1999 LAND ROVER DEFENDER engine oil

12ENGINE
4
REPAIR Refit
9.Position new crankshaft pulley to vice.
10.Remove 3 bolts and remove damper from
crankshaft pulley.
11.Using a lint free cloth, thoroughly clean oil seal
recess and the running surface on crankshaft
pulley.
12.Fit crankshaft pulley.
13.FitLRT-51-003to crankshaft pulley and secure
with 2 bolts.
14.Fit new crankshaft pulley bolt and tighten to460
Nm (340 lbf.ft).
NOTE: It is recommended that a torque
multiplier is used to tighten crankshaft
pulley bolt.
15.Remove 2 bolts and removeLRT-51-003from
crankshaft pulley.
16.Fit damper to crankshaft pulley, fit bolts and
tighten to80 Nm (60 lbf.ft).
17.Fit auxiliary drive belt.
18.Fit radiator.See COOLING SYSTEM, Repair.
19.Fit underbelly panel.See CHASSIS AND
BODY, Repair.OIL SEAL - CRANKSHAFT - REAR
Service repair no - 12.21.20
Remove
1.Remove flywheel.See this Section.
2.Remove sump gasket.See this Section.
3.Remove 5 bolts securing oil seal housing to
cylinder block.
4.Remove seal housing.
Refit
5.Clean seal housing mating face on cylinder
block.
6.Position seal protector,LRT-12-061over
crankshaft boss. Fit new seal and housing
assembly and remove toolLRT-12-061.
CAUTION: Oil seal must be fitted dry.
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ENGINE
5
REPAIR
7.Fit oil seal housing bolts and using sequence
shown, tighten to9 Nm (7 lbf.ft).
8.Fit sump gasket.See this Section.
9.Fit flywheel.See this Section.BEARING - SPIGOT - CRANKSHAFT
Service repair no - 12.21.45
Remove
1.Remove clutch assembly.See CLUTCH,
Repair.
2.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
3.Fit extractor to spigot bush.
4.Remove spigot bush from crankshaft.
Refit
5.Clean spigot bush and mating face in rear of
crankshaft.
6.Fit new spigot bush to crankshaft using a
suitable drift.
7.Fit clutch assembly.See CLUTCH, Repair.
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12ENGINE
6
REPAIR GASKET - CYLINDER HEAD
Service repair no - 12.29.02
Remove
NOTE: The following procedures cover
engines fitted with or without an EGR
cooler. The EGR cooler is bolted to the
front of the cylinder head.
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain cooling system.See COOLING
SYSTEM, Adjustment.
3.Remove camshaft cover gasket.See this
Section.
4.Remove cooling fan.See COOLING SYSTEM,
Repair.
5.Release clips and disconnect air flow meter from
air filter.
6.Disconnect multiplug from air flow meter.
7.Loosen clip and remove air inlet hose from
turbocharger.
8.Remove 3 bolts and remove exhaust manifold
heat shield.
9.Remove turbocharger oil feed banjo bolt and
discard sealing washers.
10.Remove 3 nuts, release turbocharger from
exhaust manifold, discard gasket and tie
turbocharger aside.
11.Remove 2 bolts securing engine harness to
camshaft carrier.
12.Disconnect fuel injector, coolant and compressor
sensors.
13.Disconnect 4 heater plug connectors.
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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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12ENGINE
14
REPAIR
9. Not EU3 model:-Apply two 3 mm diameter
beads of sealant, Part No.STC 5433 to areas’A’
shown on illustration.
CAUTION: Excessive use of sealant could
result in blockage of oil drain hole,
arrowed’B’in illustration.
10.Fit new gasket to camshaft cover. fit cover and
tighten bolts to10 Nm (7 lbf.ft).
11.Position breather hose and secure clip.
12.Fit engine acoustic cover.
13.Reconnect battery negative lead.
14.Fit battery cover.ENGINE AND ANCILLARIES
Service repair no - 12.41.01.99
Remove
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
2.Drain engine oil.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Remove turbocharger.See FUEL SYSTEM,
Repair.
5.Remove starter motor.See ELECTRICAL,
Repair.
6.Remove air filter.See FUEL SYSTEM, Repair.
7.Loosen clip screw and release air intake hose
from intake elbow.
8.Release clips and disconnect coolant hoses
from fuel cooler and coolant rail.
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ENGINE
17
REPAIR
23.Disconnect oil pressure switch multiplug.
