure the

Access

of

oil

pump to the

to

the right hand bolt may

of

a socket with a universal

the

two

bolts will enable the

49

1121

Removing pistons and connecting rods

ENGINE

DEFENDER

Note: On this version
possible to remove the connecting rods
pistons with the engine in the vehicle because

the method by which the ladder frame is secure.

See

note under Ladder frame removal.

1. Turn the crankshaft to bring all the connecting

rod cap nuts to an accessable position and

slacken the nuts using a

2.

Remove the connecting rod nuts and remove

the caps complete with lower bearing halves.

3.

Before removing the piston assemblies,
number each piston from
can be identified with the bore from which it

was removed.

4.

Taking care not to damage the bores, push

each connecting rod and piston, in turn, up
the bore until

cylinder
assembly
and bearing shell
that the shell locating tags are together on the
same

See piston and connecting rods

block

is

removed fit the corresponding cap

side

as

of

the Tdi engine,

15mm socket.

one

to four

it

can be withdrawn from the

combustion face.

to

the connecting rod noting

the connecting rod number.

it

or

so

As

each piston

is not

that it

of

Removing crankshaft.

1.

Slacken the ten mainbearing bolts with a

14"

2.

If

suggested method is to
both

3.

Insert a suitable bar in the hole in the inside
face
journal on the outside

of

to protect the crankshaft.

4.

Release the remaining bolts and remove the
mainbearing caps complete with the lower
bearing shells.

socket.

difficulty

timber are used under the levers particularly

is

experienced removing the cap a

lever

the cap from

sides,

as

illustrated.

of

the cap and lever against the crankshaft

face.

Ensure that blocks

50

DEFENDER

5.

Lift-out the crankshaft either by hand

If

a hoist is used be

protection between the sling and joumals

avoid damage.

6.

Remove the mainbearing upper shells from the
cylinder block.

7.

Remove the

of

the centre bearing location.

8.

Remove the four cylinder lubrication, jet tubes.

CYLINDER BLOCK

Inspection

1.

Degrease the cylinder block and carry out a

thorough visual examination checking

cracks and damage. To check each main
bearing cap and its location

?.

block, fit the bearing caps without the bearing
shells.

2. Fit the bolts and tighten to the correct torque,

then remove one bolt from each bearing cap
and check with a feeler gauge that no
clearance exists at the joint face

3.

A

clearance indicates either a bent bolt,

damaged dowl, distortion

or

that the cap has been filed
an attempt to reduce any clearance due to
wear in the bearings. Main bearing caps are
not available separately from the cylinder block
therefore any clearance should be investigated
and rectified

two

or

sure

to

insert adequate

thrust washers from each side

INSPECTION

the block renewed.

AND

on

of

the caps

or

or

hoist.

OVERHAUL

for

the cylinder

as

illustrated.

or

block,

machined in

to

Cylinder bores

4.

Measure the cylinder bores
and general wear, using any suitable
equipment. However, an inside micrometer

best

for

checking ovality and a cylinder gauge

for

taper. Check the ovality
taking measurement at the top
just below the ridge at
opposite.

5.

The difference between the

ovality at the top
measurements should be made approximately

50

mm

(2.0

ins) up from the bottom

so

bore
determined. The taper
determined by taking measurements at the top
and bottom

gudgeon pin line, the difference between the

two

that the overall ovality may

of

each bore at right angles

measurements

two

of

the bore. Similar

of

is

the taper.

n

ENGINE

for

ovality, taper

of

each bore by

of

the cylinder

points diametrically

two

figures

of

the

n

is

be

each cylinder

is

to

12

is

the

the

ST2566M

To

establish maximum overall

as

measurements at
down the bores at right angles to the gudgeon
pin line. The largest recorded figure
maximum wear and should be compared with
the original diameter

Maximum permissible ovality

mm

0,127

Maximum permissible taper

0,254

Maximum permissible overall wear

0,177

(0.005

mm (0.010 in).

mm (0.007 in).

many points as possible

of

in).

bore

wear, take

the cylinder

is
bore.

the

51

12

ENGINE

DEFENDER

If

the above figures are exceeded the cylinders must

'

be rebored
condition

Altematively,

or

sleeved depending upon the

of

the bores and the amount

if

the overall wear, taper and ovality

of

wear.

are well within the acceptable limits and the original
pistons are serviceable new piston rings may be

is

fitted. It
deglazed, with a hone, to give a cross

important however, that ,the bores are

-

hatched

finish to provide a seating for the new ring.

Fitting cylinder sleeves

Cylinder bores that cannot be rebored can be
restored by fitting
pistons to

be

sleeves

fitted. Sleeving one cylinder only will
distort the adjacent bore
carried out in pairs, i.e. cylinders

to enable standard size

so

sleeving must be

1

and 2

or

3 and

6. Machine the cylinder bores to accept the

+

sleeves to 94,425

0.0005

0,114
Press
a pressure

in). This will give the sleeve a 0,076 to

mm

(0.003

the sleeves squarely into the bore using

of

two

0,012 mm (3.7175

to 0.0045 in) interference fit.

or three tons. Excessive

+

pressure could damage the sleeve and cylinder
block.

The sleeves must not be proud

or

block top face
below the surface.

more than

2,54

of

mm

the cylinder

(0.10

in)

4.

Check crankcase main bearings

Discard

scored,

pitted, cracked and wom bearing
shells. To determine the maximum wear, assemble
the main bearing shells and caps to the crankcase
and tighten the bolts to the correct torque figure.

Using an inside micrometer, measure each bearing

at several points and note the greatest figure. The

is

maximum wear
and the smallest diameter

the difference between this figure

of

the corresponding

crankshaft journal.

is

The main bearing running clearance

given in the

data section.

CRANKSHAm

1.

Degrease the crankshaft and clear out the

oil
ways which can become clogged after long
service.

2. Examine visually, the crankpins and main
bearing joumals for obvious wear, scores,

A

grooves and overheating.

be

of

the shaft

made

stage should
condition

decision at this

as

to whether the

is

worth continuing with

a more detailed examination.

3.

With a micrometer, measure and note the

of

ovality and taper
and crankpin as

each main bearing journal

follows.

7,

Bore and hone the sleeves to accomodate the

pistons with the required clearances,

see

piston and connecting rod examination.

Camshaft bearings

8.

Measure the intemal diameter

of

each
camshaft bearing at several points using an
internal micrometer.

A

comparison

of

the respective camshaft joumals will give the
amount
renewed
in).

Or,

in any event,

This work should only be entrusted to

of

the bearing diameters with those

of

clearance. The bearings should be

if

the clearance exceeds

if

they are scored

0,0508

or

line

mm

(0.002

pitted.

boring

specialists.

It is vital to thoroughly wash the cylinder block after

machining to remove all traces

oil

ensuring that all

galleries are clean.

of

abrasive material,

4.

Ovality - Take

two

readings at right angles to
each other at various intervals. The maximum
ovality must not

5.

Taper - Take

other at both ends

exceed

two

readings parallel to each

0,040 mm (0.0015 in).

of

the main bearing journal
and crankpin. The maximum permissible taper
must not exceed 0,025

mm (0.001 in).

6. To check for straightness, support the front

'V'

and rear main bearing joumals in

postion a dial indicator

and

-

out at the centre main bearing journal.

run

-

out must not

Run

exceed

to

0,076

taking into account any ovality

blocks

check the

mm (0.003 in)

ir. the centre

journal. The overall wear limit should not

exceed 0,114

joumals and

mm (0.0045 in)

0,088

mm

(0.0035

for

main bearing

in) for

crankpins.

7.

A

crankshaft wom beyond the limints

of

maximum taper, ovality and overall wear, can
be ground

to0,25

mm (0.010 in).

When grinding the crankshaft main bearing and
crankpin joumals, rotation

of

the grinding wheel and

crankshaft must be in the same direction,

-

clockwise, viewed from the flywheel end

anti

of

crankshaft.

the

52

DEFENDER

ENGINE

n

12

.*

'

..

11

Finai finishing

using a static lapping stone with the crankshaft
rotating in a clockwise direction viewed from the
flywheel end

It

is

important to ensure that, when grinding, the
stone travels beyond the edge
avoid formation
must be taken not to machine or damage the fillet
radii

'C.

It

is

vital to thoroughly wash the crankshaft after
machining to remove all traces
ensuring that all

of

the joumals should be achieved by

of

the crankshaft.

of

the joumal

of

a step

'B'

as

oil

galleries are clean.

illustrated.

of

abrasive material,

Also

'A

to

care

Genuine Land Rover service standard size pistons

mm

are supplied 0,025
for production
fitting new pistons to a standard size cylinder, the
bores must be honed to accomodate the pistons

with the correct clearances. In addition Land Rover

pistons are available

0.040

in) oversize

tolorance on new engines. When

(0.001

0,50 and

for

fitting to rebored cylinders.

in) oversize

1,Ol

mm (0.020 and

to

allow

ST1808M

Pistons

The following checks relating to pistons and rings

must also be carried out prior to fitting new pistons
to rebored and sleeved cylinder blocks. Until it is

decided

must

of

noted.

3.

and

connecting

if

new components are required all parts

be

kept in their related sets and the position

each piston

1.

Remove the piston rings and gudgeon pin
from each piston and detach the connecting

rod.

2. Original pistons
components and carry out a visual examination

of

the piston and rings and discard any which
are unserviceable. Pistons which appear
serviceable should be subjected to a more
detailed examination described under 'New
Pistons'.
New pistons - Original pistons fitted
engines
facilitate assembly. The grade letter on the
piston crown should be ignored when

ordering new pistons.

to

its connecting

at

the

rods

rod

should be

-

Decarbonise and degrease all

to

factor?

arespecially

graded

new

to

Clearance limits
standard cylinder bore measured at right angles
the gudgeon pin are in the data section. When

taking the following measurements the cylinder

block and pistons must be the same temperature
ensure accuracy.

4.

Using a suitable micrometer
the pistons at the bottom
angles to the gudgeon pin.

ST2657M

for

new standard size pistons in a

or

vernier measure

of

the skirt at right

to

to

53

1121

ENGINE

5.

With an inside micrometer
measure the diameter
approximately half
reading.

or

cylinder gauge

of

the bore at

-

way down and note the

e

9.

