Land Rover Defender 90 110 Workshop Book 2 Rover

2.50 LITRE DIESEL ENGINE 1121 
{: :;;

I 12 I 2.50 LITRE DIESEL  ENGINE 
4 Dismantle  also the old  coupling  and use the sleeve 
to manufacture  a  suitable press tool.  Use  a round 
section file to increase  the depth  of the cross-pin 
slot 
so that it will not  bear upon the cross-pin  when 
used  to press 
in the  new  coupling.  Weld a suitable 
length 
of steel  bar or tube to  the sleeve to complete 
the tool. 
5. Fill the  annular  groove round the splines of the 
coupling  with silicone  rubber sealant. 
6. Assemble the skew gear...

2.50 LITRE DIESEL ENGINE 1121 
1 .- ,; c ,.“.:2 * 2.  Remove the main bear~ng caps and shells  and lift 
out the crankshaft.  Collect the bearing  shells from 
the  bearing  saddles and the thrust  washers from  the 
centre saddle. **,> 
>,J -ST719M v 
3.  Degrease the crankshaft  and clear  out the oil ways, 
which  can become  clogged after long service. 
4.  Examine  visually, the crankpins  and  main bearing 
journals,  for  obvious  wear, 
scorcs, grooves  and 
overheating. 
A decision  at  this...

E[ 2.50 LITRE DIESEL ENGINE 
If the  above  figures are exceeded the cylinders 
must  be  rebored 
or sleeved  depending  upon the 
general condition  of the  bores 
and amount  of wear. 
Alternatively, 
if the  overall  wear, taper and  ovality 
arc 
wcll within the acceptable  limits and  the 
original  pistons  are serviceable  new piston  rings 
may be fitted. It is important  however,  that the 
bores arc deglazed,  with a hone,  to give  a cross- 
hatched  finish to provide  a  seating  for  the...

2.50 LITRE DIESEL ENGINE 
3. New Pistons - Original  pistons fitted to new 
engines  at 
the factory  are specially  graded to 
facilitate  assembly.  The grade  letter  on the  piston 
crown  should  be ignored  when ordering  new 
pistons.  Genuine  Land  Rover  service standard  size 
pistons 
are supplied  0,025 mm (0.001  in) oversize 
to allow for production  tolerances  on new  engines. 
When  fitting 
new pistons  to a standard  size cylinder 
block  the 
bores must be honed  to accommodate  the...

El 2.50 LITRE DIESEL ENGINE 
Check piston ring side clearance 
10. It is important  that  clearances  are correct.  Rings 
that  are 
too tight will bind  when  hot, imparing the 
radial  pressure  causing  possible 
loss of 
comprcssion. Excessive  clearancc will allow the 
rings 
to rock in the  grooves  and  the resulting 
pumping  action could cause excessive  oil 
consumption  and eventually  broken rings. 
11. Fit the oil control  ring to the bottom groove. Fit the 
unpolished  compression  ring...

2.50 LITRE DIESEL ENGINE 1121 
-1 .. li-.;: .... ::* I The clearance  should be  between 0,lO and Connecting-rod end-float ’: ..;“.I .. .. .~ ., +.‘,;:!..M 0,20 mm (0.004 and 0.008  in). The  bearing nip  can 
be adjusted by the selective assembly of the 
bearing shells which  are available in slightly 
varying  thickncsscs. 
Do not  file or machine  the 
caps 
or rods  to vary the bearing  nip. Make a final 
check  to prove  the clearance  by inserting  a 0,063  26. 
Fit the  connecting-rods complete...

2.50 LITRE DIESEL ENGINE 
ASSEMBLE ENGINE 
ASSEMBLE JET TUBES TO CYLINDER BLOCK 
Oil jet tubes arc fitted  to lubricate the pistons and bores 
directly  from 
thc main oil gallery. 
1. 
2. 
3. 
4 
_. 
5 
The jet iubes are Handed  and can only  be fitted 
one  way.  It is important  to  note  that  the  jet 
retaining  bolt  contains 
a non-return valve and 
therefore 
on no  account  must an  ordinary  bolt be 
used.  Clean  the recess 
in the  cylinder  block  using  an air 
line, if available, to...

. 
2.50 LITRE DIESEL ENGINE 
_I !::c;,.”, ., .,....e, .. ... .‘:%v ... 
3. Locate  the  crankshaft in position on the upper 
bearing  halves  in the  crankcase  and  wipe any oil 
from  the  ,journals since  ‘Plastigauge’  is 
soluble in 
oil. Place  a piece  of ‘Plastigauge’  across the lower 
half  of each  crankshaft  journal 
or lower  bearing 
cap 
she!l. Fit the  cap  and tighten  to  the  correct 
torque.  Remove  the cap and bearing and  using the 
scale  supplied 
with the ‘Plastigauge’  measure...

E( 2.50 LITRE DIESEL ENGINE 
ST T 
10. To prevent  any  cork seal  material becoming 
trapped  between  the bearing  cap  and  crankcase, 
chamfer  the  inner  edge of the  corks 
0,40 to 
0,80 mm(& to B in) wide as illustrated. 
Immcrsc 
the cork seals in engine  oil and fit them  to 
the bearing  cap. 
11. Fit the bearing  cap and  lower  shell to the crankcase 
and secure  with  new bolts and washers  and tighten 
to the appropriate torque. 
12. To allow for shrinkage  after  fitting  leave the cork...