1999 LAND ROVER DEFENDER ECU

ENGINE
3
OVERHAUL GASKET - CYLINDER HEAD
Service repair no - 12.29.02.01
Remove
CAUTION: The following procedures
should only be carried out when cylinder
head is to be overhauled; for replacement
of cylinder head gasket only, see Repairs section -
Gasket - Cylinder head.
NOTE: The following procedure covers
both EU3 and non EU3 engines
1.Remove exhaust manifold gasket.See
MANIFOLD AND EXHAUST SYSTEM, Repair.
2.Remove inlet manifold gasket.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
3. Models with EGR cooler:Remove and discard
2 Allen screws securing EGR pipe to cooler.
4.Progressively loosen then remove 13 bolts
securing camshaft cover, remove cover; remove
and discard gasket.
5.Remove isolators and sealing washers from
cover.
6.Disconnect injector multiplug from camshaft
carrier.
7.Disconnect multiplug from ECT sensor.
8.Remove bolt securing alternator strap bracket to
cylinder head.
9.Set engine to TDC firing - No. 1 cylinder -
coloured links on timing chain are aligned with
timing mark on camshaft sprocket.
10.Fit timing pinLRT-12-058into slot in camshaft.
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12ENGINE
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OVERHAUL
11.Disconnect alternator/vacuum pump oil feed pipe
union from cylinder head, remove and discard
’O’ring.
12.Remove camshaft sprocket access plug from
front of cylinder head, remove and discard’O’
ring.
13.Remove timing chain fixed guide Allen screw.
14.Remove timing chain tensioner, remove and
discard sealing washer.
15.Remove and discard 3 bolts securing camshaft
sprocket to camshaft; release sprocket from
camshaft.
16.Remove bolt and nut securing front of cylinder
head to timing chain cover.
17.Using sequence shown, progressively loosen
then remove 12 cylinder head bolts; discard
bolts together with their captive washers.
18.Using assistance, remove cylinder head and
place on 2 wooden blocks.
CAUTION: Cylinder head is dowel located,
do not tap it sideways to free it from
cylinder block. Support both ends of
cylinder head on blocks of wood. With the
camshaft carrier bolted down, the injector nozzles
and some of the valves will protrude from the face
of the cylinder head.
19.Remove the cylinder head gasket.
20.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of the cylinder head.
CAUTION: If new pistons, connecting rods
or crankshaft are fitted, it will be
necessary to measure piston stand proud
in order to determine thickness of gasket
required.See this Section.
21.Remove and discard 2 plastic locating dowels
from cylinder block.
22.Carry out cylinder head overhaul procedures.
See this Section.
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12ENGINE
6
OVERHAUL 14.Clean fixed guide Allen screw and apply Loctite
242 to screw threads.
15.Fit fixed timing chain guide Allen screw and
tighten to25 Nm (18 lbf.ft).
16.Clean timing chain tensioner and fit new sealing
washer.
17.Fit timing chain tensioner and tighten to45 Nm
(33 lbf.ft).
18.Tighten camshaft sprocket bolts to36 Nm (27
lbf.ft).
19.Remove toolLRT-12-058from camshaft.
20.Lubricate a new’O’ring with engine oil and fit to
camshaft sprocket access plug.
21.Fit camshaft sprocket access plug.
22.Clean alternator/vacuum pump oil feed hose
union.
23.Lubricate a new’O’ring with engine oil and fit to
alternator/vacuum pump hose union.
24.Fit and tighten alternator/vacuum pump oil hose
union to10 Nm (7 lbf.ft).
25.Fit bolt securing alternator strap bracket to
cylinder head and tighten to25 Nm (18 lbf.ft).
26.Connect multiplugs to ECT sensor and EUIs.
CAUTION: Following cylinder head
overhaul, it will be necessary, before
fitting the camshaft cover, to adjust the
fuel injector rockers using the following
procedures:
27.Rotate engine clockwise until No. 1 EUI lobe is
at full lift.
28.Tighten No.1 rocker adjusting screw until the EUI
plunger is felt to’bottom out’.
