Land Rover Defender 90 110 Workshop 1984 Rover Manual

							2.50 LITRE DIESEL ENGINE 
66. Using  new  spacers and springs,  assemble  the 
rockers  and  brackets  to the  shaft  as  illustrated, 
ensuring that 
the rockers  move freely  on thc shaft. 
Note 
th.jt double spacers  are fitted each  side of the 
centre pedestal. 
67. 
Fit the  tappet  adjustment  screws and lock  nuts to 
the  rockers. 
68.  Invert  the rocker  assembly  and  locate 
it on the 
rocker cover to prevent it falling apart. Place  the 
reconditioncd cylinder  head  and  rocker assembly 
to one side  ready  for fitting  to the engine. 
Si1432M 66 
REMOVE AND OVERHAUL THE FLYWHEEL 2. Wear or scores on the flywheel  clutch face can be 
corrected  by machining 
provided that  the overall 
1. Remove  the  flywheel retaining bolts and  withdraw  width of the flywheel  is not  rcduccd bclow 
3. Check  that  the flywhccl has  not  been  previously 
the 
flywheel  and reinforcing  plate. 
36,96 mm (1.453 in). 
. .. . .. . ... , 
machined. 
thc gcar can be renewed. 
4. Examine the  ring gear  teeth  and if chipped or worn 
Reface  the flywheel 
5.  Remove  the clutch location dowels. 
6. Machine thc flywheel over the complete  clutch face 
removing  only thc minimum niaterial necessary  to 
achieve  a  smooth  flat surface  parallel  with the 
crankshaft  mating face  and 
within the above width 
dimensions  and 
fit new dowels. 
Renew the ring gear 
7. Drill  a 8,O mm (& in) hole betwecn the root  of any 
two  teeth  and 
the inner diametcr of the starter  ring 
decp enough  to weaken  the ring. Do not  allow  the 
drill  to enter 
the flywheel. 
59  
						

							2.50 LITRE DIESEL ENGINE 
8. Secure the flywheel in a soft  jawed  vice and cover it 
with  a cloth to protect  one from  personal  injury. 
Place  a cold  chisel  above the  drilled  hole  and strike 
it sharply to  split the ring  gear. 
ST701 M \‘ 
9. Heat the new ring  gear  uniformally  to  between 
225°C and 250°C but do not  exceed  the  higher 
figure. 
10. Place thc flywheel,  clutch face down, on a flat 
surface  and  locate  the  heated flywheel 
with the 
square  cdge of teeth  downward  towards  the 
flywheel  clutch  face  and chamfered  edge of the 
teeth  uppermost. 
1 I. Press the  starter ring firmly against  the flange until 
the  ring  contracts  sufficiently  to grip  the flywheel. 
Allow  the ring  gear 
to cool  naturally. Do not 
hasten  cooling 
in anyway. 
10 
/=- -.-;-(I 
U ” rc, 
ST 928M 
REMOVE AND OVERHAUL OIL PUMP - Early type 
1. Remove the  sump. 
2. Bend back the lock  washers  and  remove the two 
bolts securing  the oil pump to the  crankcase. 
Withdraw 
thc oil  pump  complete with strainer  and 
oil  pump  drive shaft. 
Dismantle oil pump 
3 Bend  back the lock wa\her and release  the nut 
securing  the  strainer  to the oil pump  body and 
remove  the strainer and sealing  ring. 
4. Remove four bolts  and  washers and lift off the  oil 
pump  cover and 
lift out the driven  and idler  gears. 
(a) driven  gear 
(b) 
idlcr gear 
ST591 M 
60  
						

