Land Rover Defender 90 110 Workshop 1984 Rover Manual

GENERAL 
PetroVgasoline vapour is highly flammable  and in confined  spaces is also  very  explosive  and toxic. 
When 
petrol/gasoline evaporates it produces 150 times  its own  volume in vapour,  which when diluted  with air 
becomes  a readily  ignitable  mixture. The vapour  is heavier  than air and 
will always fall to the  lowest  level. It can 
readily  be distributed  throughout  a workshop  by air  current,  consequently,  even a small  spillage  of 
petrol/gasoline is 
potentially  very...

Special Service Tools 
The use of approved  special service  tools is important.  They are essential if service 
operations  are to be  carried  out efficiently,  and safely.  The amount 
of time  which they 
save can be considerable. 
Every  special  tool 
is designed  with the close  co-operation of Land  Rover  Ltd., and no 
tool is put  into  production  which has not  been tested  and approved  by us. New tools  are 
only  introduced  where an operation  cannot be satisfactorily  carried out using...

2.25 LITRE PETROL AND DIESEL  ENGINE 
j:z--bc , DISMANTLE  ANDOVERHAUL ,: -1 
Special tools:- 
Chain wheel extractor - RO 507231 
Tappet  guide remover 
- RO 530101A 
*Camshaft  bearing remover - 274388 
* 99 ” adaptor - 531760 
* 99 ” guide plug - 274394 
” reamer - 274389 
Cork-seal  guide 
- 270304 
Seal  guide 
- rear  main  bearing - 18G 1344 
Seal replacer - rear  main  oil seal - 18G 134 - 11 
Diesel  engine  timing  gauge - R0605863 
Diesel engine  timing  gauge - MS67B 
Clutch centralising  tool...

1121 2.25 LITRE PETROL  AND DIESEL  ENGINE 
Dismantle oil pump 
3. Bend back the lock washer  and  release the nut 
securing  the strainer 
to the oil pump  body and 
remove  the strainer  and sealing  ring. 
4. Removc  four bolts  and washers  and lift off the oil 
pump  cover and lift out  the driven  and idler  gears. 
(a) driven  gear 
(b) idler gear 
5. Remove  the oil pressure  relief valve  plug and 
sealing  washer.  Withdraw  the relief  valve  spring, 
plunger  and ball. 
ST591 M 
Overhaul  the...

2.25 LITRE PETROL AND DIESEL  ENGINE 
?. 13. A scored ball valve  seat can be restored  by using a 
locally  made lapping  tool by silver  soldering  a new 
ball  (part  number  3748) onto 
a length  of suitable 
tube. 
14.  Install  the tube 
in a drill  and lap-in using  coarse 
grinding  paste. Finally  hand
-lap the  seat  with fine 
paste  using the same  diabalo  method as for lapping 
valves. 
15.  Thorougly  wash the pump  body to remove  all 
traces  of grinding  paste. 
. 
14 
ST694M 
REMOVE...

12 2.25 LITRE PETROL  AND DIESEL  ENGINE 
REMOVE TAPPETS,  ROLLERS AND GUIDES 
6. 
7. 
T 
B 
ST697M 
Examine  the sprockets  and discard if the teeth  are 
worn. 
Dismantle  the tensioner  assembly and discard  any 
worn  parts.  In particular  check the condition 
of the 
ratchet  and pawl.  Check  the tension 
of the spring  by 
comparing 
it with  a new  one.  Examine the jockey 
wheel teeth  for wear,  and renew  bush if worn. 
Key 
to tensioner  assembly 
1. Piston assembly 
2. Cylinder  assembly...

2.25 LITRE PETROL AND DIESEL  ENGINE 
RENEW  TIMING COVER OIL SEAL 
1. On initial  assembly of the engine  the mud  shield 
around  the oil seal  is rivetted  in position  but after 
removal 
in service  the rivets  are substituted  with 
self  tapping  drive screws. 
2. Drill out the rivets  securing  the oil seal  mud  shield. 
3. Press  out the oil seal  and clean  the mating  surfaces. 
4. Smear the outside  diameter  of a new  oil seal  with 
Hylomar  PL 
32-M jointing compound.  Press the oil 
seal...

12 
5. Check the journals  for wear  and if more  than 
0,050 
mm (0.002  in) the  shaft  should  be renewed. 
6. Rest  the camshaft  between V blocks and check 
for  run
-out  with a dial indicator.  If 
run-out  is in 
excess of 0,050 mm (0.002  in) the  shaft  should  be 
straightened 
or renewed. 
2.25 LITRE PETROL AND DIESEL ENGINE 
REMOVE AND OVERHAUL THE FLYWHEEL 
1. Remove  the flywheel  retaining  bolts and withdraw 
the  flywheel  and reinforcing  plate. 
2. 
3. 
4. 
Wear or scores on the...

2.25 LITRE PETROL AND DIESEL ENGINE 112 
REMOVE  THE CONNECTING-RODS  AND PISTONS  REMOVE,  INSPECT AND OVERHAUL 
CRANKSHAFT 
- During the following  instructions  it is  important  that all 
components  are kept 
in related  sets and the pistons  arc 
identified  with their  respective  bores. 
1. Turn the crankshaft to bring  the connecting-rod 
caps 
to an  accessible  position and remove  each cap 
and  lower  shell in turn.  Note that the connecting
- 
rod caps  are numbered  one to four. 
1. Remove...

1121 2.25 LITRE PETROL  AND DIESEL  ENGINE 
Inspect crankshaft 
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, scores,  grooves  and 
overheating. 
A decision  at this  stage  should  be 
made  as  to whether 
the condition  of the  shaft  is 
worth  continuing  with more  detailed  examination. 
5.  With  a  micrometer,  measure and note  the ovality 
and...