29.Loosen rocker adjusting screw 1 complete turn
to give EUI plunger the required bump clearance
and tighten rocker adjusting screw locknut to16
Nm (12 lbf.ft).
CAUTION: Ensure screw does not turn as
locknut is tightened.30.Carry out above procedures for the remaining 4
rocker arms.
31.After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no EUI’s are bottoming out
on their plungers.
32.Clean camshaft cover and mating face.
33.Fit new sealing washers and isolators as
necessary to camshaft cover.
34.Fit new camshaft cover gasket to cover.
CAUTION: Gasket must be fitted dry.
35.Fit camshaft cover to camshaft carrier, fit bolts
and working from the centre outwards, tighten
bolts to10 Nm (7 lbf.ft).
36.Fit inlet manifold gasket.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
37.Fit exhaust manifold gasket.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
38. EGR cooler fitted:-Position EGR pipe to cooler,
fit new Allen screws and tighten to10 Nm (7
lbf.ft).
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12ENGINE
8
OVERHAUL CYLINDER HEAD - OVERHAUL
Service repair no - 12.29.19.01
Dismantling
1.Remove cylinder head gasket.See this
Section.
CAUTION: Due to the design of the
cylinder head which incorporates drillings
for the fuel injection system, it is important
that absolute cleanliness is adhered to when
carrying out overhaul procedures.
2.Note the gasket thickness indicator and ensure
the same thickness gasket is used on refitment
of cylinder head.
CAUTION: If new pistons, connecting rods
or crankshaft are fitted, it will be
necessary to determine thickness of
gasket required.See this Section.
3.Remove 4 glow plugs.
4.Disconnect multiplugs from EUI’s and remove
harness from camshaft carrier. Remove and
discard’O’ring from harness multiplug.
5.Loosen lock nuts and fully unscrew rocker
adjusting screws; discard locknuts and screws.
6.Remove and discard 6 bolts securing rocker
shaft, remove shaft.
NOTE: Dowel located.
7.Using sequence shown, progressively loosen 13
bolts securing camshaft carrier to cylinder head
until valve spring pressure is released; remove
bolts.
CAUTION: Do not discard bolts at this
stage.
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ENGINE
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OVERHAUL
8.Gently tap camshaft carrier upwards to break
sealant bond, remove carrier.
NOTE: Dowel located.
9.Remove camshaft.
10.Remove and discard camshaft rear oil seal.
11.Remove finger followers and lash adjusters.
CAUTION: Store lash adjusters and finger
followers in their fitted order and store
lash adjusters upright. Maintain absolute
cleanliness when handling components.
12.Remove and discard 5 bolts securing EUI
retainers.
13.Using toolLRT-12-154/1remove EUI units from
cylinder head and collect retainers. Remove
reaction posts and keep in their fitted order.
14.Using toolLRT-12-154/4, remove and discard
sealing washer and’O’ring from each EUI unit.
15.Support cylinder head clear of valves, use a
hollow drift and tap each valve spring cap to free
collets.
16.Using toolLRT-12-034, compress valve spring.
17.Remove 2 collets from valve stem using a stick
magnet.
18.Remove toolLRT-12-034.
19.Remove valve spring cap, valve spring and
valve.
CAUTION: Keep components in their fitted
order.
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12ENGINE
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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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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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ENGINE
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OVERHAUL
7.Using sequence shown, tighten sump bolts to25
Nm (18 lbf.ft).
8.Fit new centrifuge oil drain pipe gasket.
CAUTION: Gasket must be fitted dry.
9.Fit centrifuge oil drain pipe, fit bolts and tighten
to10 Nm (7 lbf.ft).SEAL - CRANKSHAFT - REAR
Service repair no - 12.21.20.01
Remove
1.Remove flywheel.See Repair.
2.Remove sump gasket.See this Section.
3.Remove 5 bolts securing crankshaft rear oil seal
housing to cylinder block.
4.Remove and discard crankshaft rear oil seal and
housing.
NOTE: Dowel located.
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