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  facc  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. 
20. Fit the  housing  following  instructions 17 to 19. 
77  
						

							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 
in a recess  in the  connecting-rod. It is 
essential  that the head 
of each  new  bolt  is properly 
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. 
5. Lubricate  the  cylinder  walls,  piston rings and 
crankpins.  Compress 
the pistons  rings  with a 
suitable  compressor  tool  and carefully  lower the 
connecting
-rod  into  the bore  ensuring  that  the 
piston  is assembled 
in accordance with instruction 
27 under  “Assemble pistons to connecting-rods”. 
Also 
the point  of thc arrow hcaded valve clearance 
indentation 
in the  piston  crown,  must face  the 
camshaft  side of the  engine. 
6. Using a soft  mallet,  sharply  tap the piston  into  the 
bore 
so that the whole  of thc piston is just  below 
the  surface  of 
the cylinder block. 
ST1446M z 
78  
						

							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  thrust  plates  until 
the correct tolerance  is achieved. 
3. Remove  the test  indicator  and pulley,  and  secure 
the  thrust plate  with 
the two bolts. 
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 tappet 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  rollcrs 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 slidcs 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 slidcs with the word  FRONT 
towards  the front  of the  engine. 
6. Secure  the  tappet  guides with NEW Micro 
torque  figure.  Micro encapsulated  screws  should 
also be used  on engines where the screws werc 
originally  wired for security. 
encapsulated scie*s and tighten io ccjr,-eci 
FIT THE  SKEW  GEAR 
1. Lubricate  and  insert the skew  gear and coupling 
assembly  into mesh  with 
the camshaft  gear. Align 
the location  hole in the bush  and fit a new  location 
screw  into 
ihc cylinder block. 
STl674M/ I I 
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. 
continued 
79  
						

							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 run
-out  be  excessive,  remove  the 
flywheel.  and  check again for irregularities 
on 
flywheel  and  crankshaft mating faces and dowel. 
FIT  TIMING FRONT COVER, SEALS AND 
PULLEYS 
1. Fit new  cover  joint, triangular  gasket,  and  water 
gallery  gasket, 
to the cylinder block. 
2. 
Fit and  secure  the rear  cover  with the eight  bolts 
refering  to  the chart  for  location 
of the  various 
length  bolts (in  mm). 
30 
Rear cover - crankshaft  seal 
3. With the lip side leading drive in the  new  seal using 
special  tool 
18G 1456, until the seal is 
approximately  0,5 
mm below the  inner  face of the 
cover. 
ST1523M /’ 
Front cover - camshaft  seal 
4. Drive in a new  seal,  lip side  leading  until flush or 
approximately 1 .0 mm below  the inner  surface 
using special  tool 
18G1482. 
continued 
ST617M 
80 
25  
						

							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 pulley,  and loosely  secure with 
thc nut. 
Fit camshaft pulley 
8. Fit pulley, boss towards  engine, and loosely  secure 
with  special  washer, 
0 rings, plain washer  and 
new  bolt. 
DO NOT drive  pulley  onto camshaft. 
Draw  pulley 
on with a slave 10 mm diameter 
metric bolt, plain washer  and nut. 
Fit crankshaft  timing pulley 
9. Apply Loctite 518 to the pulley  face as illustrated; 
do 
not allow  sealant to contact chamfercd face. 
Lightly 
oil the  crankshaft  and pulley borc and fit 
the pulley,  with timing  dot outwards,  and drive  into 
position  using a suitable  tube as a drift. 
ST19?1M 
ST1693M 
81  
						

							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 E.P. mark on the flywheel lines-up exactly with 
the  pointer. 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 and  pointer coincide  exactly. 
7. Set a dial  type  torque  wrench  to 29,O to 23,5 Nm 
(21 to 17 Ibs ft) and whilst  holding it vertically, 
insert the drive  peg into thc square  hole in the 
tensioner  base plate.  Tension  the 
bclt and  tighten 
the  clamp nuts 
to the correct  torque. 
Check  that the  dot 
on the crankshaft  pulley and the 
cast-on arrow on the  rear  cover line-up. 
Fit  the  timing  belt tensioner  assembly and loosely 
secure  with the two  nuts  (strap  deleted 
on later 
models). 
Turn  the 
D.P.S. pump  pulley  clockwise until the 
dot  lines 
up exactly  with arrows in the rear cover. 
Similarly,  turn  the camshaft  pulley  clockwise 
so 
that the dot coincides  exactly with the cast-on 
arrow.  Fit  the  timing  belt over  the crankshaft  pulley and 
whilst  keeping  the belt  under  tension,  by hand,  run 
the beii over the carnsiiafi puiiey. if iiie beit does 
not quite mate with the grooves,  turn the pulley 
clockwise  the necessary  amount. Feed the belt  over 
the  pump  pulley  and 
if necessary turn the pulley 
clockwise  to locate  in the  grooves.  Keeping a  firm 
grip 
on the  belt pass it over the  tensioner wheel. 
8. Rotate the  engine TWO complete revolutions. 
9. Slacken the tensioncr  clamp nuts. 
10. Tension the belt  again  as described  in instruction 7 
and tighten  the clamp nuts to the correct  torque. 
CAUTION:  The double  tensioning  procedure is 
imperative,  otherwise the belt could fail  resulting  in 
serious  engine damage.  See CAUTION  Page 
84 and 
“Care of beits”. 
11. Rotate the crankshaft until,  the E.P.  mark on the 
flywheel  and the pointer line
-up. 
12. Check that the dots on the  pump  and camshaft 
pulleys  coincide  exactly  with their  respective 
arrows. 
If there  is any  misalignment thc procedure 
must  be repeated.  
						

