Land Rover Defender 90 110 Workshop 1984 Rover Manual

							2.25 LITRE PETROL  AND DIESEL  ENGINE 1121 
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12 
FIT FUEL  LIFT PUMP 
2.25 LITRE PETROL  AND DIESEL  ENGINE 
If the  fuel lift was separatcd from  the side  cover, fit 
the pump to the cover first  using  a new  joint  washcr 
and  evenly  tighten  the retaining nuts. 
Place 
a new  cover  plate joint washer in position 
and 
fit the  cover  and pump  assembly to the cylinder 
block.  Ensure  that the pump  actuating  lever 
ridcs on top 
of the camshaft. 
Secure 
the cover,  evenly  tightening  the retaining 
bolts. 
ST762M 
ST763M -4 
NOTE:  The illustration  shows a petrol engine  fuel pump 
but  the fitting  procedure  is the 
same for the  Diesel 
engine  pump.  FIT 
ROCKER COVER 
Clean 
the rocker  cover  and  cylinder  head  faces and fit 
the cover  using a new  joint  washer.  Evenly tighten  the 
dome  headed  nuts to the  correct  torque.  Do not 
ovcrtighten. 
A. Petrol engine 
B. Diesel  engine 
ST 881 M 
FIT HEATER PLUGS - Diesel  engine 
1. Clean  and  test the  heater  plugs as described in the 
maintenancc  Section. 
Fit thc heater  plugs and 
tighten  to  the corrcct  torque according 
to the size 
2. Fit the leads,  washcrs  and nuts as illustrated. 
*-e: of plug.  Do not ovcr tighten. 5 .. ,: -. w 
b- - 
ST127C!M 
30  
						

							2.25 LITRE PETROL AND DIESEL ENGINE la 
I. FIT THE  CLUTCH ( j 
						

							1121 2.25 LITRE PETROL AND DIESEL ENGINE 
Diesel engine 2. Assemble  the alternator to the engine  bracket  with 
the  two  pivot  bolts,  distance 
piece and washers, 
leaving  the 
bolts slack. 
3. Fit the  adjustment  link to the  timing  cover and 
attach 
to alternator  with the adjusting  clamp bolt. 
7. Using  a new  gasket  fit the  manifolds  and secure 
with  the retaining  nuts and clamps.  Evenly tighten 
to the specified  torque figure. 
ST768M lil 
4. Fit the  drive  belt and pivot  the alternator  away 
from  the engine,  but do not  apply  pressure 
to the 
stator 
or slip-ring  end bracket or damage  may 
result.  Tighten  the clamp 
bolt and  with  thumb 
pressure,  check the belt  tension  between  the Can FIT  ALTERNATOR,  PULLEY AND FAN BLADES 
and altcrnator pulleys which should  be 7 to 9 mm 
(Y4 to ?4 in) at the  mid-point. 
5. When  the tension  is correct  fully tighten  the clamp 
1. Fit the pulley,  spacer and fan blade  assembly 10 the 
water  pump shaft. 
bolt and the pivot  nuts and bolts. 
32  
						

							2.25 LITRE PETROL AND DIESEL ENGINE 
. 
12 
I. Clean the carburettcr and manifold  mating faces. 
2. Place a joint  washer,  over  the  studs  to the 
3. Fit the packing piece. 
4. Fit a second  joint washer. 
5. Fit the carburetter  and secure with the four  nuts 
and  washers  tightening  evenly to 
thc correct 
torque.  manifold. 
FIT 
THE  STARTER  MOTOR 
1. Secure the starter  motor to  the flywheel  housing 
noting  that  the  petrol  engine  starter is held  by two 
studs,  nuts and washers.  The 
startcr for the  diesel 
engine  is retained  by one  stud, one  bolt and one 
nut  and 
bolt. Tighten  the  fixings evenly  to the 
correct torque. 
1. Fit the pump  attachment  bracket to engine with 
2. Secure pump to bracket  with pivot  bolt  and  nuts 
3. Fit the tensioning clamp  bolt and  drive  belt. 
4. Check  that  the belt  can bc deflected 12 mm (E in) 
5. Tighten  the  pivot  bolt and nut and finally  tighten 
two 
bolts. 
leaving 
it slack. 
Tension 
the belt  and tighten  the clamp  bolt. 
by  thumb  pressure,  at 
the mid-point of its run (A). 
the clamp  bolt. 
6. Turn  the  pump  pulley so that the indicating marks 
on  the  pulley  hub and  pump body  line 
up. 
7. Remove  the oil level  plug  and inject a 
rccommended SAE 15W-50 oil up  to the level of 
the hole.  Refit the plug. See Maintenance  Section. 
6 
2. In addition,  the rear of the Diesel  engine  starter 
motor  is secured  by two  bolts  to a support  bracket 
attached 
to thc cylinder  block. 
MISCELLANEOUS iTEitiS 
Fit any  other  parts, if removed,  such as engine 
mounting  brackets, lifting eyes and  the dipstick. 
Also 
any  other  items of non-standard  equipment  peculiar to 
the  vehicle  concerned. 
Make  a careful  inspection 
of the  engine and  check  that 
all plugs 
are fitted  and properly  tightened. 
33  
						