With the appropriate feeler gauge check

ring gaps in turn, including the

rings.

The correct gaps are listed in the data section.

is

less

gap

file

the ends square, whilst holding the ring in a
filing
and not likely
limits when hot, an oversize ring should be fitted.

than that

jig

or

vice. Should any gap be excessively wide

to

specified,

close

up to within the

DEFENDER

all

oil

control

If

remove the ring, and

specified

the

any

6.

The clearance is determined by subtracting the
piston diameter from the bore diameter.

7.

If

gauge equipment
clearance can be assessed by placing a long,
suitably sized,

of

side
piston, 'upside down', in the bore and position

it

crankshaft axis. Push the piston down the bore
and stop at the tightest point and whilst
holding the piston still, slowly withdraw the
feeler gauge.
approximately
clearance

Piston ring

8.

When checking the piston ring gap in worn
bores which are within the acceptable taper
and ovality limits, the ring must be inserted
squarely into the bottom
lowest point
squareness push the ring to the correct
position using a piston.

the bore and inserting the appropriate

with the gudgeon pin parallel to the

If

is

satisfactory.

gaps

of

is

not available the

feeler

gauge down the thrust

a steady resistance

2,5

kg

(6

Ibs) is felt, the

of

the cylinder at the

the piston travel.

of

To

ensure

Once the rings have been
cylinder and piston ensure that they are not again
mixed up.

Piston ring groove clearance

10.

It

is

important that the groove clearances are
correct. Rings that are too tight may bind or
fracture when hot and cause
compression. Excessive clearance allows the

to

rock

rings

pumping action and excessive
consumption.

in the groove and may result in a

selected

for

a particular

loss

of

oil

694

p

':

z4

54

1

.

-,.":.<.

.

-

:

DEFENDER

11.

Fit

the

oil

control ring expander to the bottom

oil

groove, then fit the
that it fits over the expander. Fit the second,
narrow, compression ring with the word

uppermost. Likewise fit the first compression

ring

to

the top groove, word

uppermost.

control ring ensuring

"

TOP

"

"

TOP

"

Gudgeon

14. Examine the gudgeon pin

Connecting

pins

cracks, scores,
taper using a micrometer.

or

overheating and ovality and

rods

ENGINE

for

obvious wear,

12

-

15. Check the connecting
distortion as follows; fit the correct cap, less
the bearing shells, to each connecting rod
denoted by the number stamped near the joint
faces. This number

piston/cylinder/ crankshaft journal to which it

must

be

fitted.

16.

Tighten both nuts to the correct torque, then

11-

c

..

.

..

ST2636M

12. After fitting slide each ring around the groove

to

ensure that it is

13. Using an appropriate feeler gauge check the
groove clearance between the rings and

If

piston.

figures given in data section the rings

pistons should be renewed.

the clearances in excess

free

and does not bind.

of

the

or

the

release one nut on each cap, now check that
no clearance exists at the joint face
illustrated. A clearance may indicate a bent bolt

of

or that either
or machined previously, in attempt to rectify
excessive bearing wear.

the joint faces has been filed

rods

also

indicates the

and caps

as

for

as

..

-.

1.

.

...

_..

.

..

'_.

:,

..

ST2632M

13

ST2976M

-17.

Use an accurate connecting rod alignment
gauge to check the rods
The maximum allowable for both conditions
must not

18.

Examine and check the small-end bush
wear.
clearance
bush

19.

When renewing a bush ensure that the
in the bush lines up with the hole in the
connecting
size and clearance.

"

I

I

for

bend and twist.

exceed

If

necessary renew the bush. The correct

of

is

given in the data section.

0,127 mm

the gudgeon pin in the small-end

rod.

Finish the bush to the correct

(0.005

in).

for

oil

hole

55

(121

Big end bearing nip and clearance

21.

22.

ENGINE

20.

Connecting
scored and show signs
discarded.
show these signs they must all be renewe.
When fitting new
serviceable crankpins the clearances must be
checked.

Clean the protective coating from new
bearings before fitting.

Fit the bearing shells
and cap ensuring that the location tags are
correctly seated and aligned. Fit and tighten
both bolts to the correct torque, next
one nut on each cap then check
clearance
to

0.008).

rod

bearings that are worn, pitted,

If

more than one

or

used bearings to

to

of

between

of

overheating must be

of

the bearings

each connecting

for

0,lO

to 0,20mm

release

a nip

(0.004

rod

DEFENDER

24.

Insert a circlip in one
boss and assemble the piston to the
connecting rod with the gudgeon pin. Secure
the assembly with a circlip on the opposite

side

of

the piston.

side

of

the gudgeon pin

W

ST2977M

23. Check the joint face
and bearing shells
excessive.
shell bearings to move (possibly rotate) inside
the connecting rod when the engine
running. After satisfactory fittting
bearings temporary retain the shells and caps

to the appropriate connecting rod.

Assembling pistons

The piston must

rod

so

that the arrow on the piston crown points to

of

the front
chamber, bearing shell tags and connecting rod
number are
cylinder block viewed from the rear
(camshaft

the engine and the off-set combustion

all

on the same, right hand side

side).

-.

of

faces

of

both cap

if

the nip clearance

Too

little nip clearance

to

connecting rods

be

assembled to the connecting

of

will

of

the

is

allow the

is

the

of

engine

rod

ST2979M

the

56

..

e

DEFENDER

ENGINE

12

2,

'-?

9

.I

Ensure that the cylinder block and all oilways are

ASSEMBLE ENGINE

thoroughly clean using an air line,

if

available, prior

to assembly.

Refitting cylinder lubrication jet tubes

Oil

jet tubes are fitted to lubricate the pistons and

bores directly from the main

1.

Assemble and fit the jet tube as illustrated

oil

gallery.

ensuring that the dowls locate in the holes in
the cylinder block, and that the larger diameter

washer fits under the bolt head. Tap the jet

blocks down to ensure that the locating dowel

is

fully home. Fit and tighten the retaining

bolts to the correct torque.

The nip clearance which ensures that the bearings

0,IO

to

are correctly clamped, must be within

mm

(0.004

to

0.006

in). Investigate and correct any

0,15

nip clearance errors before removing the main
bearing caps prior to fitting the crankshaft.

Fitting crankshaft

ST2980M

Crankshaft bearings.

Main bearing nip

clearaqce

Clean the protective coating from new bearings
before

fittin.

1.

Insert

two

standard thickness thrust washers

side

of

each

with the

the centre main bearing location

oil

grooves towards the crank thrust

faces.

2.

Lubricate the cylinder block bearing shells and

carefully install the crankshaft.

1.

Fit the bearing halves to the cylinder block

ensuring full engagement

3

L.

Instal!

the

othei

half

shells

of

the location tags.

into

the

main

bearing caps, again ensuring that the tags
locate correctly.
Fit all the main bearing caps to their original

,.,-.

~

.I.

.,

.

.

,

...

3.

locations tightening the bolts

torque, then

4.

Check the clearance between the cap and the

release

one bolt on each cap.

to

the correct

block as illustrated.

57

12

ENGINE

Crankshaft end float

3.

To

determine the crankshaft end-float mount a
dial test indicator to read-off the end
crankshaft. Move the crankshaft away from the

zero

indicator and
crankshaft in the opposite direction and note
the indicator reading. The end-float should be

0,05

to

0,15

the dial, then Move the

mm

(0.002

to

0.006

in).

of

the

e

6.

Ensure that number five main bearing cap is

free

clean and
the seal guides number
crankcase,
are parallel to the crankcase edge.

from old seal material. Attach

as

illustrated, and ensure that they

DEFENDER

270304

to the

Alternatively measure the clearance with a
gauge.
oversize thrust washers. Variation
thicknesses at each side
must not exceed
the crankshaft remains centralised.

Main bearing caps

If

adjustment

Lubricate and fit the centre main bearing cap,

4.

tighten both bolts
ensure that the shaft
fitting the next bearing cap.
Lubricate and

5.

checking that the shaft
tightening the bolts

is

required substitute with

of

of

the crankshaft joumal

0,08

mm

fit

(0.003

to

the correct torque and

is

1-2

and 4 main bearing caps

for

free

is

free

each.

in)

to

thrust washer

to

ensure that

rotate

te

rdate

feeler

before

after

Sl

7.

To

prevent any seal material becoming trapped
between the bearing cap and crankcase,
chamfer the inner edge

0,80

mm wide

with engine

cap.

8.

Fit the bearing cap complete with shell bearing
to the crankcase and secure with new
and tighten to the appropriate torque. Remove
seal guides and check that the shaft

rorate.

as

oil

and fit them to the bearing

of

the seal

illustrated. Smear the seals

0,40

is

to

bolts

free to

c-?:

e2

58

DEFENDER

ENGINE

n

12

Fitting connecting

1.

Ensure that the essentric headed big end bolts
and shell bearings are correctly located in the
connecting
possible damage to the crankshaft journals
during installation
bolt threads with a layer
Check that the number on the connecting rod

is

the same

they are correctly orientated.

2.

With the cylinder block vertical, and 2 and
crankshaft journals at BDC lubricate and install

2

and 3 piston connecting

that the piston rings are resting on the block

9.

To allow

seals standing proud

then using a sharp blade, trim the seals

..

approximately

face.

for

shrinkage after fitting leave the

of

the crankcase face

0,80

mm above the crankcase

off

to

face.

3.

Stagger the piston rings on both pistons
illustrated, then using a suitable tool compress
the piston rings and gently push each piston
into the cylinder bore.

4.

Pull both connecting rod big ends on to the

journals and

numbers match and orientation
Retain the caps with new nuts but

tighten at this stage.

5.

Tum the crankshaft
at BDC and install the pistons and connecting
rods

as

previously discribed.

7.

Tighten both nuts
the correct torque and check that the
crankshaft
next connecting rod cap nuts.

8.

Investigate and rectify any big end bearing
which when tightened restricts the freedom
the crank shaft.

9.

Check that each big end
sideways on its journal and
the actual

The correct clearance

section.

rods

and pistons

rods

and

as

a precaution against

of

the pistons, cover the

of

adheasive tape.

as

the piston and cylinder and that

rod

assemblies

fit

the caps ensuring the the

is

correct.

do

not

so

that I and 4 journals are

on

one connecting

is

free to rotate before securing the

is

free

if

necessary check

side

clearance using a

is

given in the data

to

move

feeler

rod

gauge.

