Land Rover Defender 90 110 Workshop Book 2 Rover

2.50 LITRE DIESEL ENGINE 1121 
I. .I 18. Place the seal  guide on the crankshaft  flange and, 
using  the two  dowels  protruding  from the cylinder 
block  rear face  as a guide  to ensure  initial 
squareness,  fit the  flywheel  housing and 
removc 
the seal guide. Secure  the flywheel  housing evenly 
tightening  the retaining  bolts. 
I 5’ 
-. .. 
ST730M 
ST1675M 
Fit flywheel housing - Later engines 
19. In place of the ‘0’ ring  seal  a bead of Hylogrip 2000 
sealant  must be applied to the rear...

112 I 2.50 LITRE DIESEL ENGINE 
FIT THE CONNECTING-HODS AND PISTONS 
1. Turn  the crankshaft to position  numbers  one and 
four  crankpins  at  bottom dead  centrc  to 
facilitatc 
fitting thc connecting-rods. 
2. When fitting the connecting-rods  and  pistons 
ensure  that 
the bolts do not  foul  and  damage  the 
crankpins. 
As a precaution it is  recommended  that 
rubber 
or soft  plastic  sleeves  are placed  over  the 
threads. 
3. The connecting-rod  bolts  have  essentric  heads 
which  locate...

2.50 LITRE DIESEL ENGINE 1 12 1 
2. To check the camshaft end-float, fit the woodruff 
key  and  temporarily 
fit the cam-shaft  pulley  and 
mount 
a dial  test indicator, as illustrated, so that 
the  stylus  rests 
in a loaded  condition  upon the 
machined  face  of the  cylinder block. Zero the dial 
and  move 
the camshaft  back and forward  and note 
the reading.  The end-float  should be within 0,06 to 
0,13 mm (0.0025 to 0.0055 in). If the  end-float  is 
outsidc these  limits, fit different...

1121 2.50 LITRE DIESEL ENGINE 
2. Offer up the flywheel  to the  crankshaft  and secure 
with  the reinforcing  plate and  retaining 
bolts. 
Evenly  tighten the bolts to the  correct  torque 
figure. 
3. To check  the flywheel  run-out, mount  a dial  test 
indicator 
so that  the stylus  rests, in a loaded 
condition,  on 
the clutch pressurc  face  at a radius of 
114 mm (4.5 in). 
4. Turn the flywheel,  and check  that the run-out does 
not  exceed 
0.05 to  0.07 mm (0.002 to 0.003 in). 
Should  the...

2.50 LITRE DIESEL ENGINE 112 1 
:it Fit distributor pump (D.P.S.) 
8 5. Fit the  camshaft  front inspection  cover complete 
with 
thc D.P.S. pump  rear rear support  bracket. 
Using  a new  joint  washer  evenly tighten  the 
six 
6. Fit pump joint washer  and loosely secure pump to 
cover with the three  nuts and to the  rear  support 
bracket  with the single  nut and  bolt.  Position  the 
pump 
so that  the retaining  studs are midway  in the 
flange 
slots. 
bolts. - 
ST1521 M 
7. Fit D.P.S.  pump...

I 12 1 2.50 LITRE DIESEL ENGINE 
2. 
3. 
4. 
5. 
6. 
82 
TIME D.P.S.  PUMP AND VALVES - Early  Engines 
The D.P.S.  pump and valves  are timed  using the 
exhaust  valve peak 
of number  one cylinder. On early 
engines  the exhaust  peak position 
is determined  by the 
relationship 
of a  line,  marked E.P. on the flywheel 
perifery  and a timing  pointer  on  the flywheel  housing. 
The  pointer  is available  under Part Number 
ERC 2250. 
1. Turn the crankshaft in a clockwise  direction until 
the...

2.50 LITRE DIESEL ENGINE 112 
. -. , :, 1.. _.., ...,. , .- , ., 13. Remove the plug from  the side  of the D.P.S. pump ,._.... .. . .. and  insert  gauge tool 18G 1458 and if necessary 
rotate 
the pump  body  until the gauge can be fully 
inserted  and screwed  home indicating  that the 
inner  disc is centrally positioned 
with the  hole. 
14. Evenly tighten  the three  nuts securing the  pump to 
the  cover  and the single 
nut and  bolt  to the support 
bracke 
t . 
15. Align  timing  pointer on...

12 
CAUTION: The double  tensioning  procedure is 
imperative  otherwise  the belt  could  fail resulting  in 
serious  engine damage. 
Also, if a new  belt is not 
attainable  and 
it is necessary to refit  the old  belt  it 
should  be 
only torqued to 19-24 Nm (14-18 Ibs ft). 
2.50 LITRE DIESEL  ENGINE 
12. Rotate the crankshaft  until the pin  of the  special 
timing  tool can,  once  again,  bc inserted  into the 
flywheel 
E.P. slot. 
13.  Check  that 
the dots on the  camshaft  and D.P.S. 
pump...

2.50 LITRE DIESEL ENGINE 
FIT FRONT  COVER  WATER  PUMP AND 
CRANKSHAFT  PULLEY 
1. Place a new  joint  washer in position  and insert  the 
centre 
65 mm long  bolt into the cover  with the fibre 
washer on 
thc inside. 
2. Fit the  cover  over the dowels  and secure  with the 
remaining  various length bolts 
in accordance with 
the chart.  See “Fit timing  rear cover,  seals and 
pulleys”.  Tighten evenly 
to the correct torque. 
3. Fit the vent  cover  gauze  and gasket  and secure  with 
the  four...

I 12 I 2.50 LITRE DIESEL ENGINE 
7. Tighten the cylinder head retaining  bolts,  evenly, 
to the correct  torque figure in the sequence 
illustrated below. 
8. Fit and  tighten  the rocker  shaft,  small bolts to the 
specified  torque. 
5. Continue to check and adjust the remaining 
tappets 
in the  following  sequence: 
Set 
No. 3 tappet with No. 6 valve fully open. 
Set 
No. 5 tappct with No. 4 valve fully open. 
Set 
No. 2 tappct with No. 7 valve fully open. 
Set 
No. 8 tappet with No. 1 valve fully...