Land Rover Defender 90 110 Workshop Book 2 Rover

							2.25 LITRE PETROL AND DIESEL ENGINE 
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 (id to &in) wide  as  illustrated. 
Immerse  the cork  seals 
in engine  oil and  fit them  to 
the  bearing  cap. 
12 
c - .. .. . I- .  . .. 
1 I. 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 
seais 
standlng proud of the  crankcase-sump  face. If 
possible  delay the fitting  of the  sump 
for 
approximately  twelve hours and  leave  the seal 
protruding 
2,40 mm (& in) and then  place  a 
6,350 
mm (% in)  washer  over the seal  and cut off 
the  surplus. 
If it is necessary  to fit the sump 
Fit rear  main oil seal 
13. Check  that  the  crankshaft  oil seal journal is 
undamaged  and clean. Make sure the  seal housing 
is  clean  and dry and 
free from burrs. Do not touch 
the seal  lip and  ensure that  the outside  diameter  is 
clean  and dry. 
The P.T.F.E. Seal  Part No ETC 
5369  which  should  be used, is supplied with a 
former to maintain the correct  shape  and must not 
be removed  until the seal  is to be fitted. 
14.  Using special seal  replacer 
18G 134-1 1 and with the 
lip  side  leading  drive
-in the  scal  as  far  as  the  tool 
allows.  If 
the tool is not availablc fit the seal  to the 
bottom  of the  housing 
to ensure  squareness. 
17  
						

							2.25 LITRE PETROL AND DIESEL ENGINE 
15. Fit the 0 ring seal  to the  flywheel  housing. 
16. Examine the seal guide  number 18G 1344 and 
repair  any damage  that could destroy  the seal  lip. 
17. Lubricate  the outside  diameter  of the  seal  guide 
and the  seal journal 
with concentrated  Oildag in a 
25% solution with clean engine oil. 
18. Place thc 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 remove 
the  seal  guide.  Secure  the flywheel  housing evenly 
tightening 
the retaining bolts. 
5. Lubricate  the  cylinder walls,  piston  rings  and 
suitable  compressor  tool and carefully  lower the 
connecting
-rod  into  the  bore  ensuring that the oil 
spray  hole  faces  the camshaft  side of the  engine. 
With  diesel  engines  the  point of the  arrow  headed 
valve  clearance  indentation 
in the piston  crown, 
and  the oil spray 
hole must  face  the camshafi side 
of  the  engine. 
6. Using  a soft  mallet,  sharply  tap thc piston into the 
bore 
so that the whole of the  piston is just bclow 
the surface  of the cylinder  block. 
crankpins.  Compress  the 
piston rings 
with a 
FIT THE CONNECTING-RODS AND PISTONS 
1. Turn the crankshaft to position  numbers  one and 
four  crankpins  at  bottom 
dcad centre to facilitate 
fitting  the 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  eccentric  heads 
which  locate 
in a recess in the  connecting-rod. It is 
essentia! that the head of each new bo!t is proper!y 
located before  tightening. 
4. Stagger the  compression  rings so that the gaps  are 
equidistantly  spaced round  the  piston but, 
so 
arranged, that no gap is positioned  on  the thrust 
side of the  piston  i.e. opposite  the  camshaft.  Turn 
the 
oil control  ring so that the gap is in line  with  the 
gudgeon  pin. 
18 
ST731 M 2 
7. Check  that  the  bearing  shell is properly  located in 
the connecting-rod  and  pull  the rod  onto  the 
crankpin.  Locate 
the bearing shell correctly  and fit 
the  cap so that  the  identification  numbers  are 
together 
on the  camshaft side of thc engine. Fit and 
tighten  new nuts  to the  correct  torque  figure. 
Repeat  the  foregoing  instructions 
for fitting the r-. remaining  piston and connecting-rod assemblies. rf: ,~. I:. .I e  
						