							112 1 2.25 LITRE PETROL  AND DIESEL  CYLINDER  HEAD 
REMOVE OVERHAUL  AND REFIT 
Special  tools: 
Drift  inlet valve  guides  274400 
Drift  exhaust  valve guides  274401 
Drift  exhaust  valve guide  600959 
Drift  inlet valve  guide  601508 
Seat  cutters 
MS621 MS627 
Insert  replacer  530625 
Before the cylinder  head can be removed the following 
ancilliary  items, common  to petrol  and  diesel  engines, 
need  to be  removed 
or disconnected for access  and 
safety. 
I. Disconnect  the battery for  safety. 
2.  Drain  the cooling  system. 
3.  Remove the  bonnet. 
3. Disconnect heater rail pipes  and  move  aside. 
5. Disconnect  top hose from thermostat  housing. 
6.. Disconnect hcater control cables. 
7. Release  fan  cowl  from  bracket  attached to 
t h e r m os t a t ho usi n g . 
8. Disconnect  lead  from  coolant temperature sensor. 
9. Disconnect  oil gallery pipe  at rcar of engine. 
10. Disconnect  coolant by-pass hose. 
11. Disconnect  the exhaust pipc from the manifold. 
The  following  items concern  the petrol  engine  only 
I?. Disconnect  the air cleaner hose  from the 
13. Disconnect  brake vacuum  hose  from the 
14. Disconnect  mixture control cable from 
15. Disconnect  throttle cable. 
16. Disconnect  fuel  shut-off valve  lead  from 
17. Disconnect  vacuum  ignition  advance pipe. 
18. Remove H.T. leads from spark plugs. 
carburetter. 
manifold. 
carburetter. 
carburetter. 
The  following  items concern only the diesel  engine 
19. Disconnect  the  fuel spill return  union conncctcd 
to  spill rail. 
20. Disconnect  injector supply  pipes  from the 
injectors. 
21. Remove  injectors  complete with spill rail. 
22. Disconnect  air hose  from  manifold. 
23. Disconnect the heater  plug electrical  connections. 
Remove the cylinder  head 
The following  instructions  for removing  and 
overhauling  the  cylinder  head are  common  to petrol 
and diesel engines  unless otherwise stated. 
24.  Remove  the  rocker  cover  and slacken  the tappet 
screw  lock nuts.  Turn  the  adjusting  screws to 
release  them from the push  rods. 
25.  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. 
34 
26. Withdraw  the push  rods and retain  them in 
numbered sequence. 
27. Evenly  slacken  the  remaining  cylinder  head 
retaining  bolts  and  lift
-off the  cylinder  head 
complete 
with manifolds.  Remove and discard thc 
cylinder  head  gasket. 
ST674M 
28. Remove  the  eight bolts and three  nuts  and 
remove  the inlet  and exhaust  manifolds  complete 
with  carburetter  (petrol engine). 
29. Remove  three  bolts and lift-off the  thermostat 
housing, elbow  and thermostat. 
30.  Removc  spark plugs,  (pctrol  cnginc) 
tcmpcrature 
sensor and engine  lifting eyes. 
31. Using  valve spr-ing compressor 276102 or ;I 
suitable  alternative,  remove  the valve and spring 
assemblies,  keeping 
them identified with their 
original  locations 
for possible  refitting.  Discard 
the  valve  spring and  valve guide 
oil seals. Remove 
carbon  deposits from  the  valves and combustion 
chambers  and 
dcgrcase all  parts  ready  for 
examination. 
e- ,  
						

