Defender (1999-2002). Manual — part 45
ENGINE
37
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.
12
ENGINE
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 to 8
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.
17 - EMISSION CONTROL
CONTENTS
Page
DESCRIPTION AND OPERATION
EGR SYSTEM COMPONENTS - TYPE 1
2
. . . . . . . . . . . . . . .
EGR SYSTEM COMPONENTS - TYPE 2
4
. . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEMS
6
. . . . . . . . . . . . . . . . . ...
CRANKCASE EMISSION CONTROL
7
. . . . . . . . . . . . . . . . ..
EXHAUST GAS RECIRCULATION
8
. . . . . . . . . . . . . . . . . .
EGR MODULATOR
9
. . . . . . . . . . . . . . . . . . . . . . . ..
INLET THROTTLE (ILT) MODULATOR
10
. . . . . . . . . . . . . . . .
EGR VALVE
11
. . . . . . . . . . . . . . . . . . . . . . . . . ...
INLET THROTTLE (ILT) VALVE
12
. . . . . . . . . . . . . . . . . .
IN-LINE AIR FILTER - PRE EU ´u MODELS
13
. . . . . . . . . . . . . .
EGR SYSTEMS
14
. . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR
VALVE - EGR - NON EU3 MODELS
1
. . . . . . . . . . . . . . . . ...
VALVE - EGR - EU3 MODELS
2
. . . . . . . . . . . . . . . . . . .
INLET THROTTLE (ILT) MODULATOR
3
. . . . . . . . . . . . . . . ...
SOLENOID - VALVE - EGR
3
. . . . . . . . . . . . . . . . . . . . .
17
EMISSION CONTROL
2
DESCRIPTION AND OPERATION
EGR SYSTEM COMPONENTS - TYPE 1
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