3

so

as

to

of

59

ENGINE

Fitting rear main

The

oil

seal
supplied with a former to maintain the correct shape
which must not be removed until the seal is to be
fitted.

18G

134-11

oil

seal to flywheel housing

is

manufactured from P.T.F.E. and

is

DEFENDER

1.

Make sure the seal housing
and free from burrs.
and ensure that the outside diameter
and dry.

2.

Using special seal replacer 18C134-I 1 and with
the lip side leading drive-in the seal as far
the tool allows.
the seal to the bottom

ensure squareness.

Fitting flywheel housing

Do

If

the tool

is

clean and dry

not touch the seal lip

is

not available fit

of

the housing to

is

clean

as

.

\

3. Clean the rear face
flywheel housing, then apply a bead

102 sealant to the dimensions and
configuration, illustrated.

The illustration has been produced full size

template may be made to facilitate the application

of

the sealant. The bead should
and must extend around the periphery
bearing cap

is

sealed.

so

that the joint between cap and block

of

the cylinder block and

of

be

2,O mm diameter

of

the

Hylosil

so

that a

I

~-__

L,**

ST2988M

60

a

DEFENDER

ENGINE

n

12

4.

Examine the seal guide, number
ensuring that it
damage or scratched.
crankshaft

5.

Locate the seal guide on to the crankshaft and
lubricate the seal, guide and journal with
concentrated 'Oildag' in a
clean engine

6.

Carefully locate the flywheel housing over the
seal and on to the dowels.

7.

Remove the seal guide and secure the flywheel
housing, evenly tightening the retaining bolts
to the correct torque.

is

perfectly smooth and not

oil

seal journal

oil.

Also

is

18G1344

check that the

smooth and clea.

25%

solution with

OVERHAUL AND FITJING FLYWHEEL
Inspection

Normal wear and scores on the flywheel clutch face

can be repaired by machining provided that the

of

overall width

36,96

mm

flywheel has not been previously machined before
proceding further. The ring gear may

the teeth are chipped

Reface the flywheel

1.

Remove the clutch cover locating dowels.
Machine the flywheel

face removing only the minimum

necessary to achieve a smooth surface parallel
with the crankshaft mating face within the
dimensions given above.

Renew Ring gear

WARNING: Wear industrial

protect the eyes

2.

To

renew the ring gear, drill a 8 mm hole

between the root

inner diameter
to weaken the gear. Take care not

drill

to enter the flywheel.

the flywheel

(1.453

in) therefore check that the

or

of

is

not reduced below

be

renewed

damage.

over

the entire clutch

of

material

goggles

from

flying fragments.

of

any

two

teeth and the

the ring gear deep enough

to

to

allow the

if

ST2973M

7

61

El

ENGINE

3.

Secure the flywheel in a soft jawed vice and
cover

it with a cloth to avoid personal injury.

cold

Place a

strike it sharply

4.

Heat the new ring uniformally to between
225°C and 250°C but

higher figure.

5. Place the flywheel, clutch face down, on a flat
surface and press the starter ring firmly against
the flange until the ring contracts sufficiently to
grip the flywheel. Allow the ring
naturally.
otherwise distortion may occur.

chisel above the drilled hole and

to

split the ring gear.

do

not exceed the

to

cool

Do

not hasten cooling in anyway

5

DEFENDER

ST2991M

Fitting clutch

ST2640M

Fitting flywheel

6.

Locate the flywheel on the crankshaft and
secure with the reinforcing plate and retaining

bolts. Temporarily fit the damper to front
crankshaft and use special service tool
or

LST127 to restrain the crankshaft whilst the

eight retaining bolts are being tightened
correct torque.

7.

To

check the flywheel

mount a dial test indicator

a

rests, in
pressure face at a radius
from the centre

8.

Tum the flywheel, and check that run-out does

not exceed
in). Should any run-out be excessive, remove

the flywheel, and check again
on flywheel and crankshaft mating faces and

dowel.

loaded condition, on the clutch

0,05

for

of

of

the flywheel.

to

0,07

mm (0.002 to

possible

so

114

run-out,

that the stylus

mm (4.5 in)

for

irregularities

of

FRIOI

to

the

0.003

If

the original clutch cover
any marks made during dismantling are aligned to
maintain original balance.

1.

Clean the flywheel and place the friction plate

with the raised centre section outwards away

from the flywheel.

2. Fit the clutch assembly locating it
three dowels and loosely secure with the six
bolts.

.

3.

Centralise the centre plate using special

R0605022 or a spare primary shaft and tighten

six

the

4. Remove the tool and smear the splines
centre plate with Molybdenum disulphide
grease, such

bolts evenly to the correct torque.

as

Rocol

is

being refitted, ensure

over

the

of

MTS1000.

tool

the

ST2611

M

e

Fitting camshaft

Inspection

DEFENDER

ENGINE

n

12

T

. ..

....

..

1. Mount the camshaft on
surface plate for convenience and examine the

for

cams
edges.

2.

Examine the journals
scores and signs
check the thrust plate.

sewiceable, check with a dial gauge or

micrometer for overall wear, ovality, taper and

runout.

CAUTION:

requires renewal, the camshaft must also be
renewed even though the camshaft gear
may appear satisfactory. Once the
have run together they become a matched
pair.

3.

Lubricate the camshaft bearings and journals

with clean engine

camshaft into the cylinder block. Fit the thrust
plate and secure with the

tighten to the correct torque.

wear, scores, pitting and chipped

of

If

the skew gear is worn and

"v" blocks on a

for

obvious wear and

overheating, in particular,

If

the journals are visibly

two

oil

and carefully insert the

two

bolts and

gears

Fitting camfollowers

1.

Examine all the components
damage particularly the
seating in the slides and ensure that the tappet
slides move freely in the guides.
parts are being refitted, ensure that they are
returned to their original positions.

rollers

for

wear and

and pushrod

If

the

same

\\

ST2968M

4.

To

the camshaft gear and mount a dial test
indicator
condition upon the machined face

5.

Zero the dial and move the camshaft back and
forward and note the reading. The end
should be within

0.0055

to achieve the correct end float.

'

check the camshaft end-float, temporarily fit

so

that the stylus rests in a loaded

0,06

to 0,13 mm

in)

If

necessary fit another thrust plate

-

of

(0.0025)

/

the gear.

-

float

to

Note: The tappet retaining screws have a micro
encapsulated locking compound applied to the

threads to ensure that they

Once the screw has been used the locking ability

is

lost.

do

not become loose.

.

,

1.

63

112)

Fitting skew gear bush.

Inspect the skew gear bush
necessary.

ENGINE

2.

Insert the tappet guides into the cylinder
block, retaining each with a new screw which

be

should
rollers and slides to be installed. Ensure the
rollers are fitted in accordance with any marks
made during removal. New rollers, however,
may

3.

Before fitting the tappet slides make sure the
oilways are clear to the running surface
roller and the pushrod seating. insert the the
tappet
the front

4.

Finally tighten the screws to the correct torque
to secure the guides.

1.

Insert the bush into the cylinder block and
secure with a new screw

Do

not over tighten as this may damage the

bush.

screwed in sufficiently

be

fitted either way around.

slides

with the word

of

the engine.

for

wear and renew

to

to

'FRONT'

the correct torque.

allow the

of

the

or

'F'

to

if

e

Overhaul and fitting skew gear

1.

Remove the circlips retaining the skew gear
shaft to the bearing and the bearing in the
housing.

2.

Press the bearing and shaft assembly from the

housing and the shaft from the bearing.

Discard both rubber

components especially the bearing and

for

wear and damage and renew

CAUTION:

camshaft are

fitted

so

original position.
the camshaft are renewed, the mating
component must

"0"

rings, examine all

If

the original skew gear and

to

be re-used, they must be

that the teeth on each, mesh in the

If

either the skew gear

also

DEFENDER

skew

if

necessary.

be renewed.

gear

or

1'

.

h\

4,

ST2995M

Assembling

3.

Press the bearing into the housing and secure
with the circlip. Support the housing and press
the shaft into position and secure with the

circlip.

4.

Fit a new rubber
housing and to the intemal annular groove in
the shaft ready

"0"

ring to the outside

for

installation.

of

the

r-

<L

-

64

ST2999M

I

e

DEFENDER

ENGINE

1121

*

1

.

_.

I.

.

..

,!

Fitting

$:.

d

If

re

skew

gear

the

original skew gear and camshaft are being

-

used

it

is

important that the gear

teeth

mesh

in

the original position as follows.

5.

Turn the camshaft

oil

the

..

.

groove

so

as

illustrated.

that the key aligns with

..

6.

Fit

the skew gear assembly

ventilation slot

front

the

in

the gear housing

of

the engine as illustrated and

so

that

the

is

ensuring that any alignment marks made during
dismantling are realigned.

If

both components are new it is

correctly align

the

ventilation slot as described

only

necessary

above.

towards

to

65

1121

ENGINE

DEFENDER

OVERHAUL AND

Oil temperature thermostat

1.

Remove the

the thermostat extension housing complete
with, the
and spring

(6)

with lint-free cloth.

inspect all the parts and renew

3. Fit the spring, washer and thermostat with the
pin uppermost.

4.

Fit the extension housing using a new
Ensure that the pin protruding from the
thermostat locates in the hole in the extension
housing and secure with the

.+

washers.

1-

FITTING

two

’0’

ring (21,thermostat (3),washer

(5).

2. Clean the adaptor housing

????

OIL

FILTER

bolts and carefully withdraw

as

necessary.

two

bolts and

\

ADAPTOR

’0’

ring.

(41,

Oil filter

6.

Smear the filter sealing ring with
the filter clockwise until the seal touches the
machined face, then tighten the filter a further

Do

half turn only.
Maintenance operations, section

Fitting vacuum pump

7.

Using a new gasket fit the vacuum pump
that the brake servo connection

of

front
in the skew gear locates in the pump drive
shaft then secure with three screws tightened
to the correct torque.

the engine, ensuring that the cross-pin

not over tighten.

oil

10.

is

towards the

and screw

see

so

ST2596M

5.

Using a new joint washer fit the
adapto. Ensure that the retaining bolts pass
through the

washer. Tighten the

to the correct torque.

