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Defender 90 NAS. Manual - part 15

4.0 V8

REPAIR

ROCKER SHAFT RENEW

Service repair no - 12.29.29

1. Remove RH or LH rocker covers.

See ENGINE

4.0 V8, Repair, rocker cover - right hand or.
See ENGINE 4.0 V8, Repair, rocker cover -
left hand

2. Loosen four rocker shaft fixings.

3. Remove rocker shaft assembly.

NOTE: Each rocker shaft is notched at
ONE end. Notch must be uppermost and
towards front of engine on right hand side,

towards rear on left hand side.

4. Clean rocker pedestal locations on cylinder

head.

5. Fit rocker shaft assembly, locating push rods to

rockers.

6. Tighten rocker shaft fixings to

38 Nm, 28 lbf ft.

7. Fit rocker covers.
8. Fit RH or LH rocker covers.

See ENGINE 4.0

V8, Repair, rocker cover - right hand or See
ENGINE 4.0 V8, Repair, rocker cover - left
hand

OIL SUMP

Service repair no - 12.60.44

Remove

1. Drain engine oil

See SECTION 10,

Maintenance, Under vehicle maintenance

2. Fit and tighten drain plug to

40 Nm, 30 lbf ft.

3. Remove bolt securing dipstick tube to rocker

cover.

4. Working from the centre outwards, progressively

loosen and remove 3 screws and 14 bolts
securing sump. Remove sump.

5. Remove all traces of sealant from mating

surfaces of sump, cylinder block and timing
cover, using a suitable solvent or plastic scraper.

6. Degrease mating surfaces of sump, cylinder

block and front cover.

Refit

7. Apply RTV Hylosil White sealant to mating

surface of sump.

8. Position sump, tighten bolts finger tight.

9. Tighten nuts and bolts progressively in

sequence shown to

23 Nm, 17 lbf ft.

10. Fit bolt securing dipstick tube to rocker cover.

ENGINE

REPAIR

ROCKER COVER GASKET - LEFT HAND

Service repair no - 12.29.40

Remove

1. Disconnect battery negative lead.
2. Remove plenum chamber.

See FUEL SYSTEM,

Repair, plenum chamber

3. Remove screw securing dipstick tube to rocker

cover.

4. Release 4 spark plug leads from guide clips and

disconnect leads from spark plugs.

5. Remove 4 bolts securing rocker cover to cylinder

head.

6. Remove rocker cover.
7. Remove and discard rocker cover gasket.

Refit

8. Clean mating faces of rocker cover and cylinder

head using Bostick 6001 or equivalent. Allow to
dry.

9. Apply a thin coating of impact adhesive (Bostick

1775 or equivalent) to mating faces of rocker
cover and gasket . Use a brush to ensure an
even film. Allow adhesive to become touch dry.

CAUTION: Gasket fits one way round only.
It must be fitted accurately, first time.
Subsequent movement will destroy

bonding.

10. 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.

CAUTION: Allow cover to stand for 30
minutes before fitting.

11. Fit rocker cover to cylinder head, ensuring short

bolts are fitted inboard, tighten bolts to

9 Nm, 7

lbf ft.

12. Connect plug leads and secure to guide clips.
13. Align dipstick tube to rocker cover and tighten

screw.

14. Fit plenum chamber.

See FUEL SYSTEM,

Repair, plenum chamber

15. Reconnect battery negative lead.

4.0 V8

REPAIR

ROCKER COVER GASKET - RIGHT HAND

Service repair no - 12.29.41

Remove

1. Disconnect battery negative lead.

2. Disconnect breather hose from plenum chamber

and remove hose from rocker cover.

3. Position container to collect coolant spillage.
4. Remove bolt securing coolant pipe brackets

together and nut securing bracket to manifold.

5. Loosen clip and disconnect coolant return hose

from manifold.

6. Depressurise fuel system.

See FUEL SYSTEM,

Adjustment, fuel system depressurise

7. Position cloth to absorb fuel spillage.
8. Disconnect fuel feed hose union.

CAUTION: Plug the connections.

9. Loosen clip and disconnect fuel return hose.

CAUTION: Plug the connections.

10. Remove 2 bolts securing engine harness

bracket to manifold.

11. Release 4 spark plug leads from guide clips and

disconnect leads from spark plugs.

12. Remove 4 bolts securing rocker cover to cylinder

head.

13. Remove rocker cover.
14. Remove and discard rocker cover gasket.

ENGINE

REPAIR

Refit

15. Clean mating faces of rocker cover and cylinder

head using Bostick 6001 or equivalent. Allow to
dry.

16. Apply a thin coating of impact adhesive (Bostick

1775 or equivalent) to mating faces of rocker
cover and gasket. Use a brush to ensure an
even film. Allow adhesive to become touch dry.

NOTE: Gasket only fits one way round. It
must be fitted accurately, first time.
Subsequent movement will destroy

bonding.

17. 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.

CAUTION: Allow cover to stand for 30
minutes before fitting.

18. Fit rocker cover to cylinder head ensuring short

bolts are fitted inboard, tighten bolts to

9 Nm.

19. Connect plug leads and secure to guide clips.
20. Position harness bracket to inlet manifold and

tighten bolts.

21. Connect fuel feed and return hoses.
22. Connect coolant hose to inlet manifold and

tighten clip.

23. Secure coolant pipe brackets
24. Fit breather hose.
25. Refill cooling system.
26. Reconnect battery negative lead.

ENGINE ASSEMBLY

Service repair no - 12.41.01

Remove

1. Position vehicle on ’4-post’ ramp [hoist].
2. Drain engine oil.

See SECTION 10,

Maintenance, under vehicle maintenance

3. Remove bonnet.

See CHASSIS AND BODY,

Repair, bonnet

4. Remove radiator.

See COOLING SYSTEM,

Repair, radiator

5. Loosen 3 PAS pump pulley bolts.
6. Using a 15 mm ring spanner, release auxillary

drive belt tension and release belt from
alternator pulley.

7. Remove drive belt.

8. Disconnect A/C compressor multiplug.
9. Remove 4 bolts securing compressor to

mounting bracket.

10. Collect compressor heat shield.
11. Tie compressor aside with string.

Content .. 13 14 15 16 ..