Defender. Manual — part 100
four times.
Tighten the bolts in three stages in the sequence shown.
• NOTE: Lubricate the crankshaft and the crankshaft main
bearing shells with clean engine oil.
• NOTE: Stamp the bolt heads with a center punch to indicate
usage.
Install the crankshaft main bearing caps.
Stage 1: 45 Nm (33 lb.ft).
Stage 2: 80 Nm (59 lb.ft).
Stage 3: 105 degrees.
4.
CAUTION: Make sure the connecting rod does not
damage the crankshaft big end bearing surface.
• NOTE: The piston ring gaps must be distributed evenly
around the circumference of the piston. This also applies to the
oil control ring elements. Align the piston ring gaps at 120
degrees to each other.
• NOTE: The arrow on the piston must point to the front to the
engine.
Using a suitable tool, install the pistons.
Lubricate the cylinder bores and pistons with clean
engine oil.
5. CAUTIONS:
Connecting rod bearing cap bolts must only be used four
times.
Make sure that the fracture split connecting rod bearing
cap is installed correctly.
• NOTE: Stamp the bolt heads with a center punch to indicate
usage.
• NOTE: The identification marks on the big-end bearing caps
must point to the front of the engine.
Install the connecting rod bearing caps.
Lubricate the connecting rod bearing shells with clean
engine oil.
Tighten the bolts in two stages.
Stage 1: 30 Nm (22 lb.ft).
Stage 2: 80 degrees.
CAUTION: Do not trim or damage protruding foam
6.
CAUTION: Do not trim or damage protruding foam
pads.
• NOTE: Install new ladder frame gaskets.
Install the ladder frame.
Loosely install the bolts.
7.
CAUTION: The ladder frame and the cylinder block
must be aligned so that the side clearance does not exceed
0.05 mm overlap to 0.05 mm gap.
Using the special tool, align the ladder frame to the cylinder
block.
8.
CAUTION: The ladder frame and the cylinder block
must be aligned so that the rear clearance does not exceed
0.01 mm overlap to 0.2 mm gap.
Using a suitable straight edge, align the ladder frame to the
cylinder block.
9. NOTE: Tighten the bolts in the sequence shown.
9. NOTE: Tighten the bolts in the sequence shown.
Secure the ladder frame.
Tighten the bolts to 23 Nm (17 lb.ft).
10. NOTE: Install a new crankshaft rear seal.
• NOTE: A new crankshaft rear seal is supplied with an
alignment sleeve that must be removed following installation.
• NOTE: Tighten the bolts in the sequence shown.
Install the crankshaft rear seal.
Tighten the bolts to 10 Nm (7 lb.ft).
11. Remove the special tool.
Remove the bolt.
12. NOTE: Do not fully tighten the oil pump bolts at this
12. NOTE: Do not fully tighten the oil pump bolts at this
stage.
Install the oil pump and oil pump chain.
Install the oil pump chain to the crankshaft sprocket.
13. Using a suitable dial indicator gauge take a reference
measurement from the front face of the crankshaft sprocket.
1. Position the dial gauge holding fixture on the
cylinder block.
2. Position the dial indicator gauge plunger on the
crankshaft sprocket and set the dial to zero.
14. NOTE: Take measurements at two different points on the
oil pump sprocket.
Using the dial indicator gauge align the oil pump sprocket
and tighten the oil pump bolts.
15. Check the alignment of the oil pump sprocket with the
crankshaft sprocket. Repeat the alignment procedure if
necessary.
16. Secure the oil pump.
Tighten the bolts to 10 Nm (7 lb.ft).
17. Install the oil pump chain tensioner.
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