							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  rear  of cover,  with the 
scribed 
line on  the pump  flange and tighten the two 
screws. 
If a new pump is being  fitted and there  is no 
scribed  line,  scribe  a line in the centre  of the 
machined  area on 
the pump  flange.  Align the 
timing  pointer  and  tighten  the screws. On later 
engines  the  timing pointer  has been  deleted  and 
instruction 
15 can  be ignored. 
. 
16. Tightcn the D.P.S.  pump timing pulley nut and thc 
camshaft  pullcy  retaining bolt to  the  correct 
torque. 
17. Remove  the  timing pointer  from the flywhecl 
housing,  close the cover and secure  with the two 
nuts.  1. 
Remove the  plug from  the 
flywheel housing  and fit 
the body of special tool LST 107 without the  pin. 
2. Turn  the crankshaft in a clockwise  direction until 
the E.P. slot in the  flywheel  is in-line  with  the hole 
in  the  flywheel  housing. 
If the  crankshaft  is 
inadvertently turned  beyond  the E.P. slot, do not 
turn  the crankshaft  back but continue  on round 
in a 
clockwise  direction until the pin of the  special  tool 
can  be fully  located 
in the flywheel  slot. 
1 
3. Fit the timing  belt tensioner  assembly and loosely 
securc with  the two nuts. 
4. Turn the D.P.S.  pump pulley  clockwise until the 
dot  on the  pulley  lines
-up exactly  with the cast-on 
arrow  inside the 
front cover. 
5. Similarly, turn the camshaft  pulley  clockwise until 
thc dot lines-up with  the cast-on arrow in the  front 
covcr. 
6. Fit  a new timing  belt over the  crankshaft  pulley  and 
whilst  keeping 
the belt under  tension,  by hand, run 
the  belt  over  the camshaft  pullcy.  Should thc belt 
not  quite  mate with 
the grooves,  turn the pullcy 
clockwise  the necessary  amount. 
Fced the belt  over 
the D.P.S. pump  pulley  and if necessary turn the 
pulley  clockwise  to locate 
in the  grooves.  Keeping 
a firm grip on the belt,  pass it over the tensioner 
jockey pulley. 
7. Withdraw  the  special tool timing pin from the 
Time D.P.S. PUMP AND VALVES - Later  Engines 
with  slot 
in flywheel  for determining the E.P. 
The  D.P.S.  pump  and valves  are timed  using the 
exhaust  valve peak 
of number  one cylinder.  This  is 
determined 
on later engines  by the relationship  of a slot 
in the flywheel  periphery  and a plugged hole in the 
flywheel  housing through  which 
a flywheel  timing  pin, 
special  tool number 
LST 107, is inserted. 
-- 
flywheel  slot. 
8. Set a dial type  torque  wrench  to 20.0 to 23.5 Nm 
(21 to 17 Ibs ft) and whilst  holding it vertically, 
insert  the drive  peg 
into the square  hole in the 
tensioner  base plate.  Tension 
the belt  and  tighten 
iiie 
ciamp nuts to the  correct torquc. 
9. Rotate the crankshaft TWO complete revolutions. 
10. Slacken  the tensioner clamp  nuts. 
I 1. Tension  the belt again as described in instruction 8 
and tighten the clamp  nuts to the correct  torque. 
83  
						

