TD5 Defender
12
ENGINE
10
REPAIR
Refit
39. Clean mating faces of cylinder head and cylinder
block.
40. Check cylinder head for warping, across centre
and from corner to corner:
Maximum warp = 0.10 mm (0.004 in)
CAUTION: Cylinder heads may not be
refaced, replace cylinder head assembly if
warping exceeds figure given.
41. Ensure coolant and oil passages are clean.
42. Clean dowel holes and fit new dowels.
43. Fit new cylinder head gasket of the correct
thickness with the word ’TOP’ uppermost.
44. Using assistance, fit cylinder head and locate on
to dowels.
45. Carefully enter new cylinder head bolts together
with their captive washers, DO NOT DROP.
Lightly tighten bolts.
46. Using sequence shown, tighten cylinder head
bolts to:-
Stage 1 - 30 Nm (23 lbf.ft)
Stage 2 - 65 Nm (48 lbf.ft)
Stage 3 - 90
°
Stage 4 - Further 180
°
Stage 5 - Further 45
°
CAUTION: Ensure correct tightening
sequence is followed for all 5 tightening
stages. Do not tighten bolts 315
°
in one
operation.
47. Fit nut and bolt securing cylinder head to timing
chain cover and tighten to 25 Nm (18 lbf.ft) .
48. Clean camshaft sprocket and mating face on
camshaft.
49. Ensure engine is set to TDC No. 1 cylinder and
mark on camshaft sprocket is positioned
between the 2 coloured links.
50. Position camshaft sprocket to camshaft, fit and
lightly tighten new bolts then loosen bolts half a
turn.
51. Clean fixed guide retaining pin and apply Loctite
242 to threads.
52. Fit and tighten fixed guide retaining pin to 25 Nm
(18 lbf.ft).
53. Clean timing chain tensioner and fit new sealing
washer.
54. Fit timing chain tensioner and tighten to 45 Nm
(33 lbf.ft) .
55. Tighten camshaft sprocket retaining bolts to 36
Nm (27 lbf.ft).
56. Remove LRT-12-058 from camshaft.
57. Remove LRT-12-158 from gearbox bell housing.
58. Clean access plug recess in cylinder head and
fit new ’O’ ring. Fit access plug.
59. Clean vacuum pump union.
60. Tighten vacuum pipe union to 10 Nm (7lbf.ft) .
61. Fit bolts securing alternator bracket to cylinder
head and tighten to 25 Nm (18 lbf.ft).
62. Connect top hose, heater hoses and secure with
clips.
