Defender (1993+). Manual — part 24

ST841M

CAUTION: The space between key and

FIT CYLINDER HEADS

keyway acts as an oilway for lubrication

of

drive gear. Ensure that key is seated to

full

depth of keyway. Overall dimension

of

uppermost.

Do

NOT use sealant.

shaft and key must

not

exceed

30.15

mm,

dimension A below.

1.

Fit new cylinder head gaskets with word

'TOP'

ST843M

2.

Locate cylinder heads on dowels.

3. Clean threads of cylinder head bolts and

lubricate with engine

oil.

7.

Check timing marks line up,

fit

spacer with

flange

to

front.

8.

Fit the distributor drive gear. Ensure that

annular grooved side is

fitted

to

rear, towards

spacer.

9. Fit bolt and washer, tighten to correct torque,

60

Nm.

RR755M

4.

Locate the cylinder head bolts in position
illustrated and

fit

dipstick tube.

Long bolts

-

1,

3

and 5.

Medium

bolts

-

2,4,6,7,8,9 and 10.

Short bolts

-

11,12,13 and 14.

RR1799E

ENGINE

ENGINE

5.

Tighten head bolts progressively in sequence
shown. Finally tighten

to

correct torque, outer

row

60

Nm centre and inner row

90

Nm.

tightened.

3.

Ensure each rocker shaft

I

S

fitted with notch

uppermost and towards front of engine on
right hand side, towards rear on left hand

6.

Re-check torques when all bolts have been

side.

ST845M

NOTE: Left-hand cylinder head illustrated.
Arrow points to front of vehicle.

RR2241E

FIT TAPPETS, PUSH RODS AND ROCKER

4.

Fit rocker shaft assemblies. Ensure pushrods

ASSEMBLIES

engage rocker cups. Tighten bolts

to

correct

torque, 38 Nm.

NOTE: Immerse tappets

in

clean engine oil.

Before fitting, pump inner sleeve

of tappet

several times using a pushrod, to reduce tappet
noise when engine i s started.

1.

Fit tappets and push rods in original positions.
Ensure tappets move freely

in bores.

NOTE: Tappet noise can

be expected on

initial starting after overhaul or if vehicle
has been standing a very long period. Run

engine at

2,500

rev/min for a few minutes

(subject to following caution), when noise
should

be

eliminated.

2. Rocker shafts are handed and must be fitted

correctly

to

align oilways.

CAUTION:

Do not exceed

1,000

engine

rev/min for

15

seconds when first starting

engine, otherwise crankshaft rear oil seal
will

be damaged.

8.

Fit all manifold bolts, evenly tighten a little

at

a time, alternate sides working

from

centre

to

each end. Finally tighten to correct torque,

40

9.

Tighten gasket clamp bolts

to

correct torque,

FIT INTAKE MANIFOLD

1.

Apply globule of Hylomar SQ32M sealing

Nm.

compound to notches between cylinder head
and block.

18 Nm.

2. Locate

NEW seals

in position with ends

engaged in notches.

RR2268E

FIT TIMING COVER AND CRANKSHAFT PULLEY

3.

Apply 'Hylomar' SQ32M on corners of cylinder
head, manifold gasket and manifold, around
water passage joints.

4.

Fit manifold gasket with word 'FRONT' to front
and open bolt hole at front

R.H. side.

5.

Fit gasket clamps, do not fully tighten bolts.

1.

Position a new timing cover joint washer, fit

timing cover, locating

it

on

two dowels.

2. Clean threads of timing cover securing bolts,

coat them with Loctite 572.

3.

Fit and evenly tighten timing cover bolts to

correct torque, 28 Nm.

4.

Fit crankshaft pulley. Tighten retaining bolt to
correct torque, 270 Nm.

5. Fit timing pointer.

6.

Locate manifold on to cylinder head.

7.

Clean threads of manifold securing

bolts.

ENGINE

ST849M

ENGINE

RR1795E

FIT WATER PUMP

TEST

AND

FIT

THERMOSTAT

1.

Lightly grease a new joint washer and place

it

in position on timing cover.

1.

Remove

two

bolts securing thermostat

2. Clean threads of four long bolts and coat with

Loctite

572

thread lubricant sealant.

2. Remove housing gasket.

Locate water pump in position.

3.

Withdraw thermostat.

3.

Locate alternator adjusting link on water

pump.

4.

Leaving alternator adjusting link loose, tighten

remaining water pump housing bolts evenly

to

correct torque

28

Nm.

housing to intake manifold.

RR1791E

4. Note fully open temperature stamped on

thermostat,

88°C.

FIT

SUMP

1.

Remove old sealant from sump and cylinder

block joint faces.

face of sump as

shown

in

illustration below.

2. Apply 2 mm wide bead of Hylosil 102 to joint

RR799M

5. Place thermostat and a thermometer in a

suitable container half

full

of

water.

RR1867E

3.

Place sump in position,

fit

sump bolts, evenly

tighten bolts to correct torque,

10

Nm, rear

bolts

19

Nm.

4.

Tighten sump plug

to

correct torque, 44Nm.

5. Allow thirty minutes sealant curing time before

starting engine.

4

ST858M