1999 LAND ROVER DEFENDER light

12ENGINE
20
OVERHAUL GASKET - ENGINE SUMP
Service repair no - 12.60.38.01
Remove
1.Remove 2 bolts securing centrifuge oil drain pipe
to sump, remove and discard gasket.
2.Using sequence shown and noting their fitted
positions, remove 20 bolts securing sump to
cylinder block.
3.Remove sump, remove and discard gasket.
CAUTION: Do not lever between sump and
cylinder block.Refit
1.Clean sump and mating faces, ensure bolt holes
in cylinder block are clean and dry.
2.Using suitable solvent, remove all traces of
sealant from joint faces of timing chain cover and
crankshaft rear oil seal housing.
3.Clean centrifugal filter oil drain pipe and mating
faces.
4.Apply a bead of sealant, Part No. STC 3254 to
joint faces of timing chain cover and crankshaft
rear oil seal housing.
CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.
5.Position new sump gasket.
CAUTION: Gasket must be fitted dry.
6.Position sump, fit and lightly tighten bolts
ensuring they are in their original fitted positions.
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12ENGINE
22
OVERHAUL Refit
1.Clean crankshaft rear oil seal housing mating
face on cylinder block, ensure bolt and dowel
holes are clean and dry. Remove all traces of oil
from oil seal running surface on crankshaft.
2.Position seal protectorLRT-12-061over
crankshaft boss. Fit new seal and housing,
removeLRT-12-061.
CAUTION: Oil seal must be fitted dry.
3.Fit oil seal housing bolts and using sequence
shown, tighten to9 Nm (7 lbf.ft).
4.Fit sump gasket.See this Section.
5.Fit flywheel.See Repair.STARTER RING GEAR
Service repair no - 12.53.19
Remove.
1.Remove flywheel.See Repair.
2.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
3.Apply a cold chisel to root of teeth, break ring
gear and remove from flywheel.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
Refit
1.Heat ring gear evenly to 350°C, indicated by
light blue colour.
2.Locate ring gear on flywheel and press on to
flange.
WARNING: Handle hot ring gear with care.
3.Allow ring gear to air cool.
4.Fit flywheel.See Repair.
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ENGINE
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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12ENGINE
28
OVERHAUL Inspection
1.Clean all components.
2.Check condition of timing chain running surfaces
on adjustable and fixed guides.
CAUTION: Adjustable guide fitted to
Engine Serial No. Prefixes 15P to 19P may
be fitted to Engine Serial No. Prefixes 10P
to 14P provided that timing chain tensioner having
a YELLOW colour coded body is also fitted.
3.Check timing chains and sprockets for signs of
wear.
CAUTION: Timing chains and sprockets
fitted to Engine Serial No. Prefixes 15P to
19P may be fitted to Engine Serial No.
Prefixes 10P to 14P as an assembly only, oil pump
sprockets are interchangeable. Timing chains
fitted to Engine Serial No. Prefixes 15P to 19P
have BRONZE coloured timing links.
4.Check that drilling in timing chain lubrication jet
is clear.
5.Clean oil seal recess in timing cover and oil seal
running surface on crankshaft.
6.Remove all traces of sealant from mating faces
of timing cover and cylinder block using suitable
solvent.
CAUTION: Do not use metal scrapers.
7.Ensure bolt and dowel holes are clean and dry.
8.Clean oil pump sprocket bolt threads.Refit
1.Fit timing chain lubrication jet.
2.Fit bolt securing lubrication jet and tighten to10
Nm (7 lbf.ft).
3.If crankshaft has been rotated, check that No. 1
piston is at TDC using the following procedures:
4.Temporarily fit and lightly tighten a new
crankshaft pulley bolt.
5.Assemble a magnetic base DTI to cylinder block
top face, position stylus to cylinder block top face
and zero gauge.
6.Using crankshaft pulley bolt, rotate crankshaft
clockwise until No. 1 piston is at top of its stroke
and Woodruff key slot in crankshaft is at 12
o’clock position.
7.Position stylus of DTI to No. 1 piston crown and
rotate crankshaft until highest reading is
indicated on DTI.
8.Check that Woodruff key slot in crankshaft is still
at 12 o’clock position indicating No. 1 piston is at
TDC firing.
9.Remove DTI.
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ENGINE
31
OVERHAUL 8.Remove and discard big-end bearing shell from
connecting rod.
CAUTION: Engine Serial No. Prefixes 10P
to 14P:- The’sputter type’connecting rod
bearings fitted to these engines, identified
by them having a slightly darker colour than the
bearing cap shells should be replaced with the
’plain type’bearing shells fitted to Engine Serial
No. Prefixes 15P to 19P.
9.Repeat above procedures for remaining big-end
bearings.
CAUTION: Keep bearing caps in their fitted
order.
Inspection
NOTE: If crankshaft is to be removed,
big-end bearing journals should be
checked when crankshaft is inspected.
1.Check each big-end bearing journal for scoring,
wear and ovality, make 3 checks at 120°intervals
in centre of journal:
Big-end journal diameter =
54.000±0.01 mm (2.125±0.0004 in)
CAUTION: Big-end journals may not be
reground undersize,only one size of
big-end bearing shell is available and if
journals are found to be scored, oval or worn,
crankshaft must be replaced. Big-end bearing
shells must be replaced whenever they have been
removed.Refit
1.Clean connecting rod journals and bearing shell
locations.
