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