							2.50 LITRE DIESEL ENGINE 12 
. . -- -. 1.. . -.j 5. Remove the oil 
sealing  washer.  Withdraw  the relief valve  spring, 
plunger  and ball.  pressure 
relief  valve  plug  and .*> Y.. . , 
NOTE: Later pumps  have ten toothed  gears and no 
relief valve ball. 
.-, 
I:- 
Overhaul  the oil pump 
6. Examine  the gears for wear, scores  and pits.  If the 
gears  appear  serviceable  check  for end
-float as 
fo 1 I0 ws : 
7. Clean the pump body  and  assemble the gears. 
Place  a straight  edge across 
[he pump  body face, as 
illustrated, and  using 
a feeler gauge,  measure  the 
clearance  between the  body and gears.  The correct 
clearances 
are as follows: 
8. Idler gear 0,07 to 0,015 mm (0.003 to 0.006 in). 
9. Driven  gear 0,05 to 0,12 mm (0 002 to 0.005 in). 
10. Gears must be  renewed in pairs. A worn,  but 
serviceable  gear, must  not  be  matched 
with a new 
one. 
11. If  necessary  renew idler gear  spindle by drilling-out 
the  peened  over  end of the  spindle 
so that the 
spindle  can  be withdrawn  from the pump  body. To 
ensure squareness when fitting the new  spindle, 
assemble 
it into the pump  body  with  the two  gears. 
Fit the  cover  and secure with the four  bolts. 
Support  the pump  body and peen  over  the  end 
of 
the new spindle. Remove  the cover and  gears and 
check  security 
of the spindle. 
12. If worn,  remove  the idler gear bush  and  press in a 
replacement. 
Drill the  lubrication  hole 3.17 mm 
(0.125 in) and  ream  the bush  to 12,7 mm (0.500 in) 
diameter. 
.. . ,_.. I_ .:.,..:... \. .. 
12 
ST911M 
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. Thoroughly  wash the pump  body to rcmovc all 
traces  of grinding  paste. 
4 h, \ ST694M 
Assemble the oil pump 
i6. Fit the idler gear  to the spindie. 
17. Fit the driven  gear with plain  part of the bore 
uppermost.  See illustration  after instruction 
9. 
18. Smear the joint  face of the  body with jointing 
compound  and fit the cover  over  the  dowels and 
the strainer  bracket and secure with the four  bolts 
and  spring  washers. 
19. Hold relief valve  bore vertically  and insert  the  ball 
followed  by the  plunger  with the ball  seat  end  first. 
Fit the spring,  sealing washer  and plug. 
20. Fit the oil strainer  sealing  ring to the  pump  body 
followed  by the  lock  washer  and  strainer. Tighten 
the  strainer  retaining  nut 
so that when  fitted  the 
strainer 
is positioned  parallel  to  the sump baffle 
plate.  Secure 
the nut with the lock  washer  tab. 
21. Secure  the lower  end of the  bracket to the strainer 
with  the single 
bolt, spring and plain  washer. 61  
						

							121 2.50 LITRE DIESEL ENGINE 
REMOVE AND OVERHAUL OIL PUMF - Later Type Dismantle oil pump 
I. Remove the sump. 
2. Bend back the lock  washers  and  remove  the  two 
bolts  securing 
the oil pump to the  crankcase. 
Withdraw  the  oil pump  complete 
with strainer and 
oil  pump  drive 
shaft. 
3. Bend  back the lock washer  and  release the nut 
securing  the  strainer to the oil pump body and 
remove the strainer  and scaling ring. 
4. Remove 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 
and  plunger. 
ST1635M 
Overhaul  the oil pump 
6. Examine the gears for wear,  scores  and pits.  If the 
gears  appear  serviceable  check 
far end-float as 
follows: 
7. Clean  the  pump body and assemblc the gears. 
Place  a straight  edge across the  pump body face, as 
illustrated,  and  using a  feeler  gauge,  measure the 
clearance 
bctween the  body  and gears.  The correct 
clearances  arc given 
in the  Data  section 05 book 
one. 
7 
ST1636M 
8. Gears  must be renewed in pairs. A worn,  but 
serviceable  gear, must 
not be matched with a new 
one. 
9. If  necessary renew idler  gear spindle by drilling-out 
the  peened  over  end 
of the spindle so that  the 
spindle can brt withdrawn from !he pump hody. To 
ensure squareness  when  fitting  the new  spindle, 
assemble 
it into  the  pump body with the two gears. 
Fit the cover  and seclire with four bolts.  Support 
the pump  body and peen  over the  end of the new 
spindle.  Remove 
the cover  and  gears  and  check 
security  of the  spindle. 
continued 
62  
						

							2.50 LITRE DIESEL ENGINE 1121 
Assemble the oil pump 
10. Fit the  idler  gear to the spindle. 
11. Fit thc driven  gear with  plain  part of the  bore 
uppermost. 
ST1637M 
12. Smear  the .joint face of the body with jointing 
compound  and 
fit the  cover  over the  dowels  and 
sccurc with the four bolts  and spring washers. 
13. Hold relief  valve bore vertically  and  insert  the 
plunger 
with the  solid cnd first. Fit the spring, 
sealing washer  and plug. 
14. Fit the oil strainer  sealing ring to  the  pump body 
followed  by 
the lock washer  and  strainer. Tighten 
the  strainer  retaining  nut 
so that whcn fitted the 
strainer  is positioned  parallel 
to the sump  baffle 
plate.  Secure  the nut  with  the 
lock washer  tab. 
REMOVE TIMING BELT, PULLEYS AND COVERS 
Remove  front cover 
1. Remove  the  four  bolts and remove  the front  cover 
vent  and wading  plug bracket,  gauze and gasket. 
2. Remove  nine timing  cover bolts, but do not 
withdraw  centre 
bolt from the cover since there is a 
fibre  washer 
on the bolt  behind  the  cover. Remove 
the  cover  and  joint  washer  and retrieve  the fibre 
was  her. 
3. Prise  out the crankshaft seal. 
Remove  timing belt and pulleys 
4. Slacken  and  remove the camshaft  retaining  bolt, 
special  washer and 
‘0’ rings. 
5. Slacken  and  remove  the distributor  pump timing 
pulley nut. 
6. Slacken the belt tensioner  clamp nuts and remove 
the  belt.  Remove  the  clamp 
nut and withdraw  the 
tensioner  assembly. 
7. Use the centre  part of special  tool 18G145711 as 
illustrated,  and  withdraw  the  distributor  pump 
pulley. 
ST1456M 7 
8. Use  special puller tool 18G1464/2/6, as illustrated 
and withdraw  the camshaft  pulley. 
63  
						

