Range Rover Classic. Manual — part 24
12
ENGINE
20
REPAIR
CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1. Disconnect battery negative lead.
2. Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3. Drain coolant.
4. Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5. Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6. Remove injection pipes.
7. Disconnect spill rail from fuel injectors.
8. Remove fuel injectors and sealing washers.
Identify each injector to the location from which it
is removed.
See FUEL SYSTEM, Repair,
Injectors
9. Remove inter-connecting harness from glow
plugs.
10. Remove glow plugs.
See FUEL SYSTEM,
Repair, Glow Plugs
11. Remove top hose, radiator to thermostat.
12. Disconnect by-pass hose from thermostat.
13. Disconnect hose, thermostat to water pump.
14. Disconnect water temperature sensor lead.
15. Remove hose inter-cooler to induction manifold.
16. Remove induction manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
Manifold - Tdi
17. Remove exhaust manifold and turbocharger
assembly.
See MANIFOLD AND EXHAUST
SYSTEM, Repair, Exhaust Manifold - Tdi
18. Disconnect heater hose from water pump and
move heater rail aside.
19. Disconnect heater hose from rear of cylinder
head.
20. Remove bolt securing air cleaner mounting
bracket to support strut.
21. Remove bolt securing harness bracket to
cylinder head.
22. Remove rear lifting bracket, this will also release
clips securing transmission and engine breather
pipes and multiplug. Note loose spacer under
clip securing engine breather pipe and multiplug.
Tdi
21
REPAIR
23. Remove rocker cover.
24. Remove nuts and bolts and withdraw rocker
shaft assembly.
25. Remove push rods, store as an identified set to
allow refitment to same location.
26. Remove valve stem caps.
27. Evenly slacken, then remove, bolts retaining
cylinder head to block. Two of the bolts also
secure the air cleaner mounting bracket.
28. Lift off cylinder head and remove gasket.
Refit
29. Ensure face of cylinder block is thoroughly clean.
30. Select new gasket of correct thickness.
CAUTION: Three thicknesses of gasket are
available, different thicknesses are
identified by the number of small holes
punched in the right hand side of the gasket. One
hole identifies the thinnest gasket and three holes
the thickest. When renewing gaskets the gasket
being fitted must be of the same thickness as the
one removed. Therefore if the removed gasket had
two holes punched in the side the replacement
gasket must also have two holes punched in the
side.
31. Place gasket on cylinder block with identification
holes positioned towards rear on right hand side
and side marked TOP uppermost.
32. Clean mating face of cylinder head.
33. Lower cylinder head onto block ensuring correct
location with dowels.
12
ENGINE
22
REPAIR
NOTE: Cylinder head retaining bolts can
be used up to a maximum of five times.
34. Lubricate threads of bolts with light oil and fit to
positions illustrated.
Bolt sizes:
M10 x 117mm locations 3, 5, 12, and 13.
M12 x 140mm locations 1, 2, 7, 8, 9, 10, 15, 16, 17,
and 18.
M12 x 100mm locations 4, 6, 11, 14.
35. Tighten bolts so that underside of heads just
make contact with cylinder head.
36. Following the sequence illustrated tighten all
bolts to
40 Nm.
37. Attach degree disc special tool LRT-12-007 to a
power bar.
38. Make a suitable pointer from welding rod and
attach to a bolt screwed into a rocker shaft
securing bolt hole.
39. Tighten all bolts through 60
°
strictly in sequence
illustrated.
40. Repeat 60
°
tightening procedure, again strictly in
sequence illustrated.
41. Tighten the ten longer bolts (M12 x 140mm) a
further 20
°
, again following the sequence
illustrated.
NOTE: Repositioning of the pointer will be
necessary to reach all bolts, the pointer
can be fitted to the rocker shaft securing
studs using two nuts.
CAUTION: The double tightening
procedure must be carried out, on no
account should the total angles of
tightening be performed in one operation,
otherwise damage to the cylinder head may occur.
42. Fit valve stem caps.
43. Fit push rods to locations from which they were
removed.
44. Fit rocker shaft assembly evenly tightening
securing nuts and bolts to correct torque.
45. Fit rocker cover ensuring oil seal is satisfactory
for continued use.
NOTE: Rocker cover seals can be re-used
up to a maximum of five times.
46. Secure rocker cover with special seal washers
and nuts tightened to correct torque.
47. Refit remainder of items by reversing operations
1 to 22 tightening securing bolts to correct torque
where applicable.
Tdi
23
REPAIR
VACUUM PUMP
Service repair no - 70.50.19
Remove
NOTE: To ease pump removal set engine
to T.D.C. on No.1 cylinder.
1. Disconnect battery negative lead.
2. Detach servo hose from vacuum pump.
3. Remove six bolts securing vacuum pump.
4. Detach pump complete with harness bracket.
Note location of bracket for refitting.
Refit
5. Clean mating faces of pump and block.
6. Loosely assemble pump to block with a new
gasket and with harness bracket located under
head of bolt noted during removal.
7. Evenly tighten bolts, to depress pump plunger,
finally tightening to
25 Nm.
8. Connect vacuum hose and secure with clip.
9. Reconnect battery negative lead.
GENERATOR
Service repair no - 86.10.02
Remove
1. Disconnect battery negative lead.
2. Remove drive belt.
See Drive Belt Renew
3. Disconnect electrical leads from rear of
generator.
4. Remove securing bolt from bottom of generator.
5. Remove long through bolt from top fixing and
withdraw generator.
Refit
6. Reverse removal procedure.
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