Defender 90 NAS. Manual — part 17
4.0 V8
11
REPAIR
59. Remove 2 alternator terminal nuts and
disconnect Lucar.
60. Remove screw securing heater pipe to bracket.
61. Loosen clip screw and remove heater hose/pipe
assembly from inlet manifold.
62. Remove 2 screws securing engine harness to
RH side of inlet manifold.
63. Disconnect 4 RH injector multiplugs.
64. Disconnect RH rocker cover breather pipe from
ram housing.
65. Release RH bank HT leads from clips and
disconnect from spark plugs.
66. Remove 2 screws securing engine harness to
LH side of inlet manifold.
67. Disconnect multiplug from ECT sensor.
68. Disconnect multiplug from fuel temperature
sensor.
69. Disconnect temperature sensor thermistor.
70. Disconnect 4 LH injector multiplugs.
71. Release ignition coil multiplug from mounting
bracket and disconnect multiplug.
72. Position engine harness aside.
12
ENGINE
12
REPAIR
73. Fit engine lifting tool LRT-12-514 to hoist.
74. Lower hoist and connect lifting chains to engine
brackets.
75. Raise hoist until lifting chains become taught and
use a jact to support gearbox.
76. Remove 6 bell housing to engine bolts.
77. With assistance, raise engine on hoist from
engine compartment.
CAUTION: During the engine removal
procedure ensure that the engine does not
damage any surrounding components.
78. Move engine clear of vehicle and lower onto
work bench.
79. Disconnect lifting chains from engine.
80. Raise hoist and position aside.
Refit
81. Clean engine and gearbox mating faces.
82. Clean dowel and dowel holes.
83. Position hoist above engine.
84. Connect lifting chains to engine.
85. Raise engine from work bench and position
above engine compartment.
86. Position jack beneath gearbox fluid pan and
raise transmission to ease alignment of bell
housing to engine.
CAUTION: Use a block of wood or hard
rubber pad to protect fluid pan.
87. With assistance, lower engine into engine
compartment.
CAUTION: During the engine fitment
procedure ensure that the engine does not
damage any surrounding components.
88. With assistance, align engine to bell housing
dowels.
89. Fit bolts securing bell housing to engine and
tighten to
46 Nm, 34 lbf ft.
NOTE: Align harness brackets to 2
uppermost bell housing retaining bolts.
90. Remove jack supporting gearbox fluid pan.
91. Lower engine hoist ensuring mountings are
aligned with chassis brackets.
92. Disconnect lifting chains from engine eyes.
93. Remove lifting tool LRT-12-514from hoist.
94. Remove hoist from above vehicle.
95. Position engine harness around engine.
96. Connect ignition coil multiplug and secure to
bracket.
97. Connect LH injector multiplugs.
98. Connect gauge temperature thermistor.
99. Connect multiplug to fuel temperature sensor.
100. Connect multiplug to ECT sensor.
101. Connect RH bank HT leads to spark plugs and
secure to guides.
102. Connect RH rocker cover breather pipe to ram
housing.
103. Connect RH injector multiplugs.
104. Align engine harness to RH side of inlet manifold
and secure with screws.
105. Fit heater hose/pipe assembly to inlet manifold
and secure with clip.
106. Align heater pipe to bracket and secure with
screw.
107. Position alternator terminal leads and secure.
108. Route harness down front of engine.
109. Connect Lucar to oil pressure switch.
110. Connect multiplug to camshaft position sensor.
111. Connect radiator bottom hose to heater pipe and
secure with clip.
112. Raise vehicle.
4.0 V8
13
REPAIR
113. Fit nut securing LH engine mounting rubber to
chassis mounting and tighten to
30 Nm, 22 lbf
ft.
114. Fit nut securing RH engine mounting rubber to
chassis mounting and tighten to
30 Nm, 22 lbf
ft.
115. Fit bell housing to engine bolts and tighten to
46
Nm, 34 lbf ft .
116. Remove piece of wood from bell housing access
hole.
117. Align converter to drive plate.
118. Fit bolts securing converter to drive plate and
tighten to
45 Nm, 33 lbf ft.
NOTE: Rotate crankshaft during the above
procedure.
119. Fit bell housing access plate and secure with
bolts tightened to
9 Nm, 7 lbf ft.
120. Clean bell housing cover plate and mating face.
121. Fit plate and secure with bolts tightened to
9
Nm, 7 lbf ft.
122. Connect multiplug to crankshaft position sensor.
123. Fit crankshaft position sensor heat shield and
secure with screw.
124. Position engine harness to LH engine mounting
bracket and secure with cable tie.
125. Connect multiplug to LH knock sensor.
126. Position engine harness to RH engine mounting
bracket and secure with cable ties.
127. Connect multiplug to RH knock sensor.
128. Connect Lucar to starter motor solenoid.
129. Position battery leads to starter motor solenoid
terminal and secure with nut.
130. Position starter motor heat shield.
131. Clean exhaust manifold to front pipe mating
faces.
132. Fit NEW front pipe to manifold gaskets.
133. Connect front pipe to manifold studs and secure
with nuts.