ST3000M

two

small holes in the joint

two

retaining bolts evenly

oil

filter

-

Fitting front and rear side covers and fuel lift

Pump

8.

Check that the front side cover baffle plate
secure and fit the cover using a new gasket

of

the

six

securing with only four
this stage, leaving out the
the injection pump support bracket
illustrated.

two

fixing bolts at

which secure

as

I

is

P

66

e

DEFENDER

ENGINE

n

12

Fitting

Fitting

10. Check that the lift pump

rear cover

9.

Fit the rear cover also using a new gasket and
secure with six bolts tightened to the correct
torque.

fuel

lift

pump

is

serviceable and refit
using a new gasket, ensuring that the pump
actuating lever locates correctly onto the
camshaft

.

3.

Also

fit a new joint washer to the coolant
aperture and
pulley clamp bolt.

Fit

the front cover locating it over the single

4.
stud and secure with the three retaining bolts
tightening evenly
correct bolt length
the following chart.

to

the tapped hole

to

the correct torque. The

for

each hole

for

the jockey

is

given in

,

ST3003M

FllTlNG FRONT

1.

Clean the front cover and remove the
crankshaft and camshaft

not to damage the seal housing. Examine the
cover
the mating
cover plate for burrs.

2. Clean the front face

use a little grease to hold in position a new

joint washer.

COVER

for

damage, cracks and distortion. Check

face

TIMING BELT

of

the cylinder block and the

of

I,,

oil

seals taking care

the cylinder

AND

block

GEARS

and

ST3005M

Front

cover seals

Lubricate a new crankshaft

5.

side leading, drive
special service tool

6. Similarly, lubricate and drive-in a new camshaft
oil

seal,

lip

tool

18G1482.

-

in the seal, squarely, using

18C1456.

side leading, using special service

-

oil

seal. With the lip

67

112)

ENGINE

e

DEFENDER

Fitting injection pump

1.

Insert the timing pin in the pump hub and

body. Fit the injection pump and secure with
the three nuts and tighten evenly to the
correct torque.

2.

Fit the pump rear support bracket
side cover and secure to the pump with
bolts and nuts.

3.

Inspect the pump drive gear

is

damage, ensure it

before fitting
with three bolts and renforceing plate.
overtighten the bolts at this stage.

to

thoroughly clean and dry

the pump. Retain the gear

for

wear and

to

the front

Do

two

not

Cleanliness and accuracy are vital when carrying out
the timing operations and fitting the drive belt.

1.

Check the gear wheels are not damaged
scratched and that they are thoroughly clean
and dry.

2.

Ensure that the belt adjustment idler bearing

sound and not leaking lubricant.

3.

Fit the crankshaft and camshaft gears ensuring
that the camshaft gear
special bolt, washer and new
not tighten at this stage.

is

retained with the

'0'

ring but do

or

is

Injection pump, valve timing and drive belt.

Drive belt.

During use, a belt develops a wear pattern relative

to

its running direction, therefore,

is

to

be re-used it must be fitted

to

rotate in the original direction, otherwise the belt

must be renewed.
Drive belts must be stored on edge on a clean flat

surface and in such a manner that bends are not

less

than

50

mm

(2

in) radius.
at an acute angle or radius
otherwise premature failure
reinforcement

could

less

of

result.

if

the original belt

so

that it continues

Do

not bend the belt

than

50

mm

the fibre

(2

in)

4.

Rotate the camshaft

the camshaft gear is aligned with the arrow in

the front cover.

5.

Temporarily refit the crankshaft pulley and turn
th crankshaft
at TDC and the crankshaft key
the arrow in the front cover.

so

so

that the centre dot on

that one and four pistons are

is

aligned with

68

e

-_

.

\\

1

I

:,,..,L

l’,

i

.

%?

DEFENDER

6.

Screw the body
bottom

the pin will locate into the flywheel slot. It is
important to note that there are
the flywheel and that the narrowest is the
that must be used for this direct injection
engine.

of

of

timing pin LST128 into the

the flywheel housing and check that

two

slots in

one

ENGINE

n

12

0

ST2641

M

Fitting and tensioning belt drive

Note: It is vitally important that the
following belt tensioning procedure it
carried out carefully and accuratly. The

procedure involves tensioning the belt
twice. New and original delts are tensioned
to different figures.

8.

Ensure that the crankshaft, camshaft
jection pump are correctly aligned then
carefully fit the belt observing any rotational
marks made during removal. Feed the delt over

it

the gears keeping

9.

Fit

the belt tensioner with the special washer
and single bolt. Insert a
drive extension into the tensioner plate and
with a dial type torque meter, apply a tension

of

21.7 Nm

Nm

for an original belt. When the tension is
correct and the meter
position, tighten the clamp bolt.

(16

tight on the drive side.

13

mm

(0.5

Lbf

ft)

for

a new belt, or

is

in the vertical

and

in

in) square

16.3

10.

Tighten the three bolts that secure the pump
gear and reinforcing plate to the pump hub to
the correct torque and remove the timing pin

LSTI

2912.

CAUTION: Unlock the injection pump and
fit the keeper plate before attempting to

Also

turn the crankshaft.
flywheel timing pin
flywheel slot.

11.

Rotate the crankshaft
and slacken the tensioner clamp bolt and
tension the belt again, as previously described.

ensure that the

LST128 is clear

two

complete revolutions

of

the

Note:

To

ensure correct belt tension it is

is

very important that the tensioner

is

when the torque meter

position and the applied tension is correct.

in the vertical

clamped

ST301

OM

69

1

121

ENGINE

DEFENDER

CAUTION:

The double tensioning procedure is vital

otherwise the belt could fail resulting in serious

damage to the engine.

12.

Tum

the crankshaft again in a clockwise

direction until the flywheel timing pin locates

T.D.C.

in the

13.

insert the timing pin in the pump hub and
check that the crankshaft key aligns with the
arrow on the front cover.
dot on the camshaft gear aligns with the arro.

if

the timing pin cannot be inserted fully into
the pump hub slot, it
the three pump gear retaining

turn the hub, in the appropriate direction, to
allow the pin to locate. Retighten the bolts to
the correct torqu.

Fitting front cover plate

14.

Remove the wom seal from the cover and
clean the

surface and using service tool 1861456 press

in the new seal into the location, lip side
leading,

from the crankshaft.

slot.

Also

check that the

is

necessary toslacken

boltsand slightly

recess.

so

Support the

that when fitted the lip faces away

cover

on a flat

15. Ensure that the front cover and plate joint

fit

faces are clean and
front cover using a little grease.

16.

Fit a new gasket to the centre hole in the
cover plate and locate in position by inserting

a bolt. Then fit the plate to the cover securing
with the eleven retaining bolts using the
location chart showing the various lengths.

Tighten the bolts evenly to the correct torque.

a new gasket to the

100"

ST2

91

8M

75"

Fitting front damper and pulley

17.

Check that the damper rubber

condition then locate the unit on the

crankshaft key and secure with the distance
piece and special bolt. Apply

242 to the bolt threads and tighten to the
correct torque using service tool
restrain the crankshaft,

18. Refit the pulley securing with the four bolts

to

and tighten

the correct torque.

as

is

in good

a

little Loctite

LST127 to

illustrated.

.

70

ST3

1

25M

L

-

..,.,.

'i

i:;.;::

,

.

,::..::!..v

_.,.

.

DEFENDER

!-.,

,&

..

:.i

..

...

..

I*^

WATER PUMP INSPECTION AND FllTlNC

The water pump

is

not a reconditionable unit but its
condition can be determined by the following
checks

.

1.

Spin the pump spindle and listen

for

bearing
noise, also push and pull the spindle and
check for sideways movement.

the bearing

is

If

in good condition the clearance between the

impeller and the pump body should not vary.

2.

Inspect the vent hole in the pump body

signs

of

coolant

any evidence

or

lubricant leaks.

of

leakage, the pump should be

If

there is

for

renewed.

Fitting ladder frame

Since the sealant specified to seal the ladder frame

to

the crankcase cures within fifteen minutes it
important to fit sufficient bolts
compression while the

1.

Clean both sides
remove all traces
frame

is

not distorted and

sealeant cures.

of

the ladder frame and

of

old

and damage on the mating faces that could

oil

cause

2.

Coat both faces with Hylogrip Primer

or bypass

gas

to leak.

and hasten curing then apply a bead
"

Hylogrip

2000

"

3,O

mm wide to the mating

ENGINE

12

is

to

ensure adequate

sealant. Check that the

is

free

from burrs

to

clean

of

face with the crankcase.

3.

Fitting water

3.

Lightly grease a new joint washer and place it

.

in position on the timing cover.

4.

Clean the threads
bolts and apply Loctite
sealant to the threads

pump

of

the water pump retaining

572

thread lubricant

of

the long bolts which

Fit ten securing bolts through the ladder frame

two

flange and

more through the sump face

illustrated. Tighten all bolts evenly

to

the

as

correct torque.

3

penetrate into the cylinder block.

5.

Fit the pump to the cylinder block and secure
in accordance with the bolt chart. Tighten the

six

bolts and one nut evenly to the correct

torque.

35"

6.

If

separated, fit the fan blades to the viscous

coupling with the four screws. Fit the fan and

viscous coupling assembly to the water pump

spindle noting that it is secured with a

-

hand thread.

left
not at this stage fit the drive belt until the
compressor belt

If

air conditioning

is

fitted.

is

fitted do

ST3012M'

*

OIL

PUMP

1.

2.

3.

4.

5.

OVERHAUL

Bend back the
securing the strainer to the

lock

washer and

release

oil

pump body and
remove the. strainer and sealing ring.
Remove the four bolts and washers, lift
oil

pump cover and remove the driving and
driven gear.
Remove the

pressure

relief

valve plug and

oil

sealing washer. Withdraw the relief valve spring

for

and plunger and examine

for

Examine the gears
and renew

if

necessary. Note: Gears must be

wear, scores and pitting

wear and scores.

renewed in pairs only.

If

showing signs

spind!e

may

of

be

renewed.

wear the driven gear

the nut

off

the

71

J

12

I

ENGINE

e

DEFENDER

6.

Clean all the components then install both
gears into the body ensuring that the recessed

of

end

7.