							2.25 LITRE PETROL AND DIESEL ENGINE 
FIT THE  CAMSHAFT 
1. Lubricate  the  camshaft  bearings and with care, 
insert  the camshaft  into  the  cylinder block. 
Temporarily  secure a 
new thrust plate with the two 
bolts. 
.. 
2. To check  the camshaft  end-float, fit the  woodruff 
key  and  temporarily 
fit the  camshaft  chain  wheel 
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 nim (0.0025 to 0.0055 in). If the end-float  is 
outside  these  limits, 
fit different  thrust  plates until 
the correct  tolerance  is achieved. 
3. Removc the test indicator and chain  wheel  and 
secure  the thrust  plate 
with the two bolts and  tab 
washers.  (Tab washers 
ommitted on later engines). 
FIT TAPPETS, GUIDES AND  ROLLERS 
1. If the same parts are being  refitted  ensure that they 
are returned  to their original positions.  Ensure that 
the 
tappct slides  move freely in the guides. 
2. Insert the tappet  guides  into the cylinder  block and 
align  the locating screw  holes. 
3. Fit the tappet rollers ensuring  that they  are fitted in 
accordance with the  marks  made  during removal. 
New rollers,  however. may be fitted  either way 
round. 
4. Before  fitting the tappet slides make sure the 
oilways are clear to the tappet  bearing surface,  the 
cross drilling and  the oil 
feed to the  push rod. 
5. Insert the tappet slides with the word FRONT 
towards the front of the engine. 
6. Secure  the tappet  guides  with NEW Micro 
encapsulated  screws and tighten to thc correct 
torque  figure.  Micro  encapsulated screws  should 
also  be  used  on  engines where the  screws  were 
originally  wired 
for security. 
4, 
..._. - ... . .-.. ... .. ...,... ., .. 
19  
						

							El 2.25 LITRE PETROL  AND DIESEL  ENGINE 
FIT THE  FLYWHEEL 
1. Examine  the flywheel  and crankshaft  mating faces 
and  remove  any burrs 
or imperfections  that could 
prevent  the flywheel  locating correctly.  Check that 
the  dowel 
is in position. 
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  pressure  face at a radius 
of 
114 mm (4.5 ins). 
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 run
-out  be excessive,  remove the 
flywheel,  and check  again for any  irregularities 
on 
flywheel  and crankshaft  mating faces and dowel. 
Diesel  engine 
3. Turn the crankshaft  in a clockwise  direction until 
the 
E.P. mark on the  flywheel  is in  line  with  the 
pointer 
on the  flywheel  housing.  The pointer on 
later  engines  has been  omitted  but can  be obtained 
from  Land  Rover  spares  stockists  under part 
number  ERC 
2250. If the  crankshaft  is 
inadvertently  turned beyond  the 
E.P. mark, do not 
turn it back  but continue  on round  in a clockwise 
direction  until the mark 
is exactly  in-line with the 
pointer. 
To avoid  serious  damage  to the  valves  and 
pistons 
once the  cylinder  head has been  fitted,  the 
crankshaft  must not be rotated  until the valves 
have  been  timed. 
continued 
FIT  CYLINDER  HEAD AND ROCKER  SHAFT 
ASSEMBLY 
Petrol  engine 
1. Temporarily  fit the  timing  cover with pointer  and 
crankshaft  pulley. 
2. Turn the crankshaft  clockwise, in the normal 
running  direction,  to bring  numbers  one and  four 
pistons 
to T.D.C. If the  crankshaft is inadvertently 
turned  beyond 
T.D.C. do not turn  it back,  but 
continue  on round  until the T.D.C.  mark on 
the 
pulley  coincides  with the pointer  on the  timing 
cover.  Do not  allow  the crankshaft  to be  moved 
again  until the valves  are timed. 
2b  
_--. 
ST 927M 
ST613M I Ill 
						

