Defender 300Tdi (1996+). Instruction - page 20

ENGINE

23

REPAIR

43. Check and adjust valve clearances.

See Adjustment, Valve clearances - check

and adjust

44. Fit rocker cover, ensuring oil seal is satisfactory

for continued use, and renew if necessary.

45. Secure rocker cover with special seal washers

and nuts. Tighten to

10 Nm (7 lbf/ft).

46. Fit rear engine lifting bracket, securing breather

pipe and multi-plug retaining clips. Tighten fixing
bolts to

25 Nm (18 lbf/ft).

47. Fit engine harness bracket to cylinder head.
48. Secure air cleaner mounting bracket to support

strut.

49. Connect heater hose to rear of cylinder head.
50. Position heater rail and connect hose from water

pump.

51. Fit exhaust manifold and turbocharger assembly.

See MANIFOLD AND EXHAUST SYSTEM,

Repair, Exhaust manifold

52. Fit induction manifold.

See MANIFOLD AND

EXHAUST SYSTEM, Repair, Induction
manifold

53. Connect water temperature sensor lead.
54. Connect water pump hose at thermostat.
55. Fit bleed hose at thermostat.
56. Connect radiator top hose at thermostat.
57. Fit heater plugs.

See FUEL SYSTEM, Repair,

Heater plugs

58. Fit fuel injectors.

See FUEL SYSTEM, Repair,

Fuel injectors

59. Fit crankcase ventilation valve and side breather

hose.

60. Fit air cleaner.

See FUEL SYSTEM, Repair,

Air cleaner

61. Refill cooling system.

See COOLING SYSTEM,

Repair, Drain and refill cooling system

62. Fit bonnet.
63. Reconnect battery.

OIL PUMP

Service repair no - 12.60.26

Remove

1. Remove engine front cover.

See Front cover

gasket

2. Remove 7 screws and release oil pump retaining

plate from engine front cover.

3. Mark oil pump inner gear rotor, outer gear rotor

and front cover housing for reassembly.

4. Check for rotor clearances:

Outer rotor to housing, 0,025 - 0,075 mm (0.010
- 0.030 in).
Inner rotor to outer rotor, 0,025 - 0,075 mm
(0.010 - 0.030 in).
Rotor end float, 0,026 - 0,135 mm (0.010 - 0.054
in).

5. Remove inner and outer rotors.
6. Check condition of oil pump components.

NOTE: If the oil pump seating in the front
cover or retaining plate is badly worn,
pitted or scored, a new front cover must

be fitted.

See Front cover gasket

Always renew oil pump rotors as a pair.

7. Clean sealant from pump retaining plate and

front cover.

12

ENGINE

24

REPAIR

Refit

8. Fit oil pump rotors in front cover.
9. Apply a bead of RTV sealant around retaining

plate.

10. Fit oil pump retaining plate to front cover,

securely tighten screws.

11. Fit front cover to cylinder block.

See Front

cover gasket

OIL PRESSURE RELIEF VALVE

Service repair no - 12.60.56

Remove

1. Remove engine oil sump.

See Engine oil

sump

2. Unscrew relief valve retaining plug from base of

front cover.

3. Withdraw valve spring and plunger and check for

wear.
Valve spring free length, 68.00 mm (2.68 in).

NOTE: If the valve plunger sleeve is badly
worn, pitted or scored, a new front cover
must be fitted.

See Front cover gasket

Always renew valve spring and plunger as a pair.

Refit

4. Insert valve plunger and spring into sleeve in

front cover and secure with retaining plug.

5. Fit engine oil sump.

See Engine oil sump

ENGINE

1

SPECIFICATIONS, TORQUE

TORQUE VALUES

NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.

Nm

Engine block

Bearing cap

133

...............................................................................................

Blanking plug, oil gallery, rear

37

....................................................................

Oil squirt jet assembly

17

................................................................................

Drain plug, cylinder block

25

...........................................................................

Oil squirt jet, vacuum pump cam

7

.................................................................

Connecting rod to cap

59

................................................................................

Oil pick up assembly to bearing cap

9

...........................................................

Oil pick up assembly to front cover

25

............................................................

Camshaft thrust plate

9

..................................................................................

Oil drain pipe to block (internal)

25

.................................................................

Oil drain pipe to block (external)

25

................................................................

