Content .. 43 44 45 46 ..

Defender 90 / 110 / 130. Manual - part 45

CYLINDER ENGINE

Reclaiming cylinder head threads

Damaged

or stripped threads

the cylinder head can

be salvaged by fitting Helicoils

as follows:

A - These

holes may be drilled 0.3906 in.

0.937

0.040

in. deep. Tapped

with

Helicoil Tap

No. 6 CPB

6CS

0.875

in. (min.) deep

UNC

insert).

Holes B

These eight holes may be drilled 0.3906 in.

dia.

0.040 in. deep. Tapped with Helicoil Tap

No. 6 CBB 0.749 in. (min.) deep UNC

insert).

Holes C

These

four

holes may be drilled 0.3906 in.

dia.

0.937

0.040 in. deep. Tapped with Helicoil Tap

No.

6 CPB or 6CS

0.875

in. (min.) deep

U N C 1

insert).

Holes

These four holes may be drilled 0.261

in.

dia.

0.675

0.040

in.

deep. Tapped

with

Helicoil Tap

No. 4CPB

or 4CS

0.625

in. (min.) deep

UNC

insert).

Holes

These

six

holes

be drilled 0.3906 in.

dia.

0.937

0.040 i n . deep. Tapped with Hclicoil Tap

No. 6 CPR or

x 0.875

i n .

(min.) deep

UNC

insert).

NOTE: Right-hand cylinder head illustrated.
American projection.

F Exhaust manifold face

Inlet manifold face

H Front face

Rear face

Front of engine

799M

CYLINDER ENGINE

REMOVE

AND OVERHAUL FLYWHEEL

Place a chisel immediately above the drilled
hole and strike it sharply to split the starter ring

gear.

Remove the retaining bolts and withdraw the

flywheel from the crankshaft.

2. Examine the flywheel clutch face for cracks, scores

and overheating.

the overall thickness

of the

flywheel

is in excess of the minimum thickness i.e.

(1.572 in)

can be refaced provided that

after machining it will not be below the minimum
thickness. Remove the three dowels before
machining.

3. Examine the ring gear and if worn

the teeth are

chipped and broken it can be renewed

as follows:

Heat the new ring gear uniformly t o between 170

degrees and

175 degrees

(338 degrees

347

degrees

F) but d o not exceed the higher

temperature.

Place the flywheel, clutch side down,

on a flat

surface.

9. Locate the heated starter ring gear in position on

the flywheel, with the chamfered inner diameter
towards the flywheel flange.

If the starter ring gear

chamfered both sides, it can be fitted either way

round.
Press the starter ring gear firmly against the flange
until the ring contracts sufficiently to grip the
flywheel.

11. Allow the flywheel to cool gradually.

NOT

hasten cooling in any way

or distorting may occur.

12. Fit new clutch assembly location dowels

the

flywheel.

4. Drill a

in)

diameter hole axially

between the
diameter

of the starter ring sufficiently deep

weaken the ring. D o

NOT allow the drill to enter

the flywheel.

and

a cioth over the

operator from flying fragments.

root

of any tooth and the inner

5 .

Secure the flywheel

a vice

with soft jaws

WARNING: Take adequate precautions against
flying fragments when splitting the ring gear.

100

CYLINDER ENGINE

REMOVE TIMING GEAR COVER

AND WATER

PUMP

1. Place an oil drip-tray beneath the timing cover and

Remove the crankshaft pulley bolt and special

3. Remove the t w o bolts securing the sump to the

remove

oil filter element.

washer and withdraw the pulley.

bottom

of the timing cover.

Renewing timing cover oil seal

Remove the seven drive screws and withdraw the

mud shield and the oil seal.

Position

the gear cover with the front face

uppermost and the underside supported across t h e
oil seal housing bore on

a suitable wooden block.

7. Enter the oil seal, lip side leading, into the housing

bore.

Press in the oil seal until the plain face is
(0.062 in) approximately below

gear cover

face.

9. Fit the mud shield and secure with the screws.

4. Remove the remaining timing cover retaining bolts

and withdraw the cover complete with

oil pump.

REMOVE

AND OVERHAUL THE OIL PUMP

1. Remove the bolts from t h e oil pump cover.

2. Withdraw t h e oil pump cover.
3. Lift off the cover gasket.

4. Withdraw the oil pump gears.

101

Dismantle pump

Assemble pump

5 .

Unscrew the plug from the pressure relief valve.

6. Lift off the joint washer for the plug.

8. Withdraw the pressure

valve.

17. Insert the relief valve spring.

18. Locate the sealing washer on to the relief valve

19.

Fit the relief valve plug and tighten to 4,0 to

kgf m

(30

35 Ibf ft).

20. Fully pack the oil pump gear housing

with

petroleum jelly. Use only petroleum jelly; no other
grease is suitable.

21. Fit the oil pump

so that

t h e

petroleum jelly

i s

forced into every cavity between the teeth of the
gears.

IMPORTANT: Unless

the

pump if fully packed

with petroleum jelly

it may

not prime itself when

the

engine is started.

Withdraw the spring from the relief valve.

plug.

22. Place a new gasket on the oil pump cover.
23. Locate the oil pump cover

position.

24. Fit the special fixing bolts and tighten alternately

and evenly to the correct torque.

V8 CYLINDER ENGINE

Examine pump

Check the

oil pump gears for wear or scores.

10.

Fit the oil pump gears and shaft into

t h e

Front

Place a straight-edge across the
Check the

and

the front cover.

If less than

(0.0018

in),

check the front cover gear pocket for wear.

REMOVE

TIMING

CHAIN

GEARS

AND

cover.

CAMSHAFT

Remove the retaining bolt and washer

a n d

withdraw the distributor drive gear and spacer.

continucd

13. Chcck the oil pressure relief valve for wear or

14. Check the relief valve spring for wear at the sides

15.

the

gauze filter for the relief valve.

16. Check the

fit

of the relief valve in its bore. The

valve must be an easy slide

fit

with no perceptible

side movement.

scores.

---'--

of collapse.

e'"-'-

102

Content .. 43 44 45 46 ..