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  socket  headed  screws, spring washers 
and  nuts. 
....- ... . . ,. ,:. . 13. Insert the spring  into the slipper  bore. 
14. Fit the  ratchet  over the spring and against  spring 
pressure,  insert the ratchet  into the slipper  bore 
so 
that the groove in the  ratchet  locates over the small 
dowel  inside 
the slipper  bore. Push and turn  the 
ratchet  clockwise  until 
it locks in the bore. 
15. Insert the slipper  assembly  into the tensioner body 
ensuring  that the small  flat on the  slipper  shaft 
faces the mounting  plate. 
ST7657M 
16. To prevent the tensioner  releasing,  insert a spaccr 
approximately 2.3 mm thick between  the tensioner 
body and  back  of the  slipper  prior to fitting to 
engine. 
ST 1 662M 
47  
						

							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 the line  on 
the  tooth,  also marked  with a letter 
‘P’ is in line 
with  the top  stud  hole  on the  cylinder  block as 
illustrated. II 
 
3. Remove  the camshaft  sprocket. 
4. Encircle the camshaft  and crankshaft  sprockets 
with  the timing  chain and keeping 
it taut  on the 
drive  side and with  the large  shoulder 
of the 
crankshaft  sprocket towards 
the cylindcr block, fit 
the sprockets  and chain  assembly to the engine. 
5. Secure  the camshaft  sprocket to the camshaft  with 
a  new  special  micro encapsulated  treated bolt and 
tighten  to the  correct  torque figure. 
FIT TIMING CHAIN TENSIONER 
1. Fit the timing chain tensioner  and mounting  platc 
assembly 
to the cylinder  block locating it ovcr the 
two  dowels. 
2. Secure  the assembly  with the three bolts and evenly 
tighten. 
3. Remove  the spacer  and to release  the ratchet, to 
tension  the chain, prcss the pad  at point ‘A’.  
						

							.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 available  for fitting  a 
new  insert,  it is  recommended  that this work 
is 
entrusted to a cylinder  head overhaul  specialist. 
FITTING 
PISTONS AND  CONNECTING  RODS  Fit 
rear  main 
oil seal and flywheel  housing 
2. 
3. 
4. 
Check that the crankshaft  oil seal  journal is 
undamaged  and clean.  Make sure the scal  housing 
is  clean  and dry and  free  from  burrs. 
Do not touch 
the  seal  lip and 
ensurc that thc 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. 
Using  special 
seal rcplacer 18G 134-1 1 and with  the 
lip  side  leading  drive
-in the  seal  as far as the  tool 
allows. 
If the tool is  not  available fit the seal to the 
bottom of the housing  to ensure squarcness. 
The  delection of the oil spray  hole in the connecting  rod 
precludes  the necessity 
of fitting  this towards  the 
camshaft  side of the  engine.  See page 
18 instruction 5. 
REMOVE  AND REFIT FLYWHEEL HOUSING  AND 
REAR 
MAlN OIL  SEAL 
1. Remove  the eight  bolts securing the flywheel 
housing  to the  cylinder  block and remove  the 
housing  and rcar  main  bcaring  oil seal. 
4 ST1 842M 
ST1 699M  
						

							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  seal  guide 
and  the scal  journal  with concentrated  Oildag 
in a 
25% solution  with clean engine  oil. 
8. 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 remove 
the  seal  guide.  Secure 
the flywheel  housing  evenly 
tightening  the retaining bolts. 
50  
						

							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 thc gear firmly in a vice 
without  damaging  the teeth. 
If possibie  insert a 
scrap  drive shaft 
in the gear  internal  splines  and 
grip  the shaft. 
2. Turn  the locknut clockwisc (left-hand thread) to 
remove  and withdraw  the thrust washer and bush. 
3. Fit a new bush removing  any burrs before  hand  and 
ensure  that the location 
hole is towards the lower 
end 
of the  gear. 
4. Fit a new  thrust  washer, if the  original is worn or 
scored. Apply Loctite 601 to the thread  and fit the 
locknut  turning anti
-clockwise  and  tighten to 27 - 
34 Nm (20 - 25 Ibf.tt). 
1 
I 
-4 
5. The gear should revolvc freely in the bush with  a 
clearance  of 0,051 
to 0,203 mm (0,001 to 0,007 in) 
between thrust washer  and bush. 
51  
						

