Defender (1993+). Instruction - page 26

ROCKER COVER

-

RIGHT HAND

-

RENEW

10.

Apply Bostik 1775 impact adhesive

to

rocker

cover seal face and gasket, using a brush to

1. Disconnect battery negative lead.

ensure an even film. Allow adhesive

to

2.

Disconnect purge pipe from charcoal canister

become touch dry.

at plenum.

11. Place one end of gasket into cover recess

3.

Remove breather pipe from rocker cover.

with edge firmly against recess wall, holding

4.

Remove coolant pipes from inlet manifold.

remainder

of gasket clear. Work around cover,

5. Remove spark plug leads from plugs and

pressing gasket into

place ensuring

edge

retaining clips.

6.

Remove four rocker cover bolts. Moving fuel

12.

Allow cover to stand for thirty minutes before

13. Fit rocker cover to cylinder head with four

8.

screws, short screws, inboard, tighten

to

8 Nm.

9.

15. Fit breather pipe to rocker cover, tighten clip.

pipes aside, remove rocker cover.

fitting.

Remove plug lead retaining clips from rocker
cover,

fit to new

rocker cover.

Clean and

dry

rocker cover and cylinder head

matng

faces

using Bostik cleaner 6001.

16. Fit breather pipe to inlet manifold, tighten

bolts.

17. Fit spark plug leads

to

plugs and retaining

NOTE: Gasket fits one way round only. It

Subsequent movement

will

destroy

18. Connect purge pipe from charcoal canister at

must be fitted accurately, first

time.

clips.

bonding.

plenum, tighten clip.

ROCKER COVER

-

LEFT HAND

-

RENEW

1.

Remove air flow sensor.

2. Remove plenum chamber.

3.

Remove dipstick.

4.

Remove spark plug leads from plugs and
retaining clips.

5. Disconnect

HT lead from coil.

6.

Remove alternator heat shield from rocker

cover.

7.

Remove air flow meter harness clip.

8.

Remove dipstick tube clip.

9.

Remove four rocker cover bolts, remove
rocker cover.

11. Remove plug lead retaining clips from rocker

cover, fit

to

new rocker cover.

12.

Clean and dry rocker cover and cylinder head
mating faces, using Bostik cleaner

6001.

NOTE:

Gasket fits one way round only.

It

must

be fitted accurately, first time.

Subsequent

movement

will

destroy

13. Apply Bostik 1775 impact adhesive to rocker

cover seal face and gasket, using a brush

to

ensure an even film. Allow adhesive to
become touch dry, approximately fifteen
minutes.

10. Discard gasket

I

bonding.

RR3820M

ENGINE

firmly contacts recess wall.

14. Position fuel pipes.

14.

Place one end of gasket into cover recess

with

edge firmly against recess wall, holding

remainder of gasket clear. Work around cover,

pressing gasket into place ensuring edge
firmly contacts recess wall.

2.

Loosen four rocker shaft fixings

ROCKER SHAFT

RENEW

1.

Remove rocker covers as required,

RR3821M

15. Allow cover to stand for thirty minutes before

3.

Remove rocker shaft assembly.

fitting.

16. Fit rocker cover to cylinder head with four

NOTE: Each rocker shaft i s notched at

screws, short screws inboard, tighten to 8 Nm.

ONE end. Notch must be uppermost and

17. Locate and tighten dipstick tube clip.

towards front of engine on right hand side,

18. Fit and tighten air flow meter harness clip.

towards rear on left hand side.

19. Fit alternator heat shield to rocker cover.

20. Connect HT lead to coil.

4. Clean rocker pedestal locations on cylinder

21. Connect spark plug leads to plugs and

head.

retaining clips.

5. Fit rocker shaft assembly, locating push rods

22. Fit dipstick.

to rockers.

23. Fit plenum chamber.

6. Tighten rocker shaft fixings to 38 Nm.

24. Fit air flow meter.

7. Fit rocker covers.

ENGINE

HYDRAULIC TAPPETS RENEW

CRANKSHAFT PULLEY ASSEMBLY

1. Remove rocker shafts.

1.

Remove viscous coupling, see

viscous

2. Remove inlet manifold.

3. Remove push rods, retain in removal

2. Remove water pump drive belt.

coupling, fan blades, pulley and fan cowl.