							..ltr., .... . . ,I: .:?; ?: ,.....,. i .. ::?.I ,a..... 
T 
... . 
I . 
2.25 LITRE PETROL AND DIESEL ENGINE 1121 
Petrol and Diesel  engines 
4. Clean  the cylinder  head  and  cylinder block mating 
faces.  Position  a 
ncw cylinder  head gasket on the 
cylinder  block with the word  Diesel or Petrol 
uppermost. 
5. Lower  the cylinder  head onto the cylinder  block 
using  two  long bolts  to facilitate  accurate 
positioning  of 
the head. 
6. Fit the  cylinder  head  retaining  bolts except  those 
also  used  to secure  the  rocker shaft and leave 
finger
-tight . 
7. Insert the push  rods  ensuring  that  the ball  end 
locates properly 
in the  spherical  seat in the tappet. 
8. Whilst holding  the rocker  shaft  assembly  together, 
lower 
it into  position  making  sure  that  the hollow 
dowels  locate  properly 
in the cylinder  head. Also 
ensure that the rocker adjusting  screw ball end 
9. Fit the rocker  shaft large  retaining  bolts  and leave 
. locate in the push  rods. 
finger
-tight. 
ST8 
10. Tighten  the cylindcr  head rctaining bolts,  evenly, 
to 
the correct  torque figure in the  sequence 
illustrated  below. 
11. Fit and tighten the rocker  shaft, small bolts to the 
specified  torque. 
13. Do not allow the crankshail to be  turned,  until the 
VALVE TIMING 
Petrol engines 
1. Check that numbcrs one and four  pistons  are still  at 
T.D.C. and  without  disturbing thc crankshaft, 
remove the  pulley and timing cover. 
2. One of the keyways in the camshaft  sprocket  is 
stamped  with the letter 
P and  this  must  locate  on 
the  camshaft key. 
3. Fit the  camshaft  chain wheel, as above,  and rotate 
the camshaft 
in a  clockwise  direction until the tooth 
also  marked  with 
a letter P is in line with the top 
stud hole as illustrated. 
4. Fit the crankshaft  chain whccl with  the large 
shoulder towards  the cylinder  block. 
5. Without  moving either chain wheel, fit thc timing 
chain,  keeping  it taut 
on the  drive  side. If it is not 
possible 
to obtain  a  taut fit on  the  drive  side  of the 
chain  with  the chain  wheel  in the  set position, 
withdraw  the camshaft  chain  wheel  without 
disturbing  the  camshaft,  and 
rcfit the chain  wheel 
on one of the alternative  keyways. This procedure 
may  be repeated  until a taught  chain is obtained 
on 
the  drive-side  with  the camshaft and  crankshaft in 
their  previously  set positions. 
6. Secure the camshaft sprocket to the camshaft with 
a  new  special  micro encapsulated  treated  bolt and 
tighten 
to the correct  torque figure. 
NOTE: Early engines  use an ordinary bolt and tab 
was her. 
7. Fit and  adjust  the timing  chain damper SO that 
there  is a maximum  clearance of 
025 mm 
(0.010 in)  between  the timing  chain and damper. 
Tighten  the  retaining  bolts  and secure 
with new 
lock  tabs. 
continucd valves  are timed. 
21  
						

							1121 2.25 LITRE PETROL  AND DIESEL  ENGINE 
Diesel engines 
11. Manufacture a suitable  pointer,  and attach  one end 
to  the  top  bolt  hole 
in the cylinder block and the 
pointer 
close to the camshaft  chain wheel, 21s 
il Ius t ra ted . 
12. Turn the camshaft  until the valve is fully  open ;IS 
indicated  by maximum reading on the dial gauge. 
13. Because  the top of the cam  is ‘flat’ the cnmshaft 
can  be turned ;i furthcr four degrees without 
movement of the dial  gauge  needle.  Since an error 
of four degrees  is not acceptable,  the exact centre 
of the four  degree  period must be established. ;IS 
follows. 
14. Without  moving the camshaft rub white chalk on 
the face of the chain  wheel  adjacent to the pointer. 
Zero  the dial  gauge  and carefully 
turn the camshaft 
clockwise  until the needle  indicates 
0,25 mni 
(0.010 in) which  represents  a point  down  the left- 
hand  side of the cam  lobe.  Make a thin pencil 
mark, 
on the  chalk, in line with  the pointcr. 
8. Maximum  engine performance  and efficiency 
depends 
upon the  care  and accuracy  excerciscd 
during  the following  instructions. 
9. Check that the E.P. mark on the flywheel  is still 
cxactly aligned  with the pointer on thc flywheel 
lious i n g . 
10. Thc valve  timing  is based  upon the exhaust  valve 
peak 
of number one cylinder. To determine the 
point  at which  the valve  is fully  open  mount a dial 
test  indicator, 
as illustrated,  with the bracket 
attached 
to the  number  one exhaust  valve rocker 
and  the stylus  resting, 
in a loaded  condition on a 
cylinder  head bolt head. 
15. Turn the camshaft  anti-clockwise  and watch the 
needle  move back to zero. Then  continue  turning 
until  the 
necdlc indicntcs 0.25 inn1 (0.010 in) which 
represents 
a point  down  the right-hand sick of the 
cam and n:::ke ::nother ;xark in !inc wi!h !!le 
pointer. 
22  
						

