Defender (1993+). Instruction - page 25

ENGINE

6.

Heat water and observe temperature at which

thermostat opens.

4.

Fit distributor

to

engine, check that centre line

of

rotor arm is now in line with number one

8. Clean

intake and

manifold and thermostat housing

9. Fit thermostat with jiggle pin uppermost.

NOTE:

Airlocks

may

develop

in cooling

positioned,

with

consequent

loss

of

coolant and possible overheating.

10.

Fit housing with new gasket, tighten two bolts

to

correct torque, 28 Nm.

system

if

thermostat

is

incorrectly

reset oil pump drive tongue, repeat operation.

FIT

DISTRIBUTOR

1.

Turn crankshaft

to

bring number one piston

to

BTDC on compression stroke (both valves

closed number one cylinder).

2. Turn distributor drive until rotor arm is

approximately

30"

anti-clockwise from number

one spark plug lead position on cap.

3. Turn oil pump and distributor drive shaft until

tongue is in approximate position illustrated.

RR178E

6.

Fit clamp and nut, leave loose.

7.

Rotate distributor until peak on pick-up lines
up with a peak on reluctor ring. Remove rotor
arm for better view.

CAUTION: On no account must engine be
started before this operation is carried out.

8. Secure distributor in this position by tightening

clamp nut.

ST859M

7. Disard thermostat if faulty.

mating faces.

ENGINE

RR1876E

9.

Fit

distributor cap and spark plugs. Connect

H.T.

leads as shown in illustration RR1876E.

NOTE: This distributor setting is to enable

1.

An oil baffle is

fitted

inside each rocker cover,

engine to

be started. When engine is

Remove

two

screws to remove baffle for

refitted the ignition timing must

be set

cleaning.

using electronic equipment.

2.

Remove old gasket and sealant from covers

and cylinder heads. Clean and

dry gasket

mounting face, using Bostik cleaner

6001.

Apply Bostik

1775

to seal face and gasket,

use a brush

to

ensure an even film. Allow

adhesive

to

become touch-dry, approximately

fifteen minutes.

NOTE: The gasket fits one way only,

it

must

be

fitted accurately first time.

Subsequent

movement would destroy

bond.

FIT ROCKER COVERS

ST853M

3.

Fit pilot studs in rocker cover fixing holes to

guide gasket onto cover and into recess.

Press gasket into place ensuring that outer
edge firmly contacts recess wall.

4.

Allow covers to stand for thirty minutes before
fitting.

5. Secure rocker covers to cylinder heads with

short screws inboard, long screws outboard.
Tighten

to correct torque, 9

Nm.

ENGINE

FIT ENGINE

OIL FILTER

FIT EXHAUST MANIFOLD

1.

Clean oil cooler adaptor mating face.

1.

Ensure mating surfaces of head and exhaust

2.

Coat sealing ring of new filter with clean

manifold are clean. Fit new gaskets

to

engine oil.

exhaust manifold. Coat threads of bolts with

3.

Fill filter with new oil as far as possible, noting

anti-seize compound.

angle at which filter is

to

be fitted.

2.

Position manifold on cylinder head and

fit

new

4.

Screw on filter until sealing ring touches

lockplates, securing

bolts

and plain washers.

mating face, then tighten a further half turn by

The plain washers are fitted

between manifold

hand only.

DO NOT OVERTIGHTEN.

and lockplates. Evenly tighten manifold bolts

5. Refill engine with specified grade and quantity

to correct torque. 20 Nm. Bend over lock tabs.

of oil.

MISCELLANEOUS AND NON-STANDARD ITEMS

Fit remaining items of equipment, miscellaneous
hoses, pipes, filters, clips and brackets in position.

RR2618S

ENGINE

CYLINDER HEAD GASKETS

-

RENEW

23. Tighten bolts progressively in sequence, see

illustration number ST845M. Finally tighten

to

1. Drain cooling system.

torque:

2. Remove inlet manifold.

Outer row 60 Nm

3. Remove alternator.

Centre row

90

Nm

4. Remove rocker shafts.

Inner row

90

Nm.

5.

Remove push rods.

24. When all bolts have been tightened, re-check

6. Remove power steering pump belt.

for correct torque.

7. Remove alternator bracket.

25. Reverse instructions 12

to

1.

8. Remove both exhaust manifolds.

9.

Remove air cleaner assembly.

CYLINDER HEADS

-

RENEW

10. Remove air flow meter.
11. Remove earth leads from rear

of

left hand

1.

Remove cylinder heads and gaskets.

cylinder head

2. Remove spark plugs.

12. Right hand cylinder head

-

remove breather

3. Using spring compressor 18G 106A, remove

pipe from lifting bracket.

13. Loosen

cylinder

head

bolts,

reversing

tightening sequence.

14. Remove cylinder heads.

15.

Remove cylinder head gaskets.

16. Clean exhaust mating faces.
17. Clean head and block faces.

18. Fit new cylinder head gaskets, word TOP

uppermost.

DO NOT use sealant.

19.

Oil cylinder bores.

20.

Clean threads of head bolts and coat with
Loctite 572.

21. Locate cylinder heads on block.
22. Locate cylinder head bolts

in position

illustrated.
Long bolts

-

1, 3, and 5.

Medium

bolts

-

2,

4,

6, 7, 8,

9

and 10

Short bolts

-

11,

12,

13,

and 14

valves, collets, springs and caps.

RR3819M

4.

From left hand cylinder head, remove earth

lead studs.

5. Remove PAS pump pivot stud.
6. Right hand cylinder head, remove rear lifting

bracket.

7. Fit lifting bracket to new right hand cylinder

head.

8.

Fit

PAS pump pivot stud, earth lead studs

to

new left hand cylinder head.

9. Regrind valves.

10. Lubricate valve stems,

fit

valves, springs, and

caps. Fit new seals

to

inlet valve stems only.

11. Using

spring

compressor

18G

106A,

compress springs,

fit

collets. Tap valve to

check correct collet seating.

10. Fit spark plugs.
11. Fit cylinder heads with new gaskets.

NOTE: Left hand cylinder head illustrated,
arrow points to front of

vehicle.

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