1999 LAND ROVER DEFENDER check engine

ENGINE
1
ADJUSTMENT ENGINE OIL PRESSURE CHECK
Service repair no - 12.90.09.01
Check
1.Remove oil pressure switch.See Repair.
2.Connect pressure check kitLRT-12-052C
adaptor and gauge to oil pressure switch
position on oil cooler.
3.Check and if necessary, top-up engine oil.
4.Run engine at idle speed and check that oil
pressure is within limits given.
5.Switch off ignition.
6.Remove oil pressure check kitLRT-12-052C.
7.Clean oil spillage.
8.Fit oil pressure switch.See Repair.
Adjust
1.If engine oil pressure is not within specified
limits, check condition of oil pump and/or main
and connecting rod bearings.
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ENGINE
1
REPAIR CAMSHAFT
Service repair no - 12.13.02
Remove
1.Remove cylinder head gasket.See this
Section.
2.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
3.Disconnect multiplug from injector units and
remove harness from camshaft carrier.
4.Remove and discard multiplug’O’ring.
5.Loosen lock nuts and fully retract rocker
adjusting screws.
6.Progressively loosen then remove and discard 6
bolts securing rocker shaft, remove shaft.
7.Using sequence shown, progressively loosen
then remove 13 bolts securing camshaft carrier
to cylinder head.
8.Gently tap the camshaft carrier upwards to break
the sealant bond and remove carrier noting it is
located by 2 dowels.
9.Remove camshaft.
10.Remove and discard camshaft rear oil seal.
11.Remove and discard lock nuts and rocker
adjusting screws.
12.Check bearing surfaces in cylinder head and
camshaft carrier for signs of scoring and wear.
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12ENGINE
2
REPAIR
13.Position camshaft in camshaft carrier.
14.Check end-float of camshaft using a DTI.
Camshaft end-float = 0.06 to 0.16 mm (0.002 to
0.006in).
15.Renew components as necessary to achieve
correct end-float.
CAUTION: Cylinder head and camshaft
carrier are machined together as an
assembly. If bearing surfaces in either
component are found to be damaged, complete
assembly must be replaced.
NOTE: The procedure for checking
camshaft bearing clearances is covered in
Td5 Engine Overhaul section - Cylinder
head - overhaul.Refit
16.Using a suitable cleaning solvent, clean mating
faces of cylinder head and camshaft carrier.
17.Blow out all oilways and waterways.
18.Ensure threaded holes in cylinder head and
camshaft carrier are clean and dry.
CAUTION: Support each end of the
cylinder head on blocks of wood. With
camshaft carrier bolted down some valves
and the injector nozzles will protrude from the
face of cylinder head.
19.Fit new adjusting screws fully into rocker arms.
Fit new lock nuts to screws but do tighten.
CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P
to 19P have a centre punch mark adjacent to the
adjusting screw slot. These screws are not
interchangeable with those fitted to Engine Serial
No. Prefixes 10P to 14P.
20.Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with clean engine oil.
21.Position camshaft in cylinder head with the
timing pin hole in the vertical position.
22.Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face as shown and
spread to an even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate
camshaft bearings. Assembly and bolt
tightening must be completed within 20 minutes
of applying sealant.
23.Fit camshaft carrier ensuring that it is correctly
located on dowels.
24.Fit and lightly tighten camshaft carrier bolts.
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12ENGINE
10
REPAIR Refit
39.Clean mating faces of cylinder head and cylinder
block.
40.Check cylinder head for warping, across centre
and from corner to corner:
Maximum warp = 0.10 mm (0.004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head assembly if
warping exceeds figure given.
41.Ensure coolant and oil passages are clean.
42.Clean dowel holes and fit new dowels.
43.Fit new cylinder head gasket of the correct
thickness with the word’TOP’uppermost.
44.Using assistance, fit cylinder head and locate on
to dowels.
45.Carefully enter new cylinder head bolts together
with their captive washers,DO NOT DROP.
Lightly tighten bolts.
46.Using sequence shown, tighten cylinder head
bolts to:-
Stage 1 -30 Nm (23 lbf.ft)
Stage 2 -65 Nm (48 lbf.ft)
Stage 3 -90°
Stage 4 -Further 180°
Stage 5 -Further 45°
CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages. Do not tighten bolts 315°in one
operation.
47.Fit nut and bolt securing cylinder head to timing
chain cover and tighten to25 Nm (18 lbf.ft).
48.Clean camshaft sprocket and mating face on
camshaft.
49.Ensure engine is set to TDC No. 1 cylinder and
mark on camshaft sprocket is positioned
between the 2 coloured links.
50.Position camshaft sprocket to camshaft, fit and
lightly tighten new bolts then loosen bolts half a
turn.
51.Clean fixed guide retaining pin and apply Loctite
242 to threads.
52.Fit and tighten fixed guide retaining pin to25 Nm
(18 lbf.ft).
53.Clean timing chain tensioner and fit new sealing
washer.
54.Fit timing chain tensioner and tighten to45 Nm
(33 lbf.ft).
55.Tighten camshaft sprocket retaining bolts to36
Nm (27 lbf.ft).
56.RemoveLRT-12-058from camshaft.
57.RemoveLRT-12-158from gearbox bell housing.
58.Clean access plug recess in cylinder head and
fit new’O’ring. Fit access plug.