							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 - Crankshaft  pulley remover 
18G 1456 -Crankshaft  oil seal  replacer 
18G  1482 
-Camshaft  oil seal  replacer 
18G  1458 
- Dist.  pump  timing  tool 
MS47 
- Press 
18G705-1A - Collets 
LST107 - Flywheel  timing pin 
REMOVE 
ANCILLIARY EQUIPMENT 
Remove the engine  from the vehicle.  Clean the exterior 
and 
in the  interests  of safety  and  efficient  working, 
secure  the engine  to 
a recognised engine  stand. 
Before  commencing,  make 
a careful note of the 
position  of brackets,  clips,  harnesses,  pipes,  hoses, 
filters  and  other miscellaneous  items to  facilitate  re
- 
assembly . 
Removal  of the  following  components  is a reversal of 
the  fitting  procedure  described in engine assembly. 
1. Remove the alternator  and mounting  brackets. 
2.  Remove 
the power steering pump and bracket. 
3. 
Rcmove the  fan and  pulley. 
4.  Remove  the inlet  and exhaust  manifolds. 
5. Disconnect  and remove  the  fuel supply pipes  from 
the  injectors  and D.P.S.  pump and  cover the ports. 
6. Disconnect  coolant by-pass  hose  from  the water 
pump,  release 
the seven bolts and remove the 
water  pump. 
7. Drain  the sump  and remove the  dipstick. 
8. Remove the starter motor. 
9. Restrain  the flywheel,  remove  the  crankshaft 
pulley  bolt and withdraw 
the pulley. 
10. Evenly slacken  and remove  the  clutch  retaining 
bolts  and  withdraw 
the clutch  assembly  and centre 
plate. 
11. Remove  the two  bolts  and remove  the oil filter 
assembly  complete from  the cylinder  block. 
Unscrew 
the filter element and discard. 
12. Remove  the six bolts  and  withdraw  the  rear side 
plate  complete  with fuel pump. 
REMOVE AND OVERHAUL  CYLINDER HEAD 
Remove  the cylinder  head 
1. Remove injectors  complete with  spill rail. 
2. Disconnect  the heater  plug electrical  connections. 
3. Remove the engine  lifting brackets. 
4.  Disconnect  oil gallery  pipe at rear  of engine. 
5. Remove  three  bolts and lift-off the  thermostat 
housing, elbow  and thermostat. 
6. Remove  the  rocker  cover  and  slacken the tappet 
screw  lock nuts.  Turn  the  adjusting screws to 
release  them from 
the push rods. 
7. Remove  the rocker shaft  retaining bolts,  lift-off the 
rocker  shaft assembly,  invert 
it and secure it to the 
rocker  cover studs to prevent  the assembly  from 
falling  apart, see instruction  25, page  34 2.25  litre 
Petrol and Diesel  engine. 
8. Withdraw the push  rods and retain  them in 
numbered sequence. 
9. Evenly slacken  the remaining  cylinder  head 
retaining bolts and  lift
-off the cylinder head. 
10. Remove the engine  lifting eyes. 
11. Using valve spring  compressor 276102 or a suitable 
alternative, remove  the valve 
and spring assemblies 
keeping  them identified  with their  original 
locations  for possible  refitting. 
12. Discard the valve  spring  and valve  guide  oil seals. 
Remove  carbon deposits  from the valves  and 
combustion  chambers and degrease 
all parts  ready 
for  examination. 
Examine  components 
13. Examine  the  cylinder head  for  cracks and 
14.  Burnt,  pitted  and  pocketed seats must be repaired. 
15. In addition,  worn or damaged  valve seats should  be 
distortion. 
renewed, 
as described  later. 
Hot plugs  and injector shrouds -examine and renew 
When  carrying  out normal  top overhaul  work on  the 
cylinder  head 
it is  not  necessary  to  remove  either the 
injector shrouds 
or the hot  plugs. 
Small surface  cracks in the hot  plug,  extending  from the 
opening  to approximately 
8,O mm (0.312  in) in length 
can  be ignored.  However, 
if any severe  cracks appear 
on the face of the  hot plugs before  attempting  to 
remove it,  closely inspect  the cylinder  head 
for signs of 
cracks, particularly  between the inlet  and exhaust  valve 
seats.  Such cracking  indicates  that  the engine  has 
overheated,  usually through  lack of coolant,  and the 
cylinder  head  should be scrapped. 
53  
						

