1999 LAND ROVER DEFENDER check engine

12ENGINE
12
OVERHAUL Lash adjusters and finger followers - Inspection
1.Check lash adjuster bores for scoring and signs
of wear or damage.
2.Check lash adjusters for signs of wear, scoring
and overheating, replace as necessary. Ensure
oil hole in each lash adjuster is clear.
CAUTION: Store lash adjusters upright
and in their fitted order.
3.Check finger followers for wear and that rollers
are free to rotate.
CAUTION: Store finger followers in their
fitted order.
Camshaft - Inspection
1.Check camshaft lobes and bearing journals for
signs of scoring and wear.
2.Check bearing surfaces in cylinder head and
camshaft carrier for signs of scoring and wear.
CAUTION: Cylinder head and camshaft
carrier are machined together as an
assembly, if bearing surfaces in either
component are damaged, both components must
be replaced as an assembly.Camshaft - Check end-float
1.Position camshaft in camshaft carrier.
2.Check end-float of camshaft using a DTI.
Camshaft end-float =0.06 to 0.16 mm (0.002 to
0.006 in).
3.Renew components as necessary to achieve
correct end-float.
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ENGINE
13
OVERHAUL Camshaft bearings - check clearance
1.Position camshaft in cylinder head.
2.Place a piece of Plastigage along the centre line
of each camshaft bearing journal.
3.Carefully fit the camshaft carrier ensuring it is
located on dowels.
CAUTION: Do not rotate camshaft.
4.Fit original camshaft carrier retaining bolts and
tighten in sequence shown to25 Nm (18 lbf.ft).
5.Using sequence shown, loosen then remove
camshaft carrier retaining bolts.
CAUTION: Do not discard bolts at this
stage.
6.Carefully remove camshaft carrier.
7.Measure and record widest portion of Plastigage
on each camshaft bearing journal.
8.Compare figures obtained with camshaft bearing
clearance.
Camshaft bearing clearance =0.04 to 0.10
mm (0.002 to 0.004 in).
9.If any bearing clearance is found to exceed
figures given, repeat the above procedure using
a new camshaft.
CAUTION: If, after repeating the bearing
clearance check with a new camshaft the
bearing clearances are still excessive, a
new cylinder head and camshaft carrier assembly
must be fitted.
10.Remove all traces of Plastigage using an oily
cloth, do not use a scraper.
11.Discard camshaft carrier bolts.
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12ENGINE
14
OVERHAUL Valve springs - Inspection
1.Check free length of valve springs:
Free length =47.0±0.25 mm (1.85±0.011 in)
CAUTION: Valve springs must be replaced
as a set, if springs are to be refitted, keep
them in their fitted order.
Valves and valve guides - Inspection
1.Clean carbon from valves, check valves for
burning, pitting or cracking; replace as
necessary.
2.Clean carbon from valve seat inserts, remove all
loose particles on completion.
3.Check valve seat inserts for pitting and burning.
CAUTION: It is not permissible to recut or
replace valve seat inserts.
4.Remove carbon deposits from valve guides
using toolLRT-12-186.
CAUTION: Tool must be inserted from
combustion chamber face side of cylinder
head, ensure all loose particles of carbon
are removed on completion.
5.Check and record diameter of each valve stem.
Valve stem diameter:
Inlet = 6.907 to 6.923 mm (0.2719 to 0.2725 in)
Exhaust = 6.897 to 6.913 mm (0.2715 to 0.2721
in)
6.Renew any valve if stem diameter is less than
specified.7.Check and record valve stem to guide clearance
using the following procedures:
8.Insert each valve into its respective guide.
9.Extend valve head 10 mm (0.375 in) out of valve
seat and position a DTI gauge to rear of valve
head.
10.Move valve towards front of cylinder head and
zero DTI gauge ensuring that stylus of gauge
remains in contact with valve head.
11.Move valve towards rear of cylinder head, record
gauge reading to give valve stem to guide
clearance.
Valve stem to guide clearance:
Inlet valve = 0.025 to 0.059 mm (0.0009 to
0.0023 in)
Exhaust valve = 0.035 to 0.069 mm (0.0013 to
0.0027 in)
CAUTION: If stem to guide clearance
exceeds figures given and valve stem
diameters were as specified, cylinder head
assembly must be replaced; it is not possible to
replace valve guides.
12.Repeat above procedures for remaining valves.
CAUTION: Keep valves in their fitted order.
13.Check face angle of each valve, renew any
valve with incorrect face angles, do not attempt
to recut.
Valve face angle:
Inlet =29°48’±12’
Exhaust =44°48’±12’
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ENGINE
15
OVERHAUL Valves - Lapping-in
1.Lap each valve to its seat using grinding paste.
2.Apply Prussian Blue to valve seat, insert valve
into guide and press it firmly, without rotating on
to seat.
3.Remove valve and check that a continuous,
even line of Prussian Blue has been transferred
on to valve face.
NOTE: Line does not have to be across
whole width of valve face.
4.Remove all traces of grinding paste on
completion.
5.Check valve head stand-down.See this
Section.
Valve head stand down
1.Insert each valve into its respective guide.
2.Using a straight edge and feeler gauges, check
and record stand down of each valve head.
3.Compare figures obtained with figures given
below.