							2.25 LITRE PETROL AND DIESEL  ENGINE 
16. Using a rule, determine  the  exact mid-point 
between  the two  marks  and 
make a third  mark. 
- .. 
17. Remove  the  dial indicator,  and  turn the camshaft 
until  the  middle mark lines 
up with the  pointer. 
The number  one cylinder  exhaust tappet roller 
should now  be  resting in the  centre  of the four 
degree  flat period 
of the cam  and the camshaft  and 
crankshaft 
are in their  correct relationship. 
18. Fit the crankshaft  chain  whee! with the large 
shoulder  towards the cylinder block. 
19. Without  moving the camshaft  and crankshaft fit the 
timing chain  keeping it taut on the  drive  side. 
Should 
it be  impossible  to obtain  a taut fit, remove 
the  chain  wheel  and position 
it in one of the five 
remaining  keyways  until the best  position  is 
obtained.  It 
is preferable to choose a keyway  which 
gives 
;I slightly  tight  chain on the drive side rather 
than  a slack  one. 
20. Secure  the  camshaft  chain  wheel to the  camshaft 
with 
a new,  special,  micro encapsulated  treated 
bolt  and  tighten 
to the correct torque  figure - See 
Petrol en,‘ (rine. 
21. Fit  and adjust  the  timing chain damper so that 
there  is 
a maximum  clearance of 03 mm 
(0.010 in) between  the  timing  chain and  damper. 
Tighten  the  two bolts  and secure 
with new  lock 
tabs. 
. ... 
FIT TIMING CHAIN TENSIONER 
I. Assemble  the timing  chain  tensioner in accordance 
with 
the illustration in “Dismantling”. 
2. Compress the  assembly against the spring and fit to 
the engine  whilst engaging 
thc ratchet  pivot bolt in 
the cylinder block. 
3. Ensure that the piston  housing  locates on the 
dowels  and  single stud and  the  cylinder  spigot  fits 
into  the milled  slot 
in the cylinder block. 
3. Allow  the jockey  wheel to take up the  slack in the 
chain.  Tighten  the retaining 
nut and  two bolts to 
secure the assembly. Do not rotate  enginc,  see 
‘tappet adjustment’. 
23  
						

							11211 2.25 LITRE PETROL AND DIESEL ENGINE 
ADJUST TAPPET  CLEARANCES 
Petrol  and diesel  engines 
1. If the crankshaft  is rotated  with  excessive  valve 
clearances,  it is  possible  that  the push  rods may 
become  dislodged 
from the  tappet  seating and 
fracture  the  tappet  slide. 
To prevent damage, 
eliminate  all clearance  from  any  loose rockers 
bcfore turning  the crankshaft to adjust  the 
clearances. 
2. Turn the engine  over until  number  eight valve 
(counting  from front  of engine)  is fully  open. 
3. Using  a 0,25 mm (0.010 in) feeler gauge  check the 
clearance  between the valve  tip and  rocker  pad of 
number one  valve. 
4. Adjust the clearance by slackening  the locknut and 
turning  the  tappet  adjusting  screw clockwise  to 
reduce  clcarance  and anti
-clockwise  to increase 
the lock  nut. 
- clearance.  Recheck the clearance  after tightening 
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 tappet  with No. 4 valve fully  open. 
Set 
No. 2 tappet  with No. 7 valve fully open. 
Set 
No. 8 tappet  with No. 1 valve fully open. 
Set No. 6 tappet with No. 3 valve fully open. 
Set 
No. 4 tappet  with No. 5 valve fully open. 
Set 
No. 7 tappet  with No. 2 valve fully open. 
FIT 
1. 
TIMING  COVER AND WATER  PUMP 
Using a new  joint  washcr  assemble the water pump 
to  the  front  cover  and  loosely  tighten the three 
retaining 
bolts. 
2. Attach  a new  joint  washer  and  water  gallery joint 
to 
the timing  cover  and  secure  the  cover together 
with  the timing  pointer  (petrol engines  only)  and 
alternator  link to the  cylinder  block with the 
fourteen  bolts. Evenly tighten  to the correct  torque 
figure,  including 
the water pump  bolts. 
2 
ST1269M 
3. Fit the  crankshaft  pulley and secure with the 
special  washer  and  bolt.  Tighten  to the  correct 
torque  figure. 
3 
ST1089M 
24  
						

