1999 LAND ROVER DEFENDER check engine

12ENGINE
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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
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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
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OVERHAUL
8.Carefully move connecting rod to one side of
journal and using feeler gauges, measure
end-float of connecting rod on journal:
Connecting rod end-float =0.2 to 0.5 mm
(0.008 to 0.021 in).
CAUTION: If end-float exceeds limits
given, replace connecting rod and repeat
end-float check - See pistons, connecting
rods and cylinder bores.
9.Repeat above procedures for remaining big-end
bearings.
10.Fit oil pump.See this Section.PISTONS, CONNECTING RODS AND CYLINDER
BORES
Service repair no - 12.17.02.01
Remove
1.Remove cylinder head gasket.See this
Section.
2.Remove connecting rod bearings.See this
Section.
3.Remove ridge of carbon from top of cylinder
bore.
4.Suitably identify each piston and connecting rod
assembly to its respective cylinder bore.
5.Carefully push connecting rod to top of cylinder
bore taking care that connecting rod does not
contact oil squirt jet or cylinder wall, remove
each piston and connecting rod assembly in
turn.
6.Using a suitable expander, remove and discard
piston rings from pistons.
7.Using a squared off end of an old piston ring,
clean carbon from ring grooves.
8.Clean carbon from piston crown and skirt.
CAUTION: Do not use abrasives on
graphited area of piston skirt, do not use a
wire brush or scraper on any part of the
pistons.
9.Secure connecting rod in a soft jawed vice.
10.Suitably identify each piston to its connecting rod
and fitted position of piston on rod.
11.Using suitable circlip pliers, remove and discard
2 circlips securing gudgeon pin.
12.Push gudgeon pin out of piston and connecting
rod; remove piston.
13.Suitably identify each gudgeon pin to its
respective piston.
14.Repeat above procedures for each piston.
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ENGINE
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OVERHAUL Cylinder bores - Inspection
1.Check cylinder bores for scoring.
2.Measure cylinder bore wear and ovality at a
point 70 mm (2.75 in) from top of each cylinder
bore:
Cylinder bore diameter =84.460 to 84.442 mm
(3.325 to 3.324 in)
CAUTION: Measurement must be taken
from side to side and front to rear of bore:
CAUTION: Cylinder bore diameter and
ovality must be within limits given above,
no reboring, honing or glaze busting of
cylinder bores is permissible; cylinder block must
be replaced if bores are worn or excessively
scored.
Pistons and connecting rods - Inspection
1.Check each piston for cracks, burning and
damage.
2.Check connecting rods for alignment.
CAUTION: Do not attempt to straighten
misaligned connecting rods.
3.Ensure small-end oil feed holes in connecting
rods are clear.
4.Measure and record diameter of each piston at
right angles to gudgeon pin axis and 46 mm
(1.81 in) from bottom of skirt:
Piston diameter =84.262 mm±0.009 mm
(3.317 in±0.0003 in)
CAUTION: Measurement point must be on
the graphited area of the piston.
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12ENGINE
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OVERHAUL
5.Starting with No. 1 piston, invert piston and with
arrow on piston crown pointing towards REAR of
cylinder block, insert piston into No. 1 cylinder
bore.
6.Position piston with bottom of skirt 25 mm (1.0
in) from top of cylinder bore.
7.Using feeler gauges, measure and record
clearance between piston skirt and LEFT HAND
side of cylinder bore 60 mm (2.4 in) from top of
bore:
Piston to cylinder bore clearance =0.171 to
0.207 mm (0.007 to 0.008 in)
8.Repeat above procedures for remaining pistons.
CAUTION: Oversize pistons are not
available, if piston to cylinder bore
clearance exceeds limits given, repeat
check using a new piston; if clearances are still
excessive, replace cylinder block.
Piston and 1st compression rings fitted to Engine
Serial No. Prefixes 15P to 19P may be fitted to
Engine Serial No. Prefixes 10P to 14P in engine
sets only. Oil control and 2nd compression rings
are interchangeable between all engines.
9.Check fit of each gudgeon pin in its piston. Pin
must be a tight, sliding fit with no perceptible
side play.
10.Measure gudgeon pin diameter at each end and
centre of pin. Renew gudgeon pin and piston as
an assembly if diameters are less than specified
or if excessive pin to piston side play is evident.
Gudgeon pin diameter =29.995 to 30.000 mm
(1.180 to 1.181 in)
11.Check connecting rod small-end bushes for
wear, check that gudgeon pin is a sliding fit in
the bush with no perceptible side play.
CAUTION: Small-end bushes cannot be
replaced, a new connecting rod must be
fitted.