24.Release engine harness from underside of inlet
manifold and tie aside.
25.Release clips and remove coolant top hose from
cylinder head and coolant rail.
26.Remove 4 bolts and move A/C compressor
aside.
27.Remove 3 bolts and remove PAS pump pulley.
28.Remove 4 bolts and move PAS pump aside.
29.Raise vehicle on ramp.
30.Remove 6 bolts securing gearbox housing to
engine.
31.Lower vehicle ramp.
32.Remove 2 upper bolts securing gearbox housing
to engine.
33.Remove bolt securing engine closing panel to
gearbox.
34.Release clip and coolant hose from engine oil
cooler.
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12ENGINE
18
REPAIR
35.Remove 2 bolts and remove acoustic cover from
rear of cylinder head.
36.FitLRT-12-138to suitable lifting chains and
connect to lifting eyes on engine.
37.Remove 2 nuts from RH and LH front engine
mountings.
38.Fit trolley jack to support gearbox.
39.With assistance raise chains and remove engine
from vehicle.Refit
40.With assistance, raise engine from bench and
position in vehicle.
41.With assistance, align engine to gearbox input
shaft.
42.Position 2 upper bolts securing gearbox housing
to engine and tighten to50 Nm (37 lbf.ft).
43.Lower engine onto mountings and tighten nuts to
85 Nm (63 lbf.ft).
44.RemoveLRT-12-138from engine.
45.Fit and tighten bolt securing engine closing panel
to gearbox.
46.Raise vehicle on ramp.
47.Fit bolts securing gearbox housing to engine and
tighten to50 Nm (37 lbf.ft).
48.Lower ramp.
49.Fit acoustic cover to rear of cylinder head and
tighten bolts.
50.Position coolant hose to engine oil cooler and
secure clip.
51.Position PAS pump and tighten bolts to25 Nm
(18 lbf.ft).
52.Position PAS pulley and tighten bolts to25 Nm
(18 lbf.ft).
53.Position A/C compressor and tighten bolts to25
Nm (18 lbf.ft).
54.Route engine harness beneath inlet manifold
and connect multiplugs to oil pressure switch,
A/C compressor, and ECT sensor.
55.Fit and tighten bolts securing engine harness to
camshaft carrier.
56.Connect multiplug to alternator.
57.Connect battery lead to alternator and tighten
nut.
58.Clean CKP sensor and mating face.
CAUTION: If originally fitted:- Fit spacer to
CKP sensor.
59.Using a new’O’ring, fit CKP sensor, tighten bolt
to10 Nm (7 lbf.ft).
60.Connect CKP sensor multiplug.
61.Connect multiplugs to EGR solenoid, inlet
manifold sensor, injector harness, fuel
temperature sensor and CKP sensor.
62.Connect glow plug leads.
63.Connect multiplug to condensor cooling fan.
64.Connect vacuum hose to EGR valve.
65.Connect EGR vacuum hose to vacuum pipe.
66.Position pipe to vacuum pump and secure pipe
to acoustic cover clips.
67.Position fuel cooler. Apply Loctite 242 to bolts
and tighten to18 Nm (13 lbf.ft).
68.Disconnect fuel hose from connector block and
connect to fuel cooler.
69.Connect fuel hoses to fuel cooler and connector
block on cylinder head.
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ENGINE
19
REPAIR 70.Connect coolant hoses to fuel cooler and coolant
rail and secure clips.
71.Fit air intake hose to intake elbow and tighten
clip screw.
72.Fit starter motor.See ELECTRICAL, Repair.
73.Fit turbocharger.See FUEL SYSTEM, Repair.
74.Fit radiator.See COOLING SYSTEM, Repair.
75.Fit air filter.See FUEL SYSTEM, Repair.
76.Fill engine with oil.
77.Fit underbelly panel.See CHASSIS AND
BODY, Repair.MOUNTING - FRONT - LH
Service repair no - 12.45.01
Remove
1.Remove centrifuge assembly.See this
Section.
2.Remove 3 bolts, remove oil filter adaptor
housing and discard gasket.
3.Fit suitable lifting chains to support engine.
4.Remove 2 nuts securing engine mounting to
chassis.
5.Remove 4 bolts securing engine mounting
bracket to cylinder block.
6.Remove nut securing mounting to mounting
bracket.
7.Remove mounting and mounting bracket.
8.Remove mounting shield.
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