59.Clean vacuum pump union.
60.Tighten vacuum pipe union to10 Nm (7lbf.ft).
61.Fit bolts securing alternator bracket to cylinder
head and tighten to25 Nm (18 lbf.ft).
62.Connect top hose, heater hoses and secure with
clips.
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ENGINE
23
REPAIR FILTER - OIL
Service repair no - 12.60.04
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release clip and disconnect breather hose from
camshaft cover.
3.Release clips and disconnect air flow meter from
air filter.
4.Disconnect multiplug from air flow meter.
5.Loosen clip screw and remove air inlet hose
from turbocharger.
6.Remove 3 bolts and remove manifold heat
shield.
7.Clean area around filter head and place a
container beneath engine.
8.Using a strap wrench, unscrew and discard filter.
Refit
9.Clean mating face of filter head.
10.Lubricate sealing ring of new filter with clean
engine oil.
11.Fit filter and tighten by hand until it seats then
tighten a further half turn.
12.Start and run engine to check for leaks.
13.Stop engine, wait a few minutes, then check oil
level.
14.Top up engine oil.
15.Position exhaust manifold heat shield and
tighten 3 bolts.
16.Position air inlet hose to turbocharger and
tighten clip screw.
17.Connect air flow meter to air filter and secure
clips.
18.Connect air flow meter multiplug.
19.Connect breather hose and secure with clip.
20.Position engine acoustic cover.
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ENGINE
29
REPAIR VALVE - RELIEF - OIL PRESSURE
Service repair no - 12.60.56
Remove
1.Remove sump gasket.See this Section.
2.Remove and discard oil pressure relief valve
plug from oil pump housing.
3.Remove spring and valve.
Refit
4.Clean valve and spring.
5.Clean valve seating inside oil pump housing.
6.Lubricate valve and seating.
7.Fit valve and spring to pump.
8.Apply Loctite 243 sealant to threads of a new
plug.
9.Fit plug and tighten to23 Nm ( 17 lbf.ft).
10.Fit sump gasket.See this Section.
11.Check engine oil level, top-up if necessary.COOLER - ENGINE OIL
Service repair no - 12.60.68
Remove
1.Drain cooling system.See COOLING
SYSTEM, Adjustment.
2.Remove centrifuge assembly.See this
Section.
3.Remove clutch housing bolt and release coolant
pipe from rear of engine.
4.Release clip and coolant hose from oil cooler.
5.Disconnect oil pressure switch multiplug.
6.Remove oil filter element using a suitable strap
wrench.
7.Remove 3 bolts, remove oil filter adaptor and
discard gasket.
8.Remove 7 bolts, remove oil cooler and discard
gasket.
9.Remove oil pressure switch.
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ENGINE
5
OVERHAUL Refit
1.Thoroughly clean cylinder block and cylinder
head mating faces.
2.Ensure coolant and oil passageways are clear
and bolt holes are clean and dry.
3.Ensure locating dowel holes in cylinder block are
clean and dry.
4.Fit new plastic locating dowels in cylinder block.
5.Fit new cylinder head gasket of the correct
thickness with the word’TOP’uppermost.
CAUTION: Gasket must be fitted dry.
6.Ensure that camshaft timing pinLRT-12-158is
still in position and using assistance, fit cylinder
head.
7.Carefully enter new cylinder head bolts together
with their captive washers,DO NOT DROP.
Lightly tighten bolts.
CAUTION: Cylinder head bolts are
pre-lubricated and do not require
additional lubrication.
8.Using sequence shown, tighten cylinder head
bolts to:
Stage 1 -30 Nm (23 lbf.ft)
Stage 2 -65 Nm (48 lbf.ft)
Stage 3 -90
°
Stage 4 -Further 180°
Stage 5 -Further 45°
CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages. Do not tighten bolts 315°in one
operation.9.Fit cylinder head to timing chain cover nut and
bolt and tighten to25 Nm (18 lbf.ft).
10.Clean camshaft sprocket and mating face on
camshaft.
11.Ensure engine is set to TDC firing - No.1
cylinder.
12.Check that mark on camshaft sprocket is
positioned between the 2 coloured links on
timing chain.
13.Position sprocket to camshaft, fit and lightly
tighten 3 new bolts then loosen bolts half a turn.
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ENGINE
11
OVERHAUL
23.Remove 3 bolts and remove fuel connector
block from cylinder head.
24.Remove and discard gasket,’O’ring and fuel
filter.
25.Remove spacer block and gasket (if fitted).Cylinder head and camshaft carrier - cleaning
1.Thoroughly clean cylinder head mating faces,
ensure oil and coolant passages are clear and
bolt holes are clean and dry.
CAUTION: Take care to ensure that EUI
drillings are clear.
2.Using suitable solvent, remove all traces of
sealant and gasket material.
CAUTION: Do not use metal scrapers.
3.Remove all traces of oil from camshaft bearings
and journals.
4.Clean glow plug threads.
Cylinder head - Inspection
1.Check core plugs for signs of leakage and
corrosion, seal replacement plugs with Loctite
243.
2.Check cylinder head for warping across centre
and from corner to corner.
Maximum cylinder head warp =0.1 mm (0.004
in).
CAUTION: Cylinder heads may not be
refaced, replace the head assembly if
warping exceeds the limit given.
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