Place a straight edge across both gears as
illustrated to measure the end float
using a
backlash and the clearance between the gears
and pump body. The correct clearances are
given in the data section.

8.

Examine the gear thrust face on the pump

cover, any slight scratches may be erased by

rubbing

the driving gear

feeler

gauge.

on

fine emery cloth on a flat surface.

is

uppermost.

Also

check the gear

of

each

'

ST3014M

Pump

assembly.

9.

With gear tolorances correct, lubricate and fit
the driven gear to the spindle and install the

driving gear with the counter bored splined

end

of

the gear uppermost in the pump

housing.

10.

Fit the cover locating it over the two dowels

loosley

and
strainer

11.

Install the spring into the
lubricate and insert the valve into the relief
valve bore retaining with the sealing washer
and plug.

12.

Fit a new
insert into the pump body and loosely secure
with the

13.

Secure the strainer bracket to the pump body
and tighten the four
strainer pipe nut and secure with the

14.

Insert the pump drive shaft and check that the
gears are
engine.

secure with the

is

fitted.

'0'

ring to the

lock

washer and nut.

screws.

free

to operate before refitting to the

four

bolts until the

relief

valve then

oil

strainer pipe and

Tighten the

lock

tab.

72

DEFENDER

ENGINE

n

12

Fitting

oil

pump

15.

Ensure that the

in the appropriate spiines and fit the
and strainer assembly into the cylinder block
using a new gasket, tighten the
the correct torque.

oil

pump drive shaft

two

is

located

oil

pump

bolts to

CYLINDER HEAD OVERHAUL

CAUTION:

manufactured from an aluminium alloy care
must
combustion face, in particular,
damaged
hard
the overhaul operations.

Since the cylinder head

be

taken to ensure that the

is

or

scratched by placing it

or

abrasive surface while carrying out

is

not

on

a

Fitting the sump

16.

Ensure that all traces
removed from the sump joint face and that the

is

sump

17.

Remove the
frame to the cylinder block to allow fitting
the sump.

18.

Apply a

black to the sump face and

19.

Install and tighten the twenty remaining bolts
to the correct torque. Note that the three long
bolts pass through the sump and ladder frame
into the front cover.

thoroughly clean inside and out.

two

2,O

mm wide bead

of

old

sealant are

two

bolts securing the ladder

of

"Hylosil"

fit

the sump.

of

RN102

1.

Using valve spring compressor
suitable altemative, remove the valve and
spring assemblies identified to their original
locations.

MS

151

9A

or

a

ST3016M

73

L

ENGINE

12

2.

Discard the valve springs and valve guide
seal. Remove carbon deposits from the valves
and combustion chambers and degrease all
parts ready for examination.

3.

Examine the cylinder head for damage and
distortio. Inspect the valve seat inserts
damage. Seat inserts that are beyond repair
and require renewal should be replaced by a

of

skilled specialist in this type

4.

Examine each valve guide and valve stem

work.

wear and damage. Suspect guides should be
checked
guide and

mm clear

rock

head movement exceeds

by

inserting a new valve into the

with the valve lifted approximatly

of

the seat the valve head should not

more than

0,15

mm

(0.006

0,15

mm

in).

(0.006

the guide should be renewed.

5.

inspect the valves

for

wear and damage. Valve
heads that are burnt and cracked should
renewed.

So

should valves which are bent and
distorted. Insert the valve into a new guide and
check the side movement as described above
to determine the wear on the valve stem.

Renew valve

6.

Support the cylinder head, combustion
chamber uppermost on pieces

guides

of

timber
sufficient thickness to allow clearance
inlet

or

exhaust for the valve guides to be

driven out using special tool

R0274400.

..

.

.

oil

for

for

If

the valve

in)

be

of

for

the

DEFENDER

8

Reface

valve seat inserts

8.

The special set

for

refacing include expandable pilots that fit
tightly into new
the valve seat
guide. The refacing

of

hand

tools

recommended

or

worn guides

is

concentric with the valve

tool

has tungsten carbide

to

ensure that

cutters and can be used to cut a new seat in

is

the insert. The valve seat cutter

MS621,
MS150-8.

Loosely assemble the pilot in the sequence

9.

the handle set

MS76B

numbered

and the pilot

illustrated. Ensure that the chamfered end
the expander

is

towards the collet.

.c

1',

Q

q.,

of

7.

Turn the cylinder head

combustion face

over

so

is

downwards. Lubricate the
new valve guides and using special service
LST

130

and depth gauge

RO

the guide into position to the depth

determined

gmge

d

?9,0

by

the

in).

74

\

that the

60774A

rrm

ST2598M

tool

press

(0.748

U-

ST2644M

DEFENDER

ENGINE

12

.I

,..._.

r..

;..

.......

.i,....*

.:,*,

..,.

2

.L,._

..U

.;,

.

,,.;.

10. insert the assembled pilot into the valve guide

of

from the combustion chamber side

the

cylinder head until the shoulder contacts the

valve guide and the whole

the collet

is

of

inside the guide. To lock the pilot in the guide
turn the

tommy bar clockwise whilst holding

the knurled knob.

Valve

refacing

14. Valves that are satisfactory

for

further service
can be refaced. This operation should be
carried out using a valve grinding machine.

of

Only the minimum
removed from the valve face

of

the valve edge. The valve

material should be

to

avoid thinning

is

refaced

correctly whan all pits are removed and the

ST2670M

11.

Check that the seat cutter MS621 is assembled

key

correctly using the
angled end
and set

of

each cutter

so

that the middle

contacts the seat first. One end

45

"

angled at

and the other end

MS76 ensuring that the

is

towards the seat

of

the blade

of

the cutter is

is

30".

is

face
Inlet valve seat face

concentric with the stem.

-

Exhaust valve seat face
Inlet valve face

Exhaust valve face

-

-

-

30"

45

30"

45

+

0,25"

"

+

0,25"

-

0,25"

"

-

0,25"

ST2645M

12. Using

very

light pressure tum the cutter

clockwise until the angled face

is

approximatly

01,s mm wide.

13.

To

check the effectiveness

operation smear a small quantity

,,

I.

blue round the valve seat and revolve a
correctly ground valve against the seat.

of

the cutting

of

engineers'

A

good
seating will produce a continuous fine polished
line around the valve face.

12

more than

mm in

A

slight gap

the

polished line, can be

of

not

corrected by lapping.

75

E[

ENGINE

e

DEFENDER

Lapping

15.

16.

17.

18.

19.

20.

valves

To

ensure a
face and valve seat it
appropriate valve to its seat. It
keep the valve identified with its seat once the

lapping

Unless the faces to be lapped are in poor

condition
fine valve lapping paste.
Smear a small quantity

face and lubricate the valve stem with engine

oil.

Insert the valve in the appropriate guide
and using a suction type valve lapping tool
employ a light reciprocating action while
occasionally lifting the valve
turning it
different position on the seat.

Continue the operation until a continuous matt
grey band round the valve face

check that the lapping operation

off

wipe
seat and make a series
the valve face.

Insert the valve into the guide and while

pressing the valve onto the seat revolve the
valve a quarter
pencil lines are cut through no further lapping
is necessary. Thoroughly wash the cylinder
head ensuring no lapping paste remains before
fitting the valves.

Position the cylinder head with the combustion
face uppermost, lubricate and insert the valves
into their respective guides. To check the valve
head stand
the valve head below the combustion face, use
either a dial test indicator

feeler

and
Hold the straight edge across the centre
each valve in turn and measure the gap
between the valve head and straight edge. The
correct dimension should be

040

to
gauge on the combustion face then move the
stylus across to the valve head and note the
reading.

gas

tight seal between the valve

is

necessary to lap-in the

is

essential to

-

in operation has been completed.

it

should only be necessary to use

of

paste on the valve

off

its seat and

so

that the valve returns to a

is

obtained.

is

sucessful,

the valve paste from the valve and

of

pencil lines across

of

turn a few times.

-

down

or

the correct dimension

or

a straight edge

gauge

0.035

as

follows.

in). Using a dial gauge zero the

1,l

to

If

all the

0,9

of

mm

To

of

(0.

.

.

.-.

__

-.

-

ST2585M

Assembling valves

21.

Insert the valves to their respective guides and
locate a spring protection washer
guide. Fit new

with the garter spring uppermost. Ensure that

the seals fully locate on valve guides.

I

!

to

oil

-

I

I

cylinder head

over

seals to all the valve guides

.

each

76

e

DEFENDER

ENGINE

12

.

L.

..

.

.

'.::::Y:..

.,

...

;:.:it

.

. ..

.

.

...,

22.

Fit

. .

a spring and cup to each valve and

compress with special service tool

MS1519A

or

a suitable altemative. Retain with the
multi-groove cotters ensuring that they are

fully located in the valve stem and cup.

25. The thermostat housing may be removed from
the cylinder head at this stage and

if

necessary

the gasket renewed.

26. The

"

jiggle pin" which allows any air to escape
from below the thermostat, may be fitted in
any position. Renew the gasket when fitting
the thermostat and apply a little Hylomar

sealant

to

the threads

of

temperature sensor

and transmitter before screwing into position.

FITTING

Piston protrusion and gasket selection

Before

CYLINDER

HEAD

fitting the cylinder head, the protrusion

of

the pistons above the block face must be checked
in order that the correct thickness gasket may be
selected from the range

three. The height

of

all

of

the pistons above the cylinder block must be

of

measured and the thickness

is

based upon the largest value

illustrated. This dimension, however, must not

0,8

exceed

mm (0.032 in).

-

_.

_-

the gasket selected

of

dimension

-

'A',

as

Thermostat and housing

If

necessary remove the temperature

23.
transmitter and temperature sensor from the
housing.

24.

Release

the three bolts securing the thermostat
cover and lift out the thermostat. The
thermostat may be tested by immersing it in

of

hot water

a known temperature and
comparing its operation with the temperature
range stamped on the flange. Any leakage

wax

(which
around the
indicates that it
renewed.

is

the colour

center pin

is

faulty and should be

of

copper) from

of

the thermostat,

n

of

Al

ST2646M

Three thicknesses

size can be recognised by the number
identification holes punched in the side

as

gasket

details

illustrated. The table below gives the

of

the gaskets available. The thickness
gasket fitted can
fitted since the identification holes can
protruding from the right hand side

towards the rear.