Sump to cylinder block and front cover

25

......................................................

Drain plug, oil sump

35

...................................................................................

Tappet guide

14

..............................................................................................

Breather side cover assembly

25

....................................................................

Baffle plate to breather side cover

4

..............................................................

Vacuum pump

25

............................................................................................

Fuel lift pump

25

.............................................................................................

Flywheel housing

45

.......................................................................................

Flywheel housing clutch cover stud

10

...........................................................

Plug, flywheel housing

12

...............................................................................

Rear oil seal assembly

25

...............................................................................

Oil filter adaptor

45

..........................................................................................

Waxstat adaptor to oil filter adaptor

9

............................................................

Oil pressure switch

17

.....................................................................................

Oil filter, spin on

13

.........................................................................................

Oil cooler unions to filter adaptor

45

...............................................................

Oil level tube

25

..............................................................................................

Engine mounting foot to cylinder block

85

......................................................

Engine mounting foot to flywheel housing

45

.................................................

Engine mounting foot rubber to mounting foot (bolt and nut)

85

.....................

Flywheel to crankshaft

146

..............................................................................

Clutch cover plate to flywheel

34

....................................................................

Flex drive plate to crankshaft (auto)

146

..........................................................

Flex drive plate to ring gear (auto)

25

.............................................................

Flex drive plate to torque converter (auto)

45

.................................................

12

ENGINE

2

SPECIFICATIONS, TORQUE

Nm

Cylinder head

Cylinder head to cylinder block
M10 x 117

60

°

+ 60

°

.............................................................................................

M12 x 100

60

°

+ 60

°

.............................................................................................

M12 x 140

60

°

+ 60

°

+ 20

°

........................................................................................

Stub pipe heater feed

22

.................................................................................

Water temperature sensor

14

.........................................................................

Blanking plug cylinder head

14

.......................................................................

Engine lifting brackets

25

................................................................................

Electrical harness clip bracket

25

...................................................................

Exhaust manifold stud

10

................................................................................

Exhaust manifold nut

45

.................................................................................

Inlet manifold stud

8

.......................................................................................

Inlet manifold nut and bolt

25

..........................................................................

Air temperature sensor, inlet manifold

14

.......................................................

Blanking plug, inlet manifold

14

......................................................................

Heatshield to inlet manifold

6

.........................................................................

Glow plug

20

...................................................................................................

Glow plug terminal nut

2

................................................................................

Injector clamp (stud)

8

...................................................................................

Injector clamp (nut)

25

....................................................................................

Thermostat housing

25

...................................................................................

Water outlet elbow to thermostat housing

25

..................................................

Water temperature switch, thermostat housing

11

..........................................

Plug thermostat housing

6

.............................................................................

Rocker shaft pedestal bolt

5

°

+ 50

°

.....................................................................

Rocker cover (stud)

8

.....................................................................................

Rocker cover (fixing nut)

10

............................................................................

Breather cyclone to rocker cover

9

................................................................

Tappet adjusting nut

16

..................................................................................

Front cover to cylinder block

25

......................................................................

Front cover plate to front cover

25

..................................................................

Static idler - timing belt (stud)

10

.....................................................................

Static idler - timing belt (nut)

45

......................................................................

Tensioner (timing belt)

45

...............................................................................

Camshaft hub bolt

80

......................................................................................

Timing pulley to camshaft hub

25

...................................................................

Fuel injection pump (stud)

8

...........................................................................

Fuel injection pump (nut)

25

...........................................................................

Abutment bracket to injection pump

25

...........................................................

Support bracket injection pump to cylinder block

25

.......................................

Fuel injection pump access plate to front cover plate

25

................................

Timing pulley to injection pump hub

25

...........................................................

TV Damper pulley bolt to crankshaft

80

°

+ 90

°

.....................................................

Fan pulley to hub

25

.......................................................................................

Fan and viscous coupling to hub

45

...............................................................

Auto tensioner, auxiliary drive (stud)

14

..........................................................

Auto tensioner, auxiliary drive (nut)

45

...........................................................

Auxiliary mounting bracket to cylinder block (stud)

8

.....................................

Auxiliary mounting bracket to cylinder block (bolt and nut)

25

........................

Water pump to block and mounting plate

25

..................................................

Water pump pulley to hub

25

..........................................................................

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