							2.25 LITRE PETROL AND DIESEL CYLINDER  HEAD E[ 
T 
.. . ... 
ST675M W 
EXAMINATION OF COMPONENTS 
Petrol engine 
32. Examine the cylinder  head for cracks  and 
distortion.  Burnt, pitted and pocketed  seats  must 
be  repaired. 
Diesel  engine 
33. Same as for petrol  engine  and in addition,  worn or 
damaged  exhaust  seat inserts  should  be 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 rcmove either the 
injector  shrouds 
or the hot  plugs. 
Small  surface cracks 
in the hot plug, extending  from the 
opening  to approximately 
8,O inn1 (,0.312 in) in length 
can be ignored. However if any  severe cracks appear  on 
the  face 
of the hot  plug, 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 
hhould be scrapped. 
.. *. ,. , ,. 
34. To remove a hot plug, 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 renewed. 
35. If the injector shroud  is damaged,  drift the shroud 
out towards the injector  bore. 
36. Thoroughly  clean out  the  combustion  chamber. 
The 
hole in the  side  of the  injector  shroud is for 
manufacturing  purposes only but 
at the same time 
can  be used  as a guide  when  refitting  the shroud. 
37. Smear a  little oil on the shroud  and  insert into the 
cylinder  head  with the 
hole pointing  towards  the 
centre 
of the cylinder  head, and drift into 
position. 
34 38 ST677M 
38. Fit  the  hot  plugs  by tapping with a hidc-faced 
mallet,  and  locate  with a new roll pin. If thc hot 
plugs  are loose 
in the  cylinder  head they may be 
retained 
with a  little  grease. 
39. When fitted, the hot plugs  must  be checked  with ii 
dial test  indicator  to  ensure that they do not 
protrude  above the  level 
of the cylinder  head  Cace 
more  than 
0,025 mm (0.001 in) and  are not 
recessed  below the level 
of the cylinder  head  face 
more than 
0.05 mm (U.002 in). 
ST678M I 
35  
						

							1121 2.25 LITRE PETROL  AND DIESEL  CYLINDER  HEAD 
Petrol and diesel  engines 
40. Chcck  the  valve  guides  for  wear 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. 
41.  Inspect  the  valves and discard  any that  are burnt, 
bent 
or distorted.  Check  the  stems for wear  by 
inserting  in a new  guide.  If wear  is 
excessivc, 
discard  the  valve. Valve faces that are pitted or 
ridged  but otherwise  serviceable  may be refaced. 
42.  Renew  push rods  that  are bent 
or have  worn or 
scored  ball or socket ends. 
Renew push rod tube seals (Diesel  only) 
43.  Whilst  this is rarely  necessary 
the procedure  is 
44.  Drive  out the old  push rod tubes  using a suitable 
nevertheless 
as follows. 
drift. 
* * 
NOTE: Later  engines  are fitted  with tubes  without  seals. 
See 
2.5 litre  Diesel  engine for renewal. 
Sl 
45. Fit new  sealing  rings to new  push  rod tubes  and 
smear  with silicone  MS4 grease. 
46.  Insert the  new tubes,  chamfered  end first from 
the 
combustion  chamber side. Align the flat on the 
push 
rod tube  at right  angles  to an  imaginary  line 
between  the centre 
of the  push  rod tube  and 
centre  of the hot  plug. 
47.  Press  the  push 
rod tubes into position  whilst 
maintaining  the alignment. 
Also ensure  that the 
chamfers 
on the  tubes  and in the cylinder  head are 
fully  engaged. 
Renew valve guide 
48. Support  the  cylinder head, combustion  chamber 
uppermost  on pieces  of timber  of sufficient 
thickness 
to allow  clearance for the valve  guides 
to be driven  out. 
49. Using  special  drift 274400 for inlet  guides  and 
274401  for exhaust 
guidcs or suitable  alternatives 
drive 
out the  old guides  from the combustion  face 
side. 
[-?  ~ 
J 
NOTE: The 
illustration shows a petrol  engine 
cylinder  head. 
36  
						