							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  bore. 
Fitting hot plugs 
20. Fit the hot  plugs  by tapping  with a hide-faced 
mallet,  and locate  with a new 
roll pin.  If the  hot 
plugs are  loose in the cylinder  head they may be 
retained  with 
a little grease. 
21. When  fitted,  the hot plugs  must be checked  with a 
dial test indicator to ensure  that they  do not 
protrude  above the level 
of the cylinder  head face 
more  than 
0,76 mm (0.003 in) and are not recessed 
below  the level  of the  cylinder  head face more  than 
0.025 
mm (0.001  in). 
22 
17 
, /- n ST1 429M 
Fitting shrouds 
18. Thoroughly  clean out the combustion  chamber. 
Thc hole in the side of the injector  shroud is for 
manufacturing  purposes only bur at the same  time 
can  be 
used as a guide  when rcfitting the shroud. 
19. Turn  the cylinder  head lace down.  Smear  a little oil 
on  the  shroud  and insert  into the cylinder  head with 
the hole  pointing  towards the centre of the cylinder 
hcad, and  drift into position.  22. 
Check  the valve  guides 
lor wcar by inserting a new 
valve 
in the  appropriate  guide 8 mm above the 
seat. If movement  across the head  exceeds 0,15 
mm (0.006  in) renew  the guide. 
23.  Inspect  the valves  and discard  any that  arc burnt, 
bent 
or distorted.  Check the stems for wear  by 
the  valve.  Valve faces that are pitted 
or ridged  but 
otherwise  serviceable  may be refaced. 
24. Renew  push rods that are bent or have worn or 
scored  ball or socket ends. 
inserting a new guide. !f *Area: is exces>;i.,re, discard 
fJ .. ..._ .. .  .. ,-. . 
f-:- . , 
54  
						

							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  are dimensionally  different 
it 
is important  that the correct-guides  are fitted  to the 
appropriate  ports. 
31. Lubricate ncw guides with engine  oil and  using 
special  drift 600959  for the  exhaust  and 601508  for 
the inlet valve  guides or suitable alternatives,  drive 
in the new guides  until the shoulder  is flush with 
the casting. 
ST1444M Reface  cylinder  head valve seats 
32. Damaged or worn  valve  seats can be refaced 
provided  they are not  abnormally  wide due to 
repeated  refacing operations.  See instruction 
43. 
Renew  valve guides 
28. Support the cylinder  head, combustion  chamber 
uppermost  on  pieces 
of timber of sufficient I - - thickness  to allow  clearance  for the valve guides  to 
be driven out. - 
274401  for exhaust  guides or suitable  alternatives 
29. Using  special  drift  274400 for inlet guides  and 
drive  out the old guides  from the combustion  face A 
I, I 
,. ”. ’. ii. , :,: e. ,.. ‘ ., - 
side. 
I 
A. Correctly seated valve 
B. Undesirable condition 
C. Method of rectification 
B 
C 
55  
						

							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  the collet,  expander  and  nuts. 
Ensure  that the  chamfered  end 
of the expander  is 
towards  the collet. 
ST1440 M 
36. Insert thc assembled pilot  into the valve  guide lrom 
the combustion  face side of the cylinder  head until 
the shoulder contacts the  valve guide  and the whole 
of the collet is inside  the valve  guide. 
37. Expand  the  collet in the guide  by turning  the 
tommy bar  clockwise  whilst holding  the  knurled 
nut. 
36 I 
38. Use  cutter MS 621 and  ensure  that  the cutter 
blades  are correctly  fitted 
to the cutter  head with 
the  angled  end 
of the blade downwards  facing the 
work, 
as illustrated.  Check that  the  cutter blades 
are  adjusted 
so that  the  middle of thc blade 
contacts the area  of material 
to be  cut. Use thc key 
provided 
in the  hand set MS 76. 
ST1439M 
39. Fit the wrcnch to  the culter head  and  turn 
clockwise  using  only  very  light pressure.  Continue 
cutting 
to approximatcly thc centre of the  existing 
seat. 
40. 
To check  the  effectiveness of the  cutting opcration 
use  engineers’  blue 
or a feelcr gauge maclc from 
ceilophane. 
41.  Smear a 
mall quantity  of cngineers’ blue round thc 
valve  seat and revolve 11 properly  ground  valve 
against  the seat. 
A continuous  fine line should 
appear 
round the  valve. If there  is a gap of not 
more thar !2 mni it can be corrected  by lapping. 
56