Number

of

holes Metric Imperial

of

gasket are available and each

be

seen when the cylinder head

of

I

I

of

of

the

of

be

seen

the engine

Gasket

is

ST3022M

ERR0382

~

0.70

2

to

0.61

0.80

3

to

0.71

0.024

to

0.0275

0.0279

to

0.0314

ERR038

ERR0384

77

ENGINE

e

DEFENDER

Clean the cylinder block combustion face and

turn the crankshaft

number four pistons are at

so

that number one and

.

D.C.

Use a dial

test indicator to determine the highest travel

of

the piston then

zero

the gauge and move
the stylus over to the cylinder block and note
the reading. Repeat the procedure on the
remaining pistons. The highest figure obtained

will determine the gasket selected.

ST2581M

2.

Place the selected the head gasket in position
on the cylinder block

so

that the identification
holes are towards the rear on the right-hand
side.

2

Bolt sizes:

M1

0

locations

M12

locations

16,

17,

18

ST2619

M

5. Attach the special service

LST122

to

3,

5,

1,

12 and

2,

4,

6:

7,

tool

13

8,

9,

degree

10,

a power bar. Make a suitable pointer

from welding rod and attach it to a bolt

screwed into a

6.

Tighten all the bolts

60

"

strictly in the sequence illustrated.

is

bolt

tightened scribe a line across the head

with a piece

rocker

of

chalk or crayon to identify

shaft securing bolt hol.

down

through an angle

which bolts have been tightened, then tighten

60

"

each bolt a further

again in the correct

sequence to complete the tightening

of

procedure. Re-positioning

no doubt,

CAUTION:

torquing procedure
no account should the total angle
be performed in one operation otherwise

damage and distortion

may occur.

be

necessary to reach all bolts.

It

is

important that the double

is

the pointer

observed and that on

of

of

the cylinder head

1Ii 14, 15,

disc

of

As

each

will,

120

"

3.

Clean the cylinder head face and
guide studs may
to facilitate the lowering

be

fitted

to

of

if

the cylinder

the head into
position. Locate the head over the
dowels.

4.

Lubricate the threads
oil,

and fit to the positions illustrated

of

new bolts, with light

according to length and diameter. Tighten the

so

bolts down
contact with the cylinder head.

sequence shown, tighten
40

Nm

with a suitable torque wrench.

78

that the heads just make

Now,

all

the

holtr

preferred,

block

two

in the

down

tc!

4!83

OVERHAUL ROCKER SHAn

DEFENDER

Push

rods

ENGINE

12

1.

Remove the five rocker shaft retaining bolts

and withdraw the bearing caps,

washers and springs from the shaft.

2.

Examine

if

the bearing surface
Check also that
Inspect

3.

worn. It is
attempt to reclaim rockers.

4.

Renew the bushes

0,127
ensuring that the pre
those in the rockers and machine the inside
bore
arm and bush
cross section illustration.
Examine the tappet adjustment screws and

5.

*

check that the ball end
and that
Assemble the rockers, bearing caps, new

6.

springs and washers
the washers are fitted. Hold the assembly

together with

bolts.

the

the

rockers and discard

not

mm

(0.005

of

the bushes

the

rocker shaft for wear and discard

is

wom, scored

the

oilways are clear.

permissible

if

the clearance exceeds

in). Press in replacements

-

drilled holes align

to

18,018 mm. The rocker

oil

drillings are shown in the

is

lubrication hole is clear.

to

the shaft noting where

the

five

rocker shaft retaining

rockers,

if

the pads are

to

grind pads

not worn

or

or

pitted.

in

an

with

pitted

1. Examine the push rods and renew any that
bent

or

where the ball

or

pitted.

2.

Fit the push rods

-

the ball
camfollower slide.

FlITlNG

1.

Ensure that a new cap is fitted
stem before fitting the rocker shaft.

2.

Fit the
ensuring that the retaining bolts and push rods
are correctly located then evenly tighten

bolts

end locates properly in each

ROCKER SHAIT

rocker

to

shaft to the cylinder head

correct torque.

or

cup ends are worn

to

the engine ensuring that

to

each valve

5

are

the

ST3131M

ST3129M

79

.

ENGINE

12

Adjust tappet clearances

WARNING

excessive valve clearances, it is possible that
the push rods may become dislodged from
the tappet seating and fracture the tappet
slide.

If

the crankshaft

is

rotated with

To prevent damage, eliminate all clearance from any

loose

rockers before tuming the crankshaft to adjust

clearances.

1.

Tum the engine over until number eight valve

of

(counting from front

2.

Using a

0,20

the clearance

engine)

mm

(0.008

of

number one valve.

in)

is

feeler

fully open.

gauge adjust

a

Test

procedure crankcase ventilator

2.

With the unit removed from the

off

the

two

seal
vacuum to the third por.

is

operated the diaphragm valve will be heard

ports illustrated and apply a

DEFENDER

As

the vacuum pump

to seat. While holding the vacuum unseal
either
valve will

3.

Failure

of

the other

two

ports and the diaphram

release.

of

the diaphragm valve to seat during
test, indicates that the diaphragm
and the unit should be renewed.

4.

Refit

the unit using a new rubber

rocker

is

punctured

"0"

ring.

cover

Continue to adjust the remaining tappets in the
following sequence:

Set

No.

3

Set
Set
Set
Set
Set
Set

Rocker

7.

If

the
the

tappet with

No.

5

tappet with

No.

2

tappet with

No.

8

tappet with

No.

6

tappet with

No.

4

tappet with

No.

7

tappet with

cover and crankcase ventilator

necessary

oil
side

release

separator ventilation valve unit, from

of

the rocker cover and thoroughly

No.

6

valve fully open.

No.

4

valve fully open.

No.

7

valve fully open.

No.

1

valve fully open.

No.

3

valve fully open.

No.

5valve fully open.

No.

2

valve fully open.

the single bolt and remove

clean.

Its function
ventilation atmosphere, allowing the
the sump and the residues to

is

to separate the

oil

from the crankcase

oil

to retum to

be

drawn into the

combustio:! chamber where they are bumed. The

unit also contains a diaphragm valve which controls

of

the purge rate

operation

of

the crankcase fumes. The

the valve may

be

tested

as

follows.

Fitting

rocker

5.

Apply a continuous bead
starts and finishes

cover

10

moon grooves at both ends

of

RW

Hylosil which

mm each side

of

the rocker shaft

and press the seals into position.

6.

Locate a new seal in the rocker cover and fit

the

cover

to the cylinder head securing with
the three special bolts and conical washers.
Tighten the bolts evenly to the correct torque
and reconnect the ventilation hoses.

of

the half

&

-

E

."-*I

"

80

-

-..

.

..,..

.

...

..

42%D

DEFENDER

n

4.

Fit

the banjo-union end

of

to the rear

the injector pump and secure

with a copper washer each side

of

the

ENGINE

spill

return rail

of

the banjo

12

and the union bolt.

ST2948

M

FIITlNG HEATER PLUGS

1.

If

necessary check the operation

of

each

heater plug before fitting and tighten to the

-

is

fitted

tighten.

so

that

.

..

,

,

,

correct torque, do not over

2.

Connect the electrical harness to the plugs and
secure with the single nut and washer. Ensure
that each spade terminal
neither the terminal nor the insulation touches

oil

the cylinder head, or

separator.

FllTlNG INJECTORS AND

1.

Ensure that the injector and seating in the

PIPES

cylinder head is clean then lightly grease a new
copper washer in position on the injector.

2.

Fit

the injectors with the spill return outlet

of

facing towards the rear

the engine and
secure each with a clamp and nut. The clamps
are slightly curved and the convex

side

be fitted uppermost. Tighten the nuts to the
correct torque.

3.

Fit the spill return rail to the injectors, noting

two

that there are
must be fitted each side
screw. The in
in the injector.

copper washers and one

of

the retaining union

-

board washer locates in a recess

Do

not over-tighten the screws.

should

5.

Fit the injector fuel supply pipes securing each

of

end

loosely, then tighten evenly.

the pipes to their respective locations

Do

not,

over-tighten.

Commencing at the front

the pipes as

A.

B.

C. To number

D.

follows:

To number 1 injector.

To number 2 injector.

3

To

number 4 injector.

of

injector.

the engine connect

however,

81

19

...

FUEL

FUEL

INJECTION PUMP

SYSTEM

a

DEFENDER

Service

Remove and refit

Special tools:-

4.

5.

7.

Repair

Flywheel timing pin LST 128
Pump gear retaining tool LST

Pump timing pin LST 12912

1.

Remove the bonnet and disconnect the
battery.

2. Drain the cooling system.

3.

Remove the fan and viscous coupling assembly

see

operation 26.25.19
Remove the fan cowl
Disconnect the lower cooling hose from the

waterpump.

6.

Remove the
number one cylinder valve
to assist in obtaining T.D.C.

Tum the crankshaft
the crankshaft damper with the the web on the
front cover plate. At the same time check that
the valves

No.

19.30.07

12911

see

operation 26.25.11.

oil

filler cap

of

number one cylinder are closed.

so

that the position

rockers

to

align the T.D.C mark on

can be seen

of

9. Remove the injector pump hub blanking plate.

10.

Insert the injector pump timing pin LST 12912
Through the
into the pump body. Ensure that the pin fits
easily and

"U"

shaped slot in the pump hub

is

fully inserted.

ST3044M

8.

Remove the blanking plug from the bottom
the flywheel housing

128. Check that the pin can be inserted into

the appropriate slot in the flywheel. Note that

two

there are

narrowest one being that which determines

T.D.C.

for

slots in the flywheel the

this engine.

and

fit the timing pin LST

of

/

LST

129/2

Continued

82

e

DEFENDER

FUEL

SYSTEM

19

.

11. Slacken the pump locking screw and remove
the keeper plate. Tighten the screw to

pump.

CAUTION:

inserted and the pump shaft locked,

attempt must be made
crankshaft.

Once the timing pin

to

rotate the

LST

lock

129/2

no

the

is

14.

Remove the injector pipes and disconnect the
following items from the injector pump.

Throttle cable.
stop control solenoid lucar.
Spill return pipe.
Turbo charger boost hose.
Main

fuel

supply pipe.

15.