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2.25 LITRE PETROL AND DIESEL  CYLINDER  HEAD 12 
-:. .,. 
. I. 
50. Turn the cylinder head over so the combustion 
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. 
51. Lubricate new guides with engine oil and using 
special  drift 600959  for the  exhaust  and 601508  for 
the 
irrlet valve  guides or suitable  alternatives, 
drive 
in the new  guides until the shoulder is flush 
with  the casting. 
53. 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. 
54.  Select  the correct  expandable  collet for the  valve 
guide  concerned 
i.e. 8 mm for inlet  guides  and 
83 mm for exhaust. 
55. Loosely  assemble  the collet,  expander  and nuts. 
Ensure  that the chamfered  end 
of the expander  is 
towards 
the collet. 
Reface  cylinder  head valve  seats 
52. Damaged or worn  valve  seats can be refaced 
provided  they are not  abnormally  wide due to 
repeated  refacing operations. 
See instruction  64. 
B 
. / 
ST594M 
56. Insert  the assembled  pilot into the valve  guide 
from  the combustion  face side of the  cylinder 
head  until the shoulder  contacts 
thc valve guidc 
and the whole  of the  collet  is inside  the valve 
guide. 
57. Expand  the collet in the  guide  by turning  the 
tommy bar clockwise  whilst holding the knurled 
nut. 
58. Select the appropriate  angled cutter for the  seats 
to  be  cut. 
continued 
ST668M 
& .U A. Correctly  seated valve 
B. Undesirable  condition 
C.  Method 
of rectification 
37  
						

							(1211 2.25 LITRE PETROL AND DIESEL  CYLINDER  HEAD 
NOTE: MS 621 is a 45 and 15 cutter and MS 627 
is 30 only. 
A -Petrol engine - inlet valve seat 30 + W 
13 - Diesel engine - inlet valve  seat 45 + h 
exhaust  valve seat 45 + 9 
exhaust  valve seat 45 + % 
See illustrations  following instruction 68. 
59. 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 
IJf the  blade  contacts  the area of material 
to be  cut. Use the key  provided in the  hand  set 
MS 76. 
. 
60. Fit the  wrench to the cutter  head  and  turn 
clockwise  using  only very light pressure. Continue 
cutting to  approximately  the centre  of the  existing 
seat. 
61. To  check.  the effectiveness  of [ne cutting 
operation  use engineers  blue 
or a feeler  gauge 
made 
from cellophane. 
38 
62. Smear a small quantity of engineers  blue round cQ 
the valve  seat and revolve a properly ground  valve -- ..... 
against the seat. A continuous fine line  should 
appear  round the valve. 
If there  is a gap of not 
more  than 12 
mm it can be corrected  by lapping. 
63.  Alternatively,  insert  a strip  ofcellophanc  between 
the  valve  and seat,  hold the valve  down  by the 
stem and  slowly pull out 
the cellophane. If there  is 
a  drag the  seal is satisfactory 
in that  spot.  Repeat 
this 
in at  least  eight  places.  Lapping-in will correct 
a  small  open spot. 
64.  After  several  trueing
-up or lapping-in operations 
valve  seats may have  an excessive  width  which  can 
be  reduced  by obtaining  special correction  cutters 
which  narrow 
the seat by removing  metal from the 
top  and  bottom 
of the scat. A 60 cutter  is 
recommended  for  bottom  narrowing  and 
for top 
narrowing  use a 
15 cutter (MS 621)  for a 30 valve 
seat  and  a 30
 cutter  for a 45 seat.  The same 
correction  cutters as for refacing  cutters. IJse very 
light pressure  removing  only the minimuni 
material  necessary.  Once the  seats  have  been 
reduced  carry out the  normal  refacing operation 
as  previously  described. 
mcthod of assembly and  operation  is used for- L? :e+ 
Renew exhaust  seat inserts (Diesel only) 
65.  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. 
66.  Remove  any burrs  and swarf  from the pocket. 
Failure  to do  this  could  cause  the new  insert 
to 
crack  when being fitted. 
67.  Assemble  the  new insert  to 
the  replacer  tool 
number  530625 
so that the chamfered  edge of the 
insert  is 
lading. Using it suitable  bolt and nut 
draw the insert  into the cylinder  head pocket. 
Cut ii new 45 seat using  cutter MS 621.