							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  pulleys 
coincidc exactly  with their  respective 
cast
-on  arrows  on thc rcar covcr.  Should  there be 
any  misalignment  the foregoing  procedure  must be 
repeatcd. 
14. Remove  the plug  from  the side  of the D.P.S. pump 
and  insert  special 
tool 18G 1458 and if necessary 
rotate  the pump  body until the tool  can be fully 
inserted  and 
screwrd home indicating  that the 
inner  disc is centrally  positioned  with the hole. 
15. Evenly  tighten the three  nuts securing  the pump 
flange  to the  rear  cover  and the single  nut and  bolt 
to  the  rear  support  bracket. 
16. Align the timing  pointer on thc rcar of the cover 
with  the scribed  line on the  pump  flange  and 
tighten  the two  screws.  If a new  pump  is being 
fitted  and there  is no  scribed  line, scribe  one 
in the 
centre  of the  machined  area 
on thc flange. Align 
the  pointer  and tighten  the screws.  Remove  the 
special  tool 
18G 1458 and refit  plug.  The timing 
pointer  has been  deleted  on later  engines. 
STl518M 
17. Remove  the special  tool LST  107 and  refit  the plug 
to  the  flywheel  housing. 
18. Tighten  the D.P.S. pump pulley  nut and  the 
camshaft  pulley retaining  bolt to the  correct 
torque. 
Care of belts 
1. Drive  belts must  be stored on cdge on a clean  flat 
surfacc  and 
in such a manner  that bends  are not 
less  than 
2 in (50 mm) radius. 
2. When  a belt  is handled, it must  not be bent  at an 
acute  angle 
or an arc  of less  than 1 in (25 mm) in 
diameter,  as damage rriay be caused to the  glass 
fibrc reinforcement  and premature  failure then 
result. 
3. During  use, a belt  develops  a wear pattcrn, 
thereforc, if it is to  be  re-used,  before  removal, 
mark  the direction 
of rotation,  using soft chalk or a 
similar  marker,  and refit  the belt 
so that it runs in 
the original dircction. 
4. Belts  must be dry  and FREE FROM  ANY OIL 
OR 
OTHER FLUID  CONTAMINATION. 
5. Do not  turn  the crankshaft  by applying  leverage to 
the camshaft  pulley or its  retaining  bolt. 
6. To remove a belt  always  use clean  hands,  or a 
recommended  tool 
- NEVER use a lever. 
g?!, *
						

							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  bolts. 
4. 
Fit a  new  crankshaft  seal. Using  special  seal 
replacer 
tool 18G 1456  and with  the lip side 
leading,  drive 
in the seal  up to the  shoulder. 
12 
I 
ST1517M / 
Fit water pump and crankshaft pulley 
5. Place  a new  joint  washer in position  and offer  up 
the  water  pump.  Fit the  different  length bolts 
in 
accordance  with the diagram  and evenly  tighten  to 
the correct torque. 
6. 
Fit the  crankshaft  pulley and secure  with the 
special  washer  and bolt.  Tighten  to the  correct 
torque  figure. 
FIT OIL PUMP  AND SUMP 
1. Fit the longer  splined  end of the drive  shaft into the 
oil pump. 
2. Fit the oil pump  and drive  shaft to the crankcase, 
whilst  revolving  the shaft 
as necessary to engage 
the  splines 
of the skew  gear. 
3. Using new lock washers,  secure the pump  to the 
crankcase  tightening  the bolts  to the  correct  torque 
and  bend  over the lock  tabs. 
4. If necessary  adjust the position of the strainer so 
that  it is parallel  to the  sump  baffle  plate. 
5. Clean  the sump  and crankcase  mating faces and fit 
a  new  joint  washer.  Later engines  without  a joint 
washer,  apply a bead 
of RTV HYLOSILL 102 
black 7 mm wide  to the  sump  or cylinder  block. 
Secure  the sump  with the twenty
-one  bolts  and 
spring  washers  and one  nut.  Evenly  tighten  to the 
correct  torque. 
FIT CYLINDER  HEAD AND ROCKER  SHAFT 
ASSEMBLY 
1. Clean the cylinder head and cylinder  block mating 
faces.  Position  a new  cylinder  head gasket 
on the 
cylinder  block with the word  ‘Diesel’  uppermost. 
2. Lower the cylinder  head onto the cylinder  block 
using  two long  bolts  to facilitate  accurate 
positioning 
of the head. 
3. Fit  the  cylinder  head retaining  bolts except  those 
also  used  to secure  the rocker  shaft and leave 
finger
-tight. 
4.  Insert  the push  rods ensuring  that 
the ball end 
locates properly  in the  spherical  seat in the tappet. 
5. 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 
locate  in the  push  rods. 
6. Fit the  rocker  shaft large  retaining  bolts and leave 
finger
-tight. 
.. “  
						

							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 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 the rocker cover 
6. Using a new  gasket, fit the rocker  cover and secure 
with  the dome  nuts and  washers. Tighten  evenly to 
the  correct  torque. 
Do not overtightcn. 
ADJUST TAPPET CLEARANCES 
ST 880M 
FIT THE CLUTCH -Fit.- 5”, %-: 1. Clean  the flywheel  face and  place the centrc  plate 
with  the side  marked  ‘Flywheel  side’  towards  the 
flywheel. 
1. Tf the  crankshaft  is rotated  with exccssive valve 2. Fit the clutch  assembly  locating it over the  three 
clearances, 
it is  possible  that  the push  rods may  dowels and loosely securc with thc six bolts. 
become dislodged from tappet seating and 3. Centralise  the  centre  plate using  special  tool RO 
fracture  the tappct  slide. To prevent  damage, 605022 or a spare primary  shaft  and  tighten thc six 
eliminate  all clearance  from any loose  rockers  bolts evenly 
to the correct torque figure.  Smear thc 
before  turning  the crankshaft  to  adjust thc splines  of thc centrc  plate  with Molybdenum 
clearances. 
disulphidc grease,  such as Rocol MTS 1000. 
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 lock nut and 
turning 
the tappet  adjusting  screw clockwise  to 
reduce  clearance  and anti
-clockwise  to increase 
clearance.  Rechcck the clearance  after  tightening 
the  lock 
nut. 
ST764M 
86