3. Remove alternator drive belt.

Remove power steering pump drive belt.

5. Raise vehicle on ramp.
6. Remove bell housing bottom cover.
7. With assistance to stop flywheel rotation,

remove crankshaft pulley assembly retaining
bolt.

4

sequence.

8. Remove crankshaft pulley assembly.
9. If required: Place assembly in vice and

remove pulleys.

10. Fit pulleys to torsional vibration damper.
11. Lubricate seal face of assembly.

13. With assistance to stop flywheel rotation, fit

retaining bolt, tighten to 280 Nm.

14. Reverse instructions 1 to 6.

12. Fit pulley assembly.

I

4.

Remove hydraulic tappets

5.

Fit tappets, push rods and rocker assemblies.

6.

Fit inlet manifold.

7. Reverse remaining removal procedure.

FRONT

COVER OIL SEAL

-

RENEW

1.

Remove crankshaft pulley,

2. Remove eight screws and remove mud

excluder.

3. Fit button

of

18G1328

to

crankshaft,

fit

extractor

to seal.

4. Turn centre bolt

of

extractor

to

remove seal.

5. Remove seal from extractor.

6.

Clean seal seating.

7.

Lubricate outside diameter of seal.

8. Locate seal in front cover.

9.

Fit adaptor 18G1291/5 to 18G1291/4.

10.

Fit

tool

to seal.

11. Fit and tighten centre bolt

to

crankshaft,

tighten centre locknut to seat seal.

12.

Slacken locknut and remove

tool.

13.

Lubricate seal lip.

14. Fit mud excluder and tighten screws.
15. Fit crankshaft pulley assembly.

ENGINE

FRONT

COVER GASKET

29. Clean threads of cover fixing bolts, apply

1. Remove crankshaft pulley.

30. Fit timing cover, fit fixing bolts, tighten to 28

2. Remove water pump pulley.

Nm.

3. Release distributor cap clips.

31. Fit alternator support strut to front cover.

4. Release plug leads from plugs and clips.
5. Place cap and leads to one side.

Nm.

6. Turn engine until No. 1 piston is at T.D.C.
7. Check position of rotor arm.

34. Lubricate distributor O ring.

8. Remove fixings securing power steering pump

35. Fit distributor in position marked.

bracket to water pump bracket.

36. Align oil pump drive, if distributor does not

9. Remove power steering pump bracket from

seat correctly.

water pump.

37. Fit distributor clamp, tighten to 20 Nm.

tensioner.

bracket.

Loctite 372 to threads.

32. Tighten sump to timing cover fixings to 10

33. Tighten sump fixings to 10 Nm.

10. Remove clips securing wiring to alternator

38. Locate alternator tensioner on water pump

11. Disconnect distributor feed wire.

39. Connect heater hose, tighten clip.

12. Pivot power steering pump away from front

40. Connect oil pressure switch.
41. Connect bottom hose, tighten clip.

13. Disconnect vacuum pipe from distributor.

42. Connect vacuum pipe to distributor.

14. Remove water pump bottom hose.

43. Loosen power steering pump pivot,' lower

15. Disconnect oil pressure switch.

pump.

16. Disconnect heater hose at water pump.

44. Connect distributor feed wire.

17. Remove alternator tensioner from water pump,

45. Connect wire ties to alternator tensioner.

move tensioner aside.

46. Fit power steering pump bracket to water

18. Mark distributor position to front cover.

pump, tighten to 28 Nm.

19. Remove distributor clamp, remove distributor.

47. Fit power steering pump to bracket.

20. Remove fixings sump to front cover.

48. Position distributor cap. Fit plug leads to plugs

21. Loosen four adjacent sump fixings.

and clips.

22. Remove alternator support strut from front

49. Clip distributor cap in position.

23. Loosen remaining front cover fixings and

51. Fit crankshaft pulley.

24. Remove front cover gasket.

53. Check ignition timing.

54. Refill cooling system.

cover, tighten pivot to retain in position.

cover, move strut aside.

remove front cover.

52. Tension drive belts correctly.

50. Fit water pump pulley, tighten

to

10 Nm.

Refit

25.

Clean timing cover, clean block face.

26. Lightly grease gasket faces.

27.

Fit new gasket to block face.

28. Apply

hylosil to sump gasket.

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