TD5 Defender
ENGINE
5
OVERHAUL
Refit
1. Thoroughly clean cylinder block and cylinder
head mating faces.
2. Ensure coolant and oil passageways are clear
and bolt holes are clean and dry.
3. Ensure locating dowel holes in cylinder block are
clean and dry.
4. Fit new plastic locating dowels in cylinder block.
5. Fit new cylinder head gasket of the correct
thickness with the word ’TOP’ uppermost.
CAUTION: Gasket must be fitted dry.
6. Ensure that camshaft timing pin LRT-12-158 is
still in position and using assistance, fit cylinder
head.
7. Carefully enter new cylinder head bolts together
with their captive washers, DO NOT DROP.
Lightly tighten bolts.
CAUTION: Cylinder head bolts are
pre-lubricated and do not require
additional lubrication.
8. 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.
9. Fit cylinder head to timing chain cover nut and
bolt and tighten to 25 Nm (18 lbf.ft) .
10. Clean camshaft sprocket and mating face on
camshaft.
11. Ensure engine is set to TDC firing - No.1
cylinder.
12. Check that mark on camshaft sprocket is
positioned between the 2 coloured links on
timing chain.
13. Position sprocket to camshaft, fit and lightly
tighten 3 new bolts then loosen bolts half a turn.