Defender (1999-2002). Manual — part 28
ENGINE
3
REPAIR
25. Using sequence shown, progressively tighten
bolts to 25 Nm (18 lbf.ft).
26. Lubricate a new camshaft rear oil seal with
engine oil, fit seal using a suitable mandrel.
27. Fit rocker shaft ensuring it is located on dowel, fit
new bolts and working from the centre outwards,
tighten bolts progressively to 32 Nm (24 lbf.ft).
28. Fit new ’O’ ring to injector harness multiplug, fit
harness and connect injector multiplugs.
29. Fit cylinder head gasket. See this Section.
30. Before refitting the camshaft cover the fuel
injector rockers must be adjusted.
31. Rotate engine clockwise until No. 1 injector lobe
is at full lift.
32. Rotate rocker adjusting screw clockwise until the
injector plunger is felt to bottom out.
33. Rotate rocker adjusting screw anti-clockwise 1
complete turn to give plunger the required bump
clearance and tighten rocker adjusting screw
locknut to 16 Nm (12 lbf.ft) .
34. Carry out above procedure for the remaining 4
rockers.
35. After completion of rocker adjustment, slowly
rotate engine clockwise 2 complete turns by
hand to ensure that no injectors are bottoming
out on their plungers.
PULLEY - CRANKSHAFT
Service repair no - 12.21.01
Remove
1. Remove underbelly panel. See CHASSIS AND
BODY, Repair.
2. Remove radiator. See COOLING SYSTEM,
Repair.
3. Using a 15 mm ring spanner release the
auxiliary drive belt tensioner.
4. Remove auxiliary drive belt.
5. Remove 3 bolts and remove crankshaft damper.
6. Position LRT-51-003 to crankshaft pulley and
secure with 2 bolts.
7. Remove and discard crankshaft pulley bolt.
Remove crankshaft pulley.
8. Remove 2 bolts and remove LRT-51-003 .
12
ENGINE
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. Fit LRT-51-003 to crankshaft pulley and secure
with 2 bolts.
14. Fit new crankshaft pulley bolt and tighten to 460
Nm (340 lbf.ft).
NOTE: It is recommended that a torque
multiplier is used to tighten crankshaft
pulley bolt.
15. Remove 2 bolts and remove LRT-51-003 from
crankshaft pulley.
16. Fit damper to crankshaft pulley, fit bolts and
tighten to 80 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-12-061 over
crankshaft boss. Fit new seal and housing
assembly and remove tool LRT-12-061.
CAUTION: Oil seal must be fitted dry.
ENGINE
5
REPAIR
7. Fit oil seal housing bolts and using sequence
shown, tighten to 9 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.
12
ENGINE
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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