							2.25 LITRE PETROL AND DIESEL  ENGINE 
4. Fit the thermostat  into its housing  and using  new 
joint  washers  secure  the  assembly, together with 
the  elbow, 
to the  cylinder head. Tightcn the  three 
bolts  to the  correct  torque.  Connect  the thermostat 
elbow  to  the  water  pump 
with a new  hose  and 
secure  with hose clips. 
FITTHESKEW GEAR 
Petrol engine 
I 
1. Turn  the crankshaft  to bring  number one piston  to 
T.D.C.  with number  four cylinder  valves 
on thc 
rock.  Check  that the timing gear pointcr  coincides 
with  the mark 
on the crankshaft  pulley. 
2. Lubricate and  insert  the skew  gear assembly  into 
mesh  with the camshaft  gear. 
Due to the  helex 
angle  of the  teeth  the  gear will turn  anti
-clockwise 
as 
it slides  into mesh. The broad master  spline must 
be at 20 to the centre line when  correctly  seated, 
as  illustrated,  but 
it may take scvcral  attempts to 
achieve  this. 
-. 
3. The skew gear assembly  is located in its  final 
position  by a special  screw. Without  this screw  the 
gear  will 
go deeper  into mesh  resulting in an 
incorrect 
anglc when the assembly  is  lifted up  to 
locate  the screw.  The angle  must therefore  be 
checked  again after the screw 
is fitted.  Align the 
location  hole  in 
the bush and fit a new  location 
screw 
into the  cylinder  block and re-check  the 
angle. 
4. Fit the  distributor drive  coupling, and ensure  that it 
locates properly in the off-set slot  of the  skew  gear. 
5. Using  a new  joint washer, fit the side covcr. 
ST 882M 
ST748M 
25  
						

							2.25 LITRE PETROL  AND DIESEL  ENGINE 
Diesel engine 
6. Turn the crankshaft in the  direction  of rotation 
until both  valves  of number  one cylinder  are closed 
and  the piston  is ascending  the 
bore on the 
compression  stroke. 
7. Continue to turn the crankshaft  until the timing 
pointer  aligns  with  the 
13 mark  on  the  flywheel, 
that  is 
13 BTDC. This  must  be done carefully. If 
the flywheel in inadvertently  turned too far and  the 
timing  mark  goes past the  pointer  do not  turn  the 
flywheel  back but repeat 
the operation. 
8. Ensure  that a correct  line  of vision  is taken  when 
lining  up 
the timing  marks.  An incorrect  line of 
vision can  result 
in the timing being 1 to 2 out. 
10. The  skew  gear assembly  is located in its  final 0 .,.. position  by a special  screw. Without  this  screw  the 
gear  will go deeper  into mesh 
rcsulting in an 
incorrect  angle  when  the assembly  is lifted up to 
locate  the screw.  The angle 
must therefore  be 
checked  again after 
the screw  is fitted. 
11. Align  the location  hole in the bush and fit a new 
location  screw  into 
the cylinder block and re-chcck 
the angle. 
12. Fit D.P.A. pump drive  shaft long-splined-end 
leading  and locate  the master  spline 
in the 
corresponding  spline 
in the skew gear. 
12 
9. Lubricate and insert  the skew  gear assembly  into 
angle 
of the  teeth the gear will turn  anti-clockwise 
as it slides  into mesh.  The broad  niaster spline  must 
be 
at 20 to the  centre  line when  correctly  seated, 
as illusti-ated, but it may take  several  attempts  to 
achieve  this. 
mcsh with the  camshaft  gear. Due to the  helex g-; -a:-./ Petrol  and Diesel  engines 
13, Using a new joint washer fit the oil filter housing, 
ensuring  that  the  retaining bolts pass through the 
two small  round holes in the joint  washer. 
torque. 
iA I+. Tighten  the iwii rciaining bolts evenly to :tic corrcc: 
ST750M 
26