Remove the injector pump rear support
bracket.

16.

Remove the
bolt to allow clearance for the pump to be

withdrawn.

oil

filter adaptor rear attachment

12. Remove the pump drive gear three retaining
bolts and remove the
pin.

13. Fit the pump gear retaining tool
align and tighten the

LST

timing pin
provided in the retaining tool.

ST3037M

129/2, again, through the hole

lock

plate and timing

two

bolts. insert the

LST

129/1 and

17.

Remove the pump three retaining nuts and

withdraw the pump and gasket, with

18.

Fit blanks to the inlet and outlet ports to

of

prevent entry
screw,
screw.

fit

the keeper plate and tighten

dirt. Slacken the locking

LST

the

12912

83

FUEL

19

Reff

iting

Clean the pump flange and front cover mating

19.
face and place a new gasket in position over
the the studs.
Fit the timing pin LST

20.
necessary, rotate the pump to enable the pin
easily and fully.

21.

Slacken the pump locking screw, remove the
keeper plate and tighten the screw to

pump-

SYSTEM

129/2 to the pump,

-

ST3043M

22.

Fit the pump to the front
and secure with the three nuts tightening
evenly to the correct torqu.

23.

Fit the rear support bracket to the cylinder
block and secure the pump to the bracket.
Tighten all bolts the the correct torque.

24.

Fit the
Connect the items listed in instruction

25.

Fit the injector supply pipes securing each end

26.

to

their respective locations, loosely then
tighten evenly but
Commencing at the the front
connect the pipes

A

to number one injector.

B

to number

C

to number three injector.

D

to number four injector.

21

oil

filter adaptor rear attachment bolt.

do

as

two

injector.

20

cover

and drive gear

not over tighten.

of

the engine

follows:

-

lock

14.

if

the

DEFENDER

Remove the pump timing pin and the pump

27.
gear retaining tool

insert the pump timing pin again and fit the

28.
gear

lock

plate and secure with the three bolts

and tighten

Remove the timing pin. Unlock the pump, fit

29.

keeper

the

To

30.

31.

32.

33.

check that the pump timing
the crankshaft
check that the timing pin LST
inserted easily and fully into the pump. at the
same time check that the flywheel timing pin
can also be inserted in the flywheel slot.
If,

with the flywheel timing pin located, the
timing pin cannot be inserted cleanly into the
pump,

Turn the crankshaft the small amount necessary

1.

to

enable the timing pin to be inserted into

the pump.

2.

Remove the

Slacken the three pump gear retaining bolts.

3.
Tum the crankshaft

4.
Check that the timing pin

5.

pump and that the flywheel timing pin locates.
Tighten the pump gear retaining bolts to the

6.

correct torque.

7.

Unlock the pump, fit the keeper plate and
tighten the bolt. Remove the timing pin from
the the pump and the timing pin tool from the
flywheel.

Fit the pump aperture cover with a new gasket
and secure with the screws.
Connect the cooling system bottom hose to
the waterpump.

to

plate and tighten the bolt.

carry out the following instructions:

LST

129/1.

the correct torque.

two

complete revolutions and

129/2 can be

keeper

plate and

to

T.D.C.

is

lock

an easy fit in the

is

correct, turn

the pump.

-

84

Continued

e

DEFENDER

FUEL

SYSTEM

119

I

/p:+

,”

,

,,....

--

,::-

..

.....

......

~:

..

.

,

.

34. Place the fan cowl in position but

35. Fit the fan and viscous coupling assembly to

36. Secure the fan cowl to the radiator with the

37.

38.

AIR

Service Repair

.

Remove

do

secure it to the radiator until the fan and

is

coupling

the waterpump spindle. Tighten the
thread to the correct torque using a

fitted.

left

Tommy

bar in the hole provided in the fan pulley to
restrain the coupling.

two

nuts.
Fit the top coolant hose.

Refil

the cooling system with the correct

concentration

of

water and anti-freeze see

operation 26.10.01.

CLEANER

No.

19.10.01

and

refit

1.

Disconnect the hose from the turbo charger

compressor housing to air cleaner.

2.

Disconnect, from the air cleaner, the engine

breather hose.

3.

Disconnect from the air cleaner, the air inlet

not

hand

7.

Unscrew the wing nut and withdraw the

element.

8.

Clean the interior

9.

Fit a new element, fins leading, into the casing.

of

the casing and cover.

10. Secure the element with the wing nut.

11. Fit the end cover and aline the two arrows.

Refitting

5.

To release and remove the air cleaner from its
mounting cradle, twist the body
cleaner anti
front

-

clockwise (viewing it from the

of

the engine) and remove it from the

of

vehicle.

Renewing element

the air

12. The

clips on the side

of

the casing locate

two

in the square slots in the air cleaner mounting
cradle.
cleaner

necessary therefore, to twist

clockwise

into its final position and

the

It

is

ensure that the clips engage in the slots.

13. Secure the air cleaner with the two fastners.

14.

Connect all the hoses, reversing instructions

to

3.

15.

Finally, reset the element change indicator,

where fitted, by depressing the button.

air

1

6.

Unscrew

the

handwhee! anti-c!nckwise

remove the end cover.

and

ST3036M

12’

85

19

FUEL

SYSTEM

DEFENDER

TURBO

Service Repair

Remove

10.

11.

12.

CHARGER

No.

19.42.01

and

refit

1.

Remove the bonnet and disconnect the
battery.

2.

Remove the turbo charger heat shield.

3.

Disconnect the exhaust front

turbo charger

4.

Release

support bracket attached to the cylinder

5.

Remove the five nuts and remove the elbow
from the turbo charger.

6.

Remove the air inlet hose from the air cleaner
and turbo charger.

7.

Disconnect, from the turbo charger, the
bottom hose from the intercooler.

8.

Remove the boost pressure pipe from the

"T"

turbo

9.

Slacken the turbo charger
Disconnect the
charger centre housing.

Release

turbo charger.

Remove the four nuts and lift the turbo

charger from the exhaust manifold and retrieve

the steel joint washer.

elbow.

the front exhaust

piece.

oil

supply

the

oil

return drain

pipe

from the

pipe

from the

oil

feed pipe clamp.

pipe

from the turbo

pipe

from the

block.

e

,

.:

'.'

Refitting

13.

Fit the steel joint washer to the to the exhaust
manifold

86

Gl%B

DEFENDER

14. Fit the turbo charger and secure with the four
nuts and tighten evenly to the correct torque.

oil

feed

15. connect the

turbo charger and tighten the

16. Connect the boost pressure pipe to the

piece and secure with the

and retum pipes to the

feed

pipe

clamp.

"T"

clip.

17. Connect the intercooler hose to the turbo
inlet.

18. Fit the hose to air cleaner and turbo charger.

19.

Fit the turbo charger elbow.

20. Connect the exhaust front pipe to the elbow

Holts "Firegum" to seal the joint.

using

two

21. Fit the heat shield and secure at the

fixing

points.

22.

Fit the bonnet and connect the battery.

INTERCOOLER

FUEL

SYSTEM

..1:;::

...

.>.:.

..

Service

Repair

No.

19.42.15

Remove, clean and refit.

1. Remove the fan and viscous coupling

see

assembly,

2. Remove the fan cowl,

3.

Disconnect the top and bottom hoses from

operation 26.25.1

see

9.

operation 26.25.11.

the Intercooler.

4.

Remove the four bolts

(two

each side)

retaining the radiator top support brackets.

5.

Remove the four bolts

(two

each end) securing
the radiator surround top panel, and remove
the panel.

6. Lift out the Intercooler.

Cleaning.

7.

Flush the intercooler with ICI "GENKLENE"
propriety cleaner, following the manufacturers
instructions.

8.

Dry

the Intercooler completely ensuring that

no

liquid remains in the element.

Refitting.

9.

Slide the htercooler into position taking care
not to damage the insulation material on the
sides.

10. Fit the radiator surround top panel and secure
with the four bolts.

11.

.

,

,.

.

...

Fit the

four

two

top brackets and secure with the

bolts.

12. Connect the top and bottom hoses.

13. Fit the fan

14.

Fit

the fan and coupling assembly.

cowl.

ST2928M

I

.i

.

:.

.$!

.

..

...

.

!,

87

COOLING

SYSTEM

DEFENDER

COOLING
Engine protection

To prevent corrosion
vital that the cooling system

of

clean water and anti-freeze winter and summer.

Never

-

freeze. Never use salt water otherwise corrosion

anti

SYSTEM

of

aluminium engine parts it

is

filled

with a solution

fill

or top-up with water only. always add

will occur. In certain territories where the only

available water supply may have some salt content,
use only clean rain water or distilled water, with

-

freeze added.

anti

Use only Universal anti

-

freeze or permanent type

ethylene base, without methanol, containing, a

for

suitable inhibitor
one part

Anti

is

not necessary.

Anti

of

anti-freeze to one part water.

-

freeze should be used even in climates where it

-

freeze can remain in the cooling system and
will provide adequate protection
provided that the
checked before the onset

-

topped

up with new anti- freeze

aluminiium engine parts.

for

two

specific

gravity

of

of

the coolant

the second winter and

as

required.

Use

years

is

Refilling.

5.

Make up a solution

is

a separate container in the concentration
required.

To

allow

of

anti-freeze and water in

for

topping-up, and for

filling the expansion tank, prepare a quantity in

of

excess

6.

Remove the radiator

radiator until the coolant level

filler

7.

Fill

the expansion tank

the cooling system capacity.

filler

cap and

neck and refit the cap.

to

approximately half

fill

the

is

just below the

full and refit the cap.

8.

Connect the battery and run the engine until
normal operating temperature

Allow

the engine to

cool

removethe radiator and expansion tank caps.

is

attained.

completely and

If

necessary, top-up the the radiator to just

-

below the filler neck. Top
tank to about half full. Fit both

up the expansion

filler

caps.

Land Rovers leaving the factory have the cooling

filled

system

with a
gives protection down to minus
Centigrade (minus

50%

anti- freeze mixture. This

47

degrees

53

degrees Fahrenheit).

After the second winter the system should be
drained and thoroughly flushed.

-

freeze examine all joints and renew defective

anti

Before

adding new

hoses to make sure that the system is leak proof.

09

for

See section

Service Repair No.
Drain and

1.