134. Secure starter motor heat shield clip to solenoid.
135. Align starter motor heat shield to RH engine
mounting bracket and secure with bolt.
136. Align RH catalyst heat shield to chassis and
secure with bolt.
137. Lower vehicle.
138. Remove 3 bolts securing engine front lifting
bracket, retain bracket but discard bolts.
139. Position engine lifting bracket to PAS pump,
align to cylinder head and secure with bolts
tightened to
35 Nm, 25 lbf ft.
140. Secure knock sensor harness clip to PAS return
hose.
141. Fit PAS pulley to pump, fit bolts but do not
tighten.
142. Position brake servo pipe and connect to inlet
manifold.
143. Position purge pipe and secure to coolant hose
and harness with cable ties.
144. Fit intake hose to MAF sensor housing and
secure with clip.
145. Position breather pipe ’P’ clip to RH cylinder
head and secure with bolt.
146. Fit plenum.
See FUEL SYSTEM, Repair,
plenum chamber; Refit
147. Remove plugs from fuel return and feed hose
connections.
148. Clean fuel feed pipe connections.
149. Connect feed hose to fuel rail and tighten union.
150. Connect fuel return hose to fuel rail and secure
with clip.
151. Connect heater feed and return hoses to pipes
and secure with clips.
152. Release A/C compressor and position to
mounting bracket.
153. Position heat shield to compressor fixing, fit bolts
and tighten to
25 Nm, 18 lbf ft.
154. Connect compressor multiplug.
155. Clean drive belt and pulley grooves.
156. Using a 15 mm spanner, rotate tensioner
clockwise, fit belt to pulleys and release
tensioner.
157. Tighten PAS pump pulley bolts to
10 Nm, 7 lbf
ft.
158. Fit radiator.
See COOLING SYSTEM, Repair,
radiator
159. Fit bonnet.
See CHASSIS AND BODY, Repair,
bonnet
160. Refill engine oil.
See SECTION 10,
Maintenance, under vehicle maintenance
161. Adjust kick-down cable.
See AUTOMATIC
GEARBOX, Adjustment, kickdown cable
adjustment
4.0 V8
1
SPECIFICATIONS, TORQUE
TORQUE VALUES
Engine V8i
Nm
lbf ft
Crankshaft pully bolt
270
. . . . . . . . . . . . . . .
200
Camshaft gear bolt
58
. . . . . . . . . . . . . . ...
43
Timing cover / coolant pump bolts***
22
. . . . . . . ...
16
Rocker cover to cylinder head
9
. . . . . . . . . . ..
7
Rocker shaft bracket to cylinder head
38
. . . . . . . ..
28
Spark plug
15
. . . . . . . . . . . . . . . . . .
11
Cylinder head bolts:*
Stage 1:
20
. . . . . . . . . . . . . . . . ...
15
Stage 2:
then 90
°
. . . . . . . . . . . . . . . . ...
then 90
°
Stage 3:
further 90
°
. . . . . . . . . . . . . . . . ...
further 90
°
Generator / steering pump bracket to cylinder head
30
. .
22
Lifting bracket to cylinder heads
40
. . . . . . . . . ...
30
Power steering hose unions:
14 mm
15
. . . . . . . . . . . . . . . . . .
11
16 mm
20
. . . . . . . . . . . . . . . . . .
15
Power steering pump heat shield
25
. . . . . . . . . .
18
Drive belt tensioner
50
. . . . . . . . . . . . . . ..
39
Drive plate to converter
40
. . . . . . . . . . . . .
30
Drive plate to crankshaft
45
. . . . . . . . . . . . ..
33
Drive plate hub aligner to crankshaft socket head screws 85
65
Bell housing bolts
40
. . . . . . . . . . . . . . . .
30
Access plate
9
. . . . . . . . . . . . . . . . . .
7
Bell housing cover plate
9
. . . . . . . . . . . . ...
7
Main bearing cap rear bolts:
Stage 1:
13
. . . . . . . . . . . . . . . . ...
10
Stage 2:
72
. . . . . . . . . . . . . . . . ...
53
Oil sump drain plug
40
. . . . . . . . . . . . . . ..
30
Oil sump to cylinder block
23
. . . . . . . . . . . .
17
Starter motor bolts
45
. . . . . . . . . . . . . . .
33
Starter motor shield
9
. . . . . . . . . . . . . . ..
7
Oil cooler pipe unions to transmission
30
. . . . . . . .
22
Tie bar to transmission
45
. . . . . . . . . . . . . .
33
Gearbox breather pipe bracket
9
. . . . . . . . . .
7
Engine harness bracket
9
. . . . . . . . . . . . ...
7
Engine mountings to engine and chassis
55
. . . . . . .
40
Engine mounting rubbers to brackets
30
. . . . . . . ..
22
Compressor heat shield
25
. . . . . . . . . . . . ...
18
* Lightly oil threads prior to assembly
** Apply Loctite 222 to threads before assembly
*** Apply Loctite 577 to threads before assembly
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