Valve head stand down:
Inlet valveA= 0.555 to 0.825 mm (0.022 to
0.032 in)
Exhaust valveB= 0.545 to 1.35 mm (0.021 to
0.053 in)
CAUTION: If any valve has a stand down
greater than specified, repeat check using
a new valve. If, after checking with a new
valve, stand down is still excessive, cylinder head
assembly must be replaced. It is not possible to
replace valve seat inserts.Rocker shaft - Dismantling
1.Suitably identify each rocker arm to its fitted
position.
CAUTION: Identify type of rocker arm
fitted. Engine Serial No. Prefixes 10P to
14P - Type A rocker arms. Engine Serial
No. Prefixes 15P to 19P - Type B rocker arms.
Type B rocker arms and type B rocker shaft may
be fitted to Engine Serial No. Prefixes 10P to 14P
as an assembly.
2.Remove and discard spring ring retaining rocker
arm on shaft.
3.Remove rocker arm.
4.Remove and discard 2nd spring ring.
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12ENGINE
16
OVERHAUL 5.Repeat above procedures for remaining rocker
arms.
CAUTION: Keep rocker arms in their fitted
order.Rocker arms and shaft - Inspection
1.Clean rocker arms and shaft, ensure oilways are
clear.
CAUTION: Identify type of rocker shaft
fitted. Engine Serial No. Prefixes 10P to
14P - Type A rocker shaft. Engine Serial
No. Prefixes 15P to 19P - Type B rocker shaft.
Type B rocker arms and shaft may be fitted to
Engine Serial No. Prefixes 10P to 14P as an
assembly.
2.Check diameter of each rocker arm journal on
shaft, take 2 measurements at 180°in centre of
journal.
Journal diameter =26.971 to 26.998 mm
(1.062 to 1.063 in)
CAUTION: Any ovality must be within
limits given.
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ENGINE
17
OVERHAUL
3.Using a vernier, check internal diameter of each
rocker arm, take 2 measurements at 180°.
Rocker arm internal diameter =27.0 to 27.013
mm (1.102 to 1.103 in)
CAUTION: Any ovality must be within
limits given.Rocker shaft - Assembling
1.Fit new spring ring to groove in rocker shaft.
2.Lubricate rocker shaft journals and rocker arms
with engine oil.
3.Fit rocker arm to shaft ensuring that it is in its
original fitted order.
4.Fit new spring ring to retain rocker arm.
5.Repeat above procedures for remaining rocker
arms ensuring they are in their original fitted
order.
6.Fit new rocker adjusting screws and locknuts to
rocker arms; do not tighten screws fully into
arms at this stage.
CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P
to 19P have a centre punch mark adjacent to the
adjusting slot. These screws are not
interchangeable with those fitted to Engine Serial
No. Prefixes 10P to 14P.
Cylinder head - Assembling
1.Lubricate new valve stem oil seals with engine
oil.
2.Using toolLRT-12-071, fit valve stem oil seals.
3.Lubricate valve guides, valve stems, valve
spring caps and springs with engine oil.
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12ENGINE
24
OVERHAUL Inspection
CAUTION: Inspection/overhaul procedures
for the oil pump are limited to carrying out
dimensional checks. In the event of wear
or damage being found, a replacement pump and
stiffener plate assembly must be fitted.
Oil pump
1.Remove and discard 5 screws securing cover to
oil pump, remove cover.
2.Using a felt tipped pen, make suitable alignment
marks between inner and outer rotors and pump
body.
3.Remove inner and outer rotors.
4.Check rotors, cover and pump body for signs of
scoring and wear.
5.Fit rotors ensuring that reference marks are
aligned and identification mark on inner rotor is
facing outwards.
6.Using feeler gauges, check pump body to outer
rotor clearance:
Pump body to outer rotor clearance =0.295
to 0.375 mm (0.012 to 0.015 in)
7.Using feeler gauges, check clearance of inner to
outer rotor in 2 positions, both clearances must
be within limit given:
Inner to outer rotor clearance =0.13 mm (0.05
in)
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ENGINE
25
OVERHAUL
8.Place a straight edge across pump body and
using feeler gauges, measure end-float of outer
rotor:
Outer rotor end-float =0.038 to 0.075 mm
(0.001 to 0.003 in)
9.Check drive shaft bush in pump cover for signs
of scoring and wear.
10.Renew oil pump and stiffener plate assembly if
excessive scoring exists or clearances exceed
limits given.
11.Lubricate pump rotors and drive shaft bush with
engine oil.
12.Fit rotors ensuring reference marks are aligned
and identification mark on inner rotor is facing
forwards.
13.Fit cover to pump, fit 5 new screws and tighten
by diagonal selection to6 Nm (4.5 lbf.ft).
14.Check that pump rotors rotate freely.Oil pressure relief valve
1.Remove and discard oil pressure relief valve
plug.
2.Remove spring and relief valve plunger.
3.Clean valve plunger and spring.
4.Check valve plunger and relief valve bore for
scoring and corrosion.
NOTE: Light scoring and corrosion may be
removed using grade 600 emery cloth
soaked in oil.
5.Check spring for distortion, check free length of
spring:
Spring free length =42.00 mm (1.65 in)
CAUTION: Renew relief valve as an
assembly.
6.Lubricate valve plunger and seating.
7.Fit valve plunger and spring to oil pump.
8.Apply Loctite 243 sealant to threads of a new
plug.
CAUTION: Do not attempt to fit original
plug.
9.Fit plug and tighten to23 Nm (17 lbf.ft).
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