2.

refil

WARNING:

expansion tank filler cap when the engine

hot because the cooling system
pressurized and personal scalding could
result.

Disconnect the battery.

Disconnect the bottom coolant hose from the

protection quantities.

26.10.01

Do

not remove the radiator

or

is

radiator. Allow to drain and reconnect the

hose.

3.

To

drain the cylinder block, remove the drain
plug which is situated on the left hand
the engine immediately below front

side

core

plug.

Refit the plug, with a new washer, when the

is

draining

4.

To

drain the expansion tank, remove the cap

completed.

and disconnect the expansion hose from the
radiator and allow it to drain into a suitable
container. Flush the tank with clean water and
reconnect the hose.

of

is

ST3032M

.

\-

_

,’

\-

88

G83

FAN

COWL

DEFENDER

COOLING

SYS

TEM

26

Service Repair
Remove and refit.

1. Follow instructions 1 to 7 operation 26.25.19.

2. Remove the cowl from the engine

compartment.

Refitting.

3.

Reverse instructions 1 and 2.

FAN

AND COUPLING

Service Repair
Remove and refit.

1.

Disconnect the battery for safety reasons.

2. Drain the coolant by disconnecting the radiator
bottom hose and reconnect when coolant has
drained.

3.

Remove the top hose.

4.

Using a cranked open ended spanner and a
restraining bar in the hole in the pulley hub,
release anti
from the water pump spindle.
and coupling assembly into the base

cowl.

5.

Remove the

radiator.

No.

26.25.11

ASSEMBLY

No.

26.25.19

-

clockwise, the viscous coupling

Lower

the fan

of

two

nuts securing the cowl to

the

the

Refitting

8.

Insert the fan and coupling into the base

the cowl reversing the removal procedure.

9.

Fit the coupling to the water pump spindle
noting that it has a left hand thread. Tighten
the coupling using the restraining bar and
cranked spanner.
Fit the cowl and secure with the

10.
Ensure that the cowl fits properly in its lower
location.
Fit the top hose and refill the cooling system

11.

with the correct concentration
and water.

12.

Connect the battery, run the engine and check

for

coolant leaks.

two

of

anti-freeze

of

nuts.

6.

Lift

the cowl to

location.

7.

Move the cowl forward, towards the engine

236

ii4ihbixi

from the gap created between the
radiator.

release

the

faii

it

from its lower

aiid

coiipling

ii~~e~bly

cowl

and

89

RADIATOR
Service Repair
Remove

1.

2. Remove the fan

3.

4.

5.

6.

and

Remove the fan and viscous coupling
assembly,

Disconnect the hoses from the intercooler.
Disconnect the expansion tank hose from the
radiator.
Disconnect the
radiator and cover the ends

dirt.

Disconnect the bottom hose from the radiator.

No.

26.40.01

refit

see

operation 26.25.19.

cowl,

oil

cooler pipes from the

see

operation 26.25.11.

to

prevent entry

of

7.

Remove the four bolts,
retaining the radiator top securing brackets,
and remove the brackets.

8.

Lift out the radiator complete with the
intercooler.

two

each side,

4;--

9.

Check that the rubber grommets on the
radiator locating pegs and beneath the radiator
mounting brackets on the chassis cross

in

member are

10. Lower the radiator into position ensuring that
the pegs locate in the mounting brackets.

position.

lO----;-ii;LT

-

ST3033M

11.

Fit

the radiator top mounting brackets and

secure with the four bolts.

12.

Connect

13. Fit the oil cooler pipes to the radiator.

14.

Connect the expansion tank hose.

15. Connect the top and bottom hoses to the

intercooler.

16.

Place the fan cowl in position but do not
secure at this stage.

17. Fit the

cowl with the

18.

Check that all the coolant hose
and refill the cooling system with the correct
concentration
operation 26.10.01.

the

radiator bottom hose.

fan

and viscous coupling and secure

ZI

two

nuts.

of

water and anti-freeze,

clips

are tight

see

the

91

.

26

C

O

O

L

I

N

G

S

Y

S

TEM

DEFENDER

WATER

Service Repair

Remove and refit

PUMP

No.

26.50.01

Remove the fan and coupling assembly

1.
operation 2. 25.19.

cowl

Remove the fan

2.
Slacken the fan belt tension and remove it

3.
from the pulley.
Remove the four bolts securing pulley to hub.

4.

operation 26.25.11.

1

Refitting

Clean the water pump and front cover plate

9.
mating faces.

10.

Lightly grease a new gasket and place in

cover

position on the
Clean the threads

11.

bolts and apply Loctite 572 thread lubricant
sealant to the threads

12.

Fit the pump
the six bolts and one nut in accordance with
the chart below. Tighten the fixings evenly and
to the correct torque.
Connect the bottom hose to the water pump.

13.

14.

Fit the pulley to the water pump hub and
secure with the four bolts.
Fit and tension the water

15.
Fit the fan cowl.

16.
Fit the fan and coupling assembly.

17.

Check that all the coolant hose clips are tight

18.

refill

and
concentration
operation
Connect the battery, run the engine and check

19.

for coolant leaks.

to

the cooling system with the correct

of

26.10.01.

plate.

of

the water pump retaining

of

all the bolts.

the engine and secure with

pump/aiternator belt.

water and anti-freeze, see

re

5

%.

v

.,

Remove the thermostat housing to water

5.

pump hose.

6.

Disconnect the bottom hose from the water

pump-

Remove the

7.

water pump to the front cover plate.

8.

Remove the water pump and gasket.

six

bolts and one nut securing the

92

DEFENDER

EXHAUST

Service Repair
Remove and refit

Note:
mainifold must

1.

2.

3.

4.

5. Disconnect from the turbo charger, the

6.

AND

INLET

No.

to

remove the inlet manifold, the exhaust

Disconnect the battery.
Remove the air cleaner
hose from the turbo charger.
Disconnect hose from turbo charger to

intercooler.

Remove the turbo charger heat shield.

feed

pipe.
Disconnect the front exhaust pipe from the
turbo charger elbow.

MANIFOLDS

30.15.01

be

removed first.

to

turbo charger inlet

oil

M

A

N

I

FOL

D

S

AND

7.

Release the front exhaust pipe bracket from

the cylinder block.

8.

Disconnect the front exhaust
forward silencer pipe.

9.

Release

manifold studs.

10. Disconnect the boost pressure
turbo charger.

11. Disconnect the turbo charger
from the cylinder block.

12. Remove the exhaust
withdraw the manifold complete with the
turbo charger.

the heater rail from the exhaust

mainfold nuts and

EXH

pipe

pipe

oil

A

drain pipe

U

S

T

130

from the

from the

I

ST2938M

Inlet manifold

13. Disconnect hose from inlet manifold

two

14. Remove the
withdraw the inlet manifold.

15. Remove the common gasket.

bolts and

two

nuts and

Continued

93

-

301

MANIFOLDS

Ref

ittng

Place a new gasket in position and fit the inlet

15.

manifold and secure with the

two

nuts and tighten to the correct torque.

Fit the exhaust manifold complete with turbo

16.

charger and secure with the nuts.

Fit the heater rail to the manifold studs.

17.
Connect the turbo charger

18.

the cylinder block.
Connect the boost pressure pipe to the turbo

19.

charger.
Using

20.
exhaust pipe to the turbo charger elbow and
secure with the clamp. Note, before fitting the
pipe to the elbow make sure that the securing
clamp
will not
manifold.
Connect the front pipe to the forward silencer.

21.
Fit

22.
cylinder
Connect the turbo charger

23.

Fit the intercooler to turbo charger hose.

24.

Fit the air cleaner to turbo charger hose.

25.
Fit the turbo charge heat shield.

26.

Connect the battery, run the engine and check

27.

for

"HOLTS"

is

above the inlet manifold since the clip

pass

-

the front pipe support bracket to the

block

exhaust

gas

AND

"FIRE

between the front pipe and

with the single bolt.

leaks.

EXHAUST

oil

GUM

"

fit

oil

two

bolts and

drain pipe to

the front

feed pipe.

DEFENDER

94

DEFENDER

STEERING

n

57

"-

,

".

'.

2-

POWER STEERING
Service Repair No.
Remove and refit

1.

Working from beneath the vehicle,
drive belt tension by slackening the

PUMP

57.20.14

release

two
adjustment clamp bolts and the single pivot
bolt and remove the belt.

ST3050M

2.

Disconnect from the pump, the supply
from the fluid

reservoir

\y

1

and drain into a

suitable container.

3. Remove the banjo union bolt from the rear
the pump and allow fluid to drain into a
container.

4.

Remove the three bolts slackened in

1

instruction

and remove the pump complete

with adjustment plate and pulley.

5.

Remove the

four

bolts

to

release the drive

pulley from the pump hub.

6.

Since the adjustment plate can be fitted in

one

more than
the relationship

position on the pump, mark

of

the pump

to

the plate

before removing the four attachment bolts.

hose

the

of

Refitting

7.

Fit the adjustment plate

to

the pump aligning
the marks made when dismantling and secure
with the four bolts.

8.

Fit the drive pulley and retain with the four
screw.

9.

Fit the pump and adjustment plate to the
engine bracket and loosely secure with the

two

pivot bolt and

adjustment clamp bolts.

10. Fit the drive belt and lever the pump away
from the engine to tension the belt and

two

tighten the
bolt. The belt
the mid-point
thumb pressure

CAUTION:
against the pump'casing when tensioning
the drive belt since it will damage the
casing permanently, beyond repair.

clamp bolts and single pivot

is

correctly tensioned when, at

of

its run it can be deflected by

12"

Do

not apply any pressure

(.

5ins.)

11. Connect the fluid hose and secure with the
clip.

12. Fit the banjo bolt ensuring that a special steel

is

washer

13.

Top up the fluid reservoir with the correct

make and grade

fitted each side

of

fluid,

14. Run the engine and turn the steering from

of

the banjo.

see

section

09.

lock

to lock. Re-check the fluid level and the drive

belt tension.

1.

Pulley

2. Adjustment plate

3.

Pump

4.

inlet hose

5.

'0'

rings 10. Union nut

Also

examine

6.

Washer(specia1)

7.

Banjo

8.

Washer(specia1)

9.

bolt

for

fluid leaks.

ST3051

M

'1

95