Defender (1993+). Manual — part 27

ENGINE

TIMING CHAIN AND CHAINWHEELS

Remove

1. Remove engine.

2.

Remove flywheel.

1. Remove front cover.

3. Remove dipstick.

2.

Remove retaining bolt and washer, remove

4.

With assistance, invert engine, support

on

distributor drive gear and spacer.

3.

Ensure number one piston is at TDC.

4. Remove chainwheels and chain as an

6.

Remove rear main bearing cap.

assembly.

7.

Remove cross seals from cap.

8.

Remove crankshaft rear oil seal.

9.

Clean main bearing cap and oil seal area

of

CRANKSHAFT REAR OIL SEAL

blocks.

5.

Remove sump.

Refit

5.

Clean chainwheels and chain.

6.

Fit chainwheels to chain, aligning timing

11.

Apply Hylomar SQ32M to block as illustrated.

marks.

7.

Ensure camshaft key is fitted parallel to shaft

axis

to

ensure adequate lubrication to

distributor drive gear.

8.

Engage chainwheel assembly on camshaft

and crankshaft keys, ensure chain wheels are
fully located.

9.

Check alignment of timing marks with straight
edge.

10.

Fit spacer with flange to front,

11. Fit distributor drive gear with groove towards

spacer.

12. Fit retaining bolt and washer, tighten

to

58

Nm.

13.

Fit front cover.

10. Fit new

cross seals

to bearing cap.

FLYWHEEL

Remove

1. Remove gearbox and clutch.

2.

Slacken starter motor bolts.

3.

Lock flywheel, remove flywheel bolts and

RR3827M

flywheel.

12.

Lubricate bearing shell and cross seals using

13.

Fit bearing cap, do not tighten bolts.

on the block.

Refit

clean engine oil.

4. Clean components for reassembly.

14. Ensure cap is fully home and seated squarely

5. Fit flywheel.

6.

Lock flywheel, fit flywheel bolts, tighten to

80

Nm.

block.

RR3828M

ENGINE

15.

Ensure

oil

seal guide RO1014 and crank

journal are scrupulously clean. Coat seal
guide and oil seal journal with clean engine
oil.

CAUTION:

Do

not handle oil seal lip, check

it

is

not damaged. Ensure outside diameter

remains clean and dry.

16. Position oil seal guide RO1014 on crankshaft

flange.

NOTE: lubricant coating must cover seal

guide outer surface completely to ensure
that oil seal

lip

is

not turned back during

assembly. Position

oil

seal,

lipped side

towards engine, on seal guide. Seal
outside diameter

MUST be

clean and dry.

17. Push oil seal fully and squarely by hand into

recess

in cap and block until it contacts

machined step in recess. Remove seal guide.

18.

Tighten rear main bearing cap to 90 Nm.

19. Fit sump.

20.

Reposition engine,

fit

dipstick.

21

.

Fit flywheel.

22.

Fit engine to vehicle.

RO605351

18G1150

18G1150E

18G79

ENGINE

LRT-12-041

Guide bolts

RO605351

LRT-12-013
18G1150

Piston pin remover/replacer

-

Basic

tool

LRT-12-014
18G1150E

Adaptor remover/replacer

-

piston pin

LRT-12-001

Clutch centralising

tool.

18G79

ENGINE

MS1519A

RO.600959

LRT-12-034

Spring compressor

MS1519A

LRT-12-038
RO600959

exhaust

Drift

-

Valve guide replacement

-

intake and

LRT-12-515
RO605774A

Distance piece

for

valve guide

LRT-12-504

Valve seat cutter

MS621

MS.621