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ENGINE
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OVERHAUL Piston ring gaps - Checking
1.Insert new compression and oil control piston
rings in turn into No. 1 cylinder bore 30 mm (1.25
in) from top of bore and check ring fitted gaps;
ensure rings are kept square to bore when
checking gaps.
1st compression ring fitted gap =0.30 to 0.40
mm (0.012 to 0.016 in)
2nd compression ring fitted gap =0.40 to 0.60
mm (0.016 to 0.024 in)
Oil control ring fitted gap =0.25 to 0.50 mm
(0.01 to 0.02 in)
Repeat for each cylinder bore in turn.
CAUTION: Ensure rings are suitably
identified with the cylinder bore in which
they were checked and are fitted to the
piston for that bore.
2.Fit oil control expander and ring to piston.
3.Fit 2nd compression ring with’TOP’marking
upwards.
4.Fit 1st compression ring with’TOP’marking
upwards.
5.Check piston ring to groove clearance:
1st compression ring -Not measured
2nd compression ring =0.050 to 0.082 mm
(0.02 to 0.003 in)
Oil control ring =0.050 to 0.082 mm (0.02 to
0.003 in)
Pistons and connecting rods - Assembling
1.Lubricate gudgeon pin, gudgeon pin holes in
piston and small-end bush with engine oil.
2.Position piston to its respective connecting rod
with arrow on piston crown on the same side as
the cast boss on the connecting rod.
3.Fit gudgeon pin to its respective piston and
connecting rod; secure with new circlips.
CAUTION: Ensure circlips are fully seated
in their grooves.
4.Repeat above procedures for remaining pistons.
5.Lubricate piston rings and cylinder bores with
engine oil.
6.Check that rings are free to rotate, position ring
gaps at 120°to each other and away from the
thrust - LH side of piston - viewed from front of
piston.
7.Using a suitable piston ring clamp, compress
piston rings.
8.Insert connecting rod and piston into its
respective cylinder bore, ensuring that the arrow
on piston crown and the cast boss on connecting
rod are facing towards the front of the cylinder
block.
CAUTION: Ensure that connecting rod
does not contact cylinder bore or oil squirt
jet. Do not pull connecting rod fully down
cylinder bore at this stage.
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12ENGINE
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OVERHAUL 9.Check that the cut-out in piston skirt is
positioned above the oil squirt jet.
10.Repeat for other pistons in turn ensuring that
pistons and connecting rods are fitted in cylinder
bores from which they were removed.
11.Fit connecting rod bearings.See this Section.
CAUTION: If new pistons, connecting rods
or crankshaft have been fitted, it will be
necessary to select correct thickness of
cylinder head gasket.See this Section.CRANKSHAFT
Service repair no - 12.21.33.01
Remove
1.Remove timing chain and sprockets.See this
Section.
2.Remove crankshaft rear oil seal.See this
Section.
3.Remove connecting rod bearings.See this
Section.
4.Check that cylinder reference number is on each
main bearing cap. Make suitable alignment
marks between each main bearing cap and
cylinder block.
5.Starting at No. 3 main bearing cap and working
outwards, progressively loosen, then remove 2
bolts securing each cap. Discard main bearing
cap bolts.
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ENGINE
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OVERHAUL
6.Fit 2 slave bolts into each main bearing cap in
turn and ease bearing caps from cylinder block.
7.Remove and discard bearing shells from each
cap.
NOTE: These bearing shells are plain.
8.Using assistance, remove crankshaft.
9.Remove and discard main bearing shells and 2
thrust washers from cylinder block.
NOTE: These bearing shells are grooved.
10.Remove Torx screw securing each oil squirt jet
to cylinder block, remove squirt jets.Cylinder block - Inspection
1.Clean main bearing shell and thrust washer
locations in cylinder block, ensure bolt holes are
clean and dry.
2.Clean main bearing caps.
3.Clean crankshaft bearing journals, check oilways
are clear.
4.Ensure drillings in oil squirt jets are clear.
5.Check core plugs in cylinder block for corrosion
or signs of leakage, seal replacement plugs with
Loctite 243.
Crankshaft - Inspection
1.Check crankshaft main and big-end bearing
journals for scoring, wear and ovality, make 3
checks at 120°intervals in centre of journals.
Crankshaft bearing journal diameters:
Main bearings =
62.000 mm±0.013 mm (2.441 in±0.001 in)
Big-end bearings =
54.000±0.01 mm (2.125±0.0004in)
CAUTION: Crankshafts may not be
reground, only one size of main and
big-end bearing shell is available and if
journals are found to be scored, oval or worn,
crankshaft must be replaced. Main and big-end
bearing shells and thrust washers must be
replaced whenever they are removed.
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