Defender (1999-2002). Manual — part 40
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ENGINE
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3. Using a vernier, check internal diameter of each
rocker arm, take 2 measurements at 180
°
.
Rocker arm internal diameter =27.0 to 27.013
mm (1.102 to 1.103 in)
CAUTION: Any ovality must be within
limits given.
Rocker shaft - Assembling
1. Fit new spring ring to groove in rocker shaft.
2. Lubricate rocker shaft journals and rocker arms
with engine oil.
3. Fit rocker arm to shaft ensuring that it is in its
original fitted order.
4. Fit new spring ring to retain rocker arm.
5. Repeat above procedures for remaining rocker
arms ensuring they are in their original fitted
order.
6. Fit new rocker adjusting screws and locknuts to
rocker arms; do not tighten screws fully into
arms at this stage.
CAUTION: Ensure screws are correct for
type of rocker arms fitted. Replacement
screws for Engine Serial No. Prefixes 15P
to 19P have a centre punch mark adjacent to the
adjusting slot. These screws are not
interchangeable with those fitted to Engine Serial
No. Prefixes 10P to 14P.
Cylinder head - Assembling
1. Lubricate new valve stem oil seals with engine
oil.
2. Using tool LRT-12-071, fit valve stem oil seals.
3. Lubricate valve guides, valve stems, valve
spring caps and springs with engine oil.
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ENGINE
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4. Assemble valves, springs and valve spring caps
ensuring that they are in their original fitted
order.
5. Compress valve springs using tool LRT-12-034,
fit collets.
6. Using a wooden dowel and mallet, tap each
spring cap lightly to seat collets.
7. Lubricate new injector ’O’ rings with engine oil.
8. Using tool LRT-12-154/2, fit ’O’ ring to each
injector.
9. Using tool LRT-12-154/3, fit new sealing washer
to each injector.
10. Support each end of cylinder head on blocks of
wood.
CAUTION: Ensure blocks are clear of
valves.
11. Position reaction posts in their original fitted
order.
12. Carefully fit EUI’s, ensuring they are in their
original fitted order and that each retainer is
located on its dowel.
CAUTION: If new EUI’s are fitted, ensure
replacements are correct. Engine Serial
No. Prefixes 10P to 14 - Push rod bushes
are coloured BLACK or BLUE. Engine Serial No.
Prefixes 15P to 19P - Push rod bushes are
coloured GREEN.
13. Fit new retainer bolts and tighten to 32 Nm (24
lbf.ft) .
CAUTION: If new injectors are fitted they
must be programmed for use with the ECM
using Testbook.
14. Lubricate lash adjusters and bores with engine
oil.
15. Fit lash adjusters ensuring they are in their
original fitted order.
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ENGINE
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16. Lubricate finger followers with engine oil.
17. Fit finger followers ensuring they are in their
original fitted order.
18. Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
19. Position camshaft in cylinder head with the
timing pin hole in the vertical position.
20. Apply an even film of sealant, Part No. STC
4600 to camshaft carrier face and spread to an
even film using a roller.
CAUTION: Ensure sealant does not block
oilways (arrowed) or contaminate
camshaft bearings. Assembly and bolt
tightening must be completed within 20 minutes
of applying sealant.
21. Fit camshaft carrier ensuring it is correctly
located on dowels.
22. Fit and lightly tighten new camshaft carrier bolts.
23. Using sequence shown, progressively tighten
bolts to 25 Nm (18 lbf.ft) .
24. Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
25. Position rocker shaft on camshaft carrier,
ensuring rocker shaft is located on dowel.
26. Fit new rocker shaft retaining bolts and working
from the centre outwards, tighten bolts
progressively to 32 Nm (24 lbf.ft) .
27. Lubricate a new ’O’ ring with engine oil and fit to
injector harness multiplug.
28. Fit injector harness and connect multiplugs.
29. Clean fuel connector block and mating face.
30. Lubricate a new fuel filter ’O’ ring with engine oil.
31. Fit new fuel filter, ’O’ ring and gasket.
CAUTION: Gasket must be fitted dry.
32. Fit fuel connector block spacer and gasket (if
fitted).
33. Fit fuel connector block, fit bolts and tighten to
25 Nm (18 lbf.ft) .
34. Clean glow plugs.
35. Fit glow plugs to cylinder head and tighten to 16
Nm (12 lbf.ft) .
36. Engine Serial No. Prefixes 15P to 19P:-
Lubricate new ’O’ rings with engine oil and fit to
spill return pipe; fit pipe and tighten connectors
to 20 Nm (15 lbf.ft).
37. Fit new cylinder head gasket. See this Section.
CAUTION: Ensure that the fuel injector
rockers are adjusted following the
procedures given in Gasket - Cylinder
head - Refit.
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ENGINE
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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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