Defender 90 NAS. Manual — part 15
4.0 V8
3
REPAIR
ROCKER SHAFT RENEW
Service repair no - 12.29.29
1. Remove RH or LH rocker covers.
See ENGINE
4.0 V8, Repair, rocker cover - right hand or.
See ENGINE 4.0 V8, Repair, rocker cover -
left hand
2. Loosen four rocker shaft fixings.
3. Remove rocker shaft assembly.
NOTE: Each rocker shaft is notched at
ONE end. Notch must be uppermost and
towards front of engine on right hand side,
towards rear on left hand side.
4. Clean rocker pedestal locations on cylinder
head.
5. Fit rocker shaft assembly, locating push rods to
rockers.
6. Tighten rocker shaft fixings to
38 Nm, 28 lbf ft.
7. Fit rocker covers.
8. Fit RH or LH rocker covers.
See ENGINE 4.0
V8, Repair, rocker cover - right hand or See
ENGINE 4.0 V8, Repair, rocker cover - left
hand
OIL SUMP
Service repair no - 12.60.44
Remove
1. Drain engine oil
See SECTION 10,
Maintenance, Under vehicle maintenance
2. Fit and tighten drain plug to
40 Nm, 30 lbf ft.
3. Remove bolt securing dipstick tube to rocker
cover.
4. Working from the centre outwards, progressively
loosen and remove 3 screws and 14 bolts
securing sump. Remove sump.
5. Remove all traces of sealant from mating
surfaces of sump, cylinder block and timing
cover, using a suitable solvent or plastic scraper.
6. Degrease mating surfaces of sump, cylinder
block and front cover.
Refit
7. Apply RTV Hylosil White sealant to mating
surface of sump.
8. Position sump, tighten bolts finger tight.
9. Tighten nuts and bolts progressively in
sequence shown to
23 Nm, 17 lbf ft.
10. Fit bolt securing dipstick tube to rocker cover.
12
ENGINE
4
REPAIR
ROCKER COVER GASKET - LEFT HAND
Service repair no - 12.29.40
Remove
1. Disconnect battery negative lead.
2. Remove plenum chamber.
See FUEL SYSTEM,
Repair, plenum chamber
3. Remove screw securing dipstick tube to rocker
cover.
4. Release 4 spark plug leads from guide clips and
disconnect leads from spark plugs.
5. Remove 4 bolts securing rocker cover to cylinder
head.
6. Remove rocker cover.
7. Remove and discard rocker cover gasket.
Refit
8. Clean mating faces of rocker cover and cylinder
head using Bostick 6001 or equivalent. Allow to
dry.
9. Apply a thin coating of impact adhesive (Bostick
1775 or equivalent) to mating faces of rocker
cover and gasket . Use a brush to ensure an
even film. Allow adhesive to become touch dry.
CAUTION: Gasket fits one way round only.
It must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
10. Place one end of gasket into cover recess with
edge firmly against recess wall, holding
remainder of gasket clear. Work around cover
pressing gasket into place ensuring edge firmly
contacts recess wall.
CAUTION: Allow cover to stand for 30
minutes before fitting.
11. Fit rocker cover to cylinder head, ensuring short
bolts are fitted inboard, tighten bolts to
9 Nm, 7
lbf ft.
12. Connect plug leads and secure to guide clips.
13. Align dipstick tube to rocker cover and tighten
screw.
14. Fit plenum chamber.
See FUEL SYSTEM,
Repair, plenum chamber
15. Reconnect battery negative lead.
4.0 V8
5
REPAIR
ROCKER COVER GASKET - RIGHT HAND
Service repair no - 12.29.41
Remove
1. Disconnect battery negative lead.
2. Disconnect breather hose from plenum chamber
and remove hose from rocker cover.
3. Position container to collect coolant spillage.
4. Remove bolt securing coolant pipe brackets
together and nut securing bracket to manifold.
5. Loosen clip and disconnect coolant return hose
from manifold.
6. Depressurise fuel system.
See FUEL SYSTEM,
Adjustment, fuel system depressurise
7. Position cloth to absorb fuel spillage.
8. Disconnect fuel feed hose union.
CAUTION: Plug the connections.
9. Loosen clip and disconnect fuel return hose.
CAUTION: Plug the connections.
10. Remove 2 bolts securing engine harness
bracket to manifold.
11. Release 4 spark plug leads from guide clips and
disconnect leads from spark plugs.
12. Remove 4 bolts securing rocker cover to cylinder
head.
13. Remove rocker cover.
14. Remove and discard rocker cover gasket.
12
ENGINE
6
REPAIR
Refit
15. Clean mating faces of rocker cover and cylinder
head using Bostick 6001 or equivalent. Allow to
dry.
16. Apply a thin coating of impact adhesive (Bostick
1775 or equivalent) to mating faces of rocker
cover and gasket. Use a brush to ensure an
even film. Allow adhesive to become touch dry.
NOTE: Gasket only fits one way round. It
must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
17. Place one end of gasket into cover recess with
edge firmly against recess wall, holding
remainder of gasket clear. Work around cover
pressing gasket into place ensuring edge firmly
contacts recess wall.
CAUTION: Allow cover to stand for 30
minutes before fitting.
18. Fit rocker cover to cylinder head ensuring short
bolts are fitted inboard, tighten bolts to
9 Nm.
19. Connect plug leads and secure to guide clips.
20. Position harness bracket to inlet manifold and
tighten bolts.
21. Connect fuel feed and return hoses.
22. Connect coolant hose to inlet manifold and
tighten clip.
23. Secure coolant pipe brackets
24. Fit breather hose.
25. Refill cooling system.
26. Reconnect battery negative lead.
ENGINE ASSEMBLY
Service repair no - 12.41.01
Remove
1. Position vehicle on ’4-post’ ramp [hoist].
2. Drain engine oil.
See SECTION 10,
Maintenance, under vehicle maintenance
3. Remove bonnet.
See CHASSIS AND BODY,
Repair, bonnet
4. Remove radiator.
See COOLING SYSTEM,
Repair, radiator
5. Loosen 3 PAS pump pulley bolts.
6. Using a 15 mm ring spanner, release auxillary
drive belt tension and release belt from
alternator pulley.
7. Remove drive belt.
8. Disconnect A/C compressor multiplug.
9. Remove 4 bolts securing compressor to
mounting bracket.
10. Collect compressor heat shield.
11. Tie compressor aside with string.
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