2.Lubricate new big-end bearing shells with engine
oil and fit to connecting rods and bearing caps
ensuring that the’sputter bearings’are fitted to
the connecting rods.
NOTE:’Sputter type’bearing shells can be
identified by them by having a slightly
darker colour.
3.Rotate crankshaft until No. 1 big-end bearing
journal is at BDC.
4.Taking care not to damage oil squirt jet or to
displace bearing shell, pull connecting rod on to
crankshaft journal.
5.Check that bearing shell is correctly located in
big-end bearing cap.
6.Fit No. 1 big-end bearing cap ensuring that
reference marks are aligned.
7.Lightly oil threads of new big-end bearing cap
bolts, fit bolts and tighten to:
Stage 1 -20 Nm (15 lbf.ft)
Stage 2 -Further 80
°
CAUTION: Do not carry out stages 1 and 2
in one operation.
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12ENGINE
38
OVERHAUL Crankshaft spigot bush
1.Check crankshaft spigot bush for wear, replace if
necessary using the following procedures:
2.Secure crankshaft in a suitably padded vice.
3.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
4.Fit impulse extractor to spigot bush.
5.Remove spigot bush.
6.Clean spigot bush recess in crankshaft.
7.Fit new spigot bush to crankshaft using a
suitable mandrel.
Crankshaft - Refit
1.Fit oil squirt jets, fit Torx screws and tighten to8
Nm (6 lbf.ft).
2.Lubricate new, grooved, main bearing shells with
engine oil and fit to cylinder block.
3.Lubricate new thrust washers with engine oil and
fit, grooved side facing outwards, to recess in
each side of cylinder block No. 3 main bearing.
4.Lubricate crankshaft journals with engine oil and
using assistance, position crankshaft in cylinder
block.
5.Lubricate new, plain, main bearing shells with
engine oil and fit to main bearing caps.
6.Fit main bearing caps in their original fitted
positions ensuring that reference marks are
aligned.
7.Fit and lightly tighten new main bearing cap
bolts.
CAUTION: Do not lubricate bolt threads.
8.Starting with No. 3 main bearing cap and
working outwards, tighten main bearing cap bolts
to:
Stage 1 -33 Nm (24 lbf.ft)
Stage 2 -Further 90
°
CAUTION: Do not carry out stages 1 and 2
in one operation.
9.Check that crankshaft rotates smoothly.
10.Assemble a magnetic base DTI to front of
cylinder block with stylus of gauge on end of
crankshaft.
11.Using suitably padded levers, move crankshaft
rearwards and zero DTI.
12.Move crankshaft forwards and note crankshaft
end-float reading on gauge.
Crankshaft end-float =0.02 to 0.25 mm (0.001
to 0.011 in)
CAUTION: Oversize thrust washers are not
available, if end-float exceeds figure given,
crankshaft must be replaced.
13.Remove DTI.
14.Fit connecting rod bearings.See this Section.
15.Fit timing chain and sprockets.See this
Section.
16.Fit crankshaft rear oil seal.See this Section.
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EMISSION CONTROL
3
DESCRIPTION AND OPERATION 1.EGR Solenoid
2.Vacuum hose (light brown)
3.T-piece
4.Vacuum hose to brake servo
5.Non-return valve
6.Brake servo
7.Inlet manifold
8.Exhaust manifold
9.EGR pipe
10.Vacuum pump/alternator assembly
11.Air intake hose from intercooler
12.EGR valve assembly
13.Vacuum hose to vacuum pump
14.Vacuum hose to EGR valve suction port (blue)
15.To atmosphere
16.In-line filter
17.Vent hose - EGR solenoid to in-line filter (green)
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EMISSION CONTROL
9
DESCRIPTION AND OPERATION EGR MODULATOR
1.Port to vacuum source (white band)
2.Port to EGR valve (blue band)3.Port to atmosphere via in-line filter (green band)
4.Harness connector
The EGR modulator is located on a plate fixed to the inner RH front wing. The modulator is attached to the plate
by two studs, each with two nuts which secure the assembly to a rubber mounting, which helps reduce noise. The
modulator must be mounted vertically with the two vacuum ports uppermost.
Modulator operation is controlled by a signal from the ECM which determines the required amount of EGR needed
in response to inputs relating to air flow, engine operation, and ambient conditions. The modulator has a two pin
connector at its base to connect it to the ECM via the engine harness.
The modulator features three ports:
The top port is identified by a white band and connects to a T-piece in the vacuum line via a small bore light
brown plastic hose. The two other ports on the T-piece connect to the vacuum line hoses of black vinyl tubing
between the vacuum pump and the brake servo assembly attached to the bulkhead. The vacuum pump end of
the tubing terminates in a rubber elbow, which gives a vacuum tight seal on the suction port of the vacuum
pump. The brake servo end of the tubing terminates with a non-return valve in a plastic housing which plugs
into the front face of the brake servo housing.
The middle port is identified by a blue band, and connects to the suction port on the EGR valve through a small
bore blue plastic hose.
The lower port is identified by a green band and connects to atmosphere through an in-line filter via a small
bore green plastic hose.
The blue and brown vacuum hoses are protected by corrugated plastic sheaths. The ends of the hoses are fitted
with rubber boots to ensure vacuum tight seals at the component ports.
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