Land Rover Defender 90 110 Workshop Book 2 Rover

2.5 LITRE PETROL ENGINE 
12 L 
7. Examine the sprockets  and discard if the teeth  are 
8. Dismantle  the tensioner  assembly and discard if 
9. Examine  the tensioner  body and check  that the oi! 
10. Examine the slipper  and check  that the oil outlet 
11. Check  that the oil inlet  and exit  oil hole in the 
worn. 
, 
any of the 
parts  are worn. 
inlet  hole is clcar. 
hole  is clear. 
tensioner  mounting  plate is clear. 
12. Assemble  the tensioner body to the  mounting  plate 
with the two...

112) 2.5 LITRE PETROL ENGINE 
VALVE TIMING 6. Fit and  adjust  the timing  chain damper so that 
there  is 
a maximum  clearance of 0,25 mm 
(0.010 in) between  the timing  chain and damper. 
Tighten 
thc retaining  bolts and secure  with new 
lock  tabs. 
1. Check  that numbers  one and four  pistons  are still  at 
T.D.C.  and without  disturbing  the crankshaft, 
remove 
the pulley and timing  cover. 
2. Fit the camshaft  sprocket temporally  and rotate  the 
camshaft  in a clockwise  direction until...

.7 . .: , ...._ ,, . : . ... .:: .. . . _.. 
. .- .. 
.... .. 
2.5 LITRE PETROL ENGINE 1 
RENEW EXHAUST  VALVE SEAT INSERTS 
1. 
2. 
Hold the cylinder  head firmly in a vice, wear 
protective  goggles and grind  the old  insert  away 
until  thin enough  to be  cracked  and prised 
out. 
Take  care not to damage  the insert  pocket. 
Remove  any burrs  and swarf  from the pocket. 
Failure 
to do  this  could  cause the new  insert  to 
crack  when  being  fitted. 
NOTE:  Since no special  tool is...

2.5 LITRE PETROL ENGINE 
5. Apply  a bead of Hylogrip 2000 sealant to the  rear 
face 
of the flywheel  housing  to the dimensions and 
configuration  as illustrated  below. The illustration 
has been  produced  full  size 
so that a template may 
be  made  to facilitate  the  application of the sealant. 
The 
bead should  be 53 mm wide and 0,25 mm 
thick. 
6. Examine  the seal  guide  number 18G 1344 and 
repair  any damage  that could destroy  the seal lip. 
7. Lubricate  the  outside  diameter  of the...

2.5 LITRE PETROL ENGINE I 12 1 
FITTING SUMP 
1. Clean the sump and cylinder block mating  faces. 
2. Apply  a bead of RTV HYLOSILL 102  black 
approximately  7 
mm wide to the cylinder  block or 
sump mating face. 
3. 
Fit the  sump  within  30 minutes  of applying  sealant 
and  secure  with the bolts  and  tighten  evenly 
to the 
correct  torque. 
NOTE:  RTV Liquid  Sealant is available  under part 
number  RTC 
3254 from Land  Rover  Parts and 
Equipment  Ltd. 
SKEW GEAR 
I. To renew the bush, hold...

1121 2.5 LITRE DIESEL ENGINE 
ST1922M 
2.5 LITRE DIESEL  ENGINE 
p7 *.: ..... ”.’ ,,” _... .. 
52  

2.50 LITRE DIESEL ENGINE 
DISMANTLE AND OVERHAUL 
Special  tools: 
274400 
- Drift  inlet valve  guides 
274401 
-Drift  exhaust  valve guides 
600959 
-Drift exhaust  valve guide 
601508 
- Drift  inlet valve  guide 
MS621 -Seal cutter 
530625 
- Insert  replacer 
R0605022 - Clutch  centralising tool 
270304 - Cork-seal  guide 
18G 1344 -Seal guide - rear main  bearing 
18G 134-11 -Seal replacer  rear main  oil seal 
530102A - Crankshaft  nut spanner 
18G 1457/1- Dist.  pump  remover 
18G 
1464/2/6 -...

121 2.50 LITRE DIESEL ENGINE 
16. To remove a hot  plug  support  the cylinder  head, 
face  downwards 
on two pieces of timber  and insert 
a thin  soft metal  drift through  the injector  shroud 
throat  and tap the hot  plug 
from the inside.  Once 
removed,  a faulty  hot plug  cannot  be restored  and 
must  be scrapped. 
STl422M 
ST1428PJ A- Shroud B - Hot Plug 
17. If the injector  shroud is damaged  using a 13 mm 
(1.05 in) t~all bearing and drift,  drift the shroud out 
towards  the injector...

2.50 LITRE DIESEL ENGINE 
Whilst  this is rarely neccssary the  procedure  is 
nevertheless  as follows: 
25. Using  an 8 mni taper tap, cut a thread 30 mm 
(1,2 in) deep in the  combustion  face end of the 
tube 
to be removed. 
26.  Screw  an appropriate  bolt into  the  tube  and  press 
out  the 
tube as illustrated. 
27.  Smear  both ends 
of a new  tube with silicone  rubber 
sealant 
ancl press it into  the cylinder  head. 
12 
chambers face downwards.  Since the inlet  and 
exhaust  valve guides...

1121 2.50 LITRE DIESEL ENGINE 
33. 
34. 
35. 
The  special  set of hand tools recommended for 
refacing  include  expandable pilots that fit tightly 
into  new 
or worn  guides  to ensure  that the valve 
seat  is concentric  with  valve  guide. 
The refacing 
tool has tungsten  carbide cutters and can be used  to 
cut  a seat 
in a  new  exhaust  seat insert. 
Select  the  correct  expandable collet for the  valvc 
guide concerned  i.e. 
8 mm for inlet guides  and 8,5 
mm for exhaust. 
Loosely  assemble...