							)121 2.50 LITRE DIESEL ENGINE 
9. Withdraw the crankshaft pulley  using  complete KEY TO TIMING GEAR  AND COVER ASSEMBLY 
tool 18G1464/2 and button 18G1464/5. 1. Fan  blades 
1 ST1457M 
Remove  distributor  pump (D.P.S.  Pump) 
10. Remove  the high and low pressure  pipes  from  the - D.P.S.  pump  and injectors. (If not already 
removed)  and cover,  not plug, the ports. 
11. Disconnect  the pump  operating link from the lever 
on the bracket. (If not already removed). 
12. Remove  the nut and bolt  securing  the rear of the 
pump  to 
thc support  bracket. 
13. Remove  the  three  nuts  retaining the pump  to the 
front  cover  and  withdraw  the  pump  and  joint 
washer. 
14. Remove  the retaining  bolts  and  remove the front 
cover  and  gaskets 
from the  cylinder  block.  Prise 
out  the old 
oil seals. 
64 
2. 
3. 
4. 
5. 
6. 
7. 
8. 
9. 
10. 
11. 
12. 
13. 
Spacer 
Fan  pulley 
Special  bolt 
- Later  engines,  starter  dog  early 
engines. 
Crankshaft  pulley 
Wading  plug 
Timing cover vent 
Inspection cover 
Front  cover plate 
Front  cover plate  oil scal 
Water  pump 
Water  pump joint  washer 
Cover 
14. Timing  belt 
15. D.P.S. pump pulley 
16. Camshaft  pulley 
17. Jockey pulley (tcnsioner) 
16. Coolant  gallery joint washer 
19. Front cover to cylinder  block joint washer 
20. Front  cover plate joint washcr 
21. Camshaft  front cover  oil seal 
22. Crankshaft  cover oil seal 
23. Triangular joint  washer 
24. Fibre washer 
REMOVE TAPPETS, ROLLERS AND  GUIDES 
1. Remove the eight tappet  guide locating  bolts from 
the  right
-hand side of the cylinder block. 
CAUTION:  Do not  remove  the tappet  guides  before 
the  rollers  otherwise  the 
rollers may fall behind  the 
camshaft. 
2. Using  long nosed  pliers or a suitable bent  length of 
wire 
lift out the tappet slides and  identify  them with 
their 
respectivc guides for possible refitting.  
						

							65  
						

							2.50 LITRE DIESEL ENGINE 
3. Lift out the tappet  rollers and  mark the side facing 
the front  of the engine  for possible  reassembly. 
4. Lift out the guides and retain with their 
respective  slides  and rollcrs.  If the  guides are 
difficult to remove  use special tool 530101A. 
5. Carcfully examine  all parts  and discard  any that  are 
worn  or damaged. 
Examine 
4. Inspect  the  components  for wear  and damage  and 
renew as  necessary. 
5. To check thc rotor to body clearance, fit the  rotor 
to the body  and with  feeler  gauges  measure  the 
clearance  at  the  narrow  point  between the rotor 
and  body.  The correct  clearance 
is 0,05 mm 
(0.002 in). 
6. Check  the clearance  between  the  rotor  and end 
plate by placing  a straight  across the  body and with 
feeler  gauges  measure  the clearance  between  the 
straight  edge  and  rotor. The correct  clearance 
should  be 
0,lO to 0,12 mm (0.004 to 0.005 in). 
Assemble 
7. Fit the rotor blades  to the rotor with thc radius 
outwards  and insert 
thc rotor into the  body. 
8. Place a new ‘0’ ring  seal in position in the body 
groove  and 
fit the end platc  and sccure with the 
four 
bo 1 t s tight  en i n g eve n I y . 
9. When  fitting pump to engine  use a new  joint 
washer  and ensure  that 
the drive slot fits correctly 
over the  coupling 
drivc pin. 
ST699M 
REMOVE  AND OVERHAUL  SKEW GEAR 
COUPLING 
The  coupling can be overhauled  without  separating it 
from the skew  gear. REMOVE  ANI) OVERHAUL  VACUUM PUMP 
Dismantle  Remove skew gear assembly 
1. Reniove the pump from the engine. 
2. Remove  the four bolts securing  the end  plate  and 
3. Tap the shaft-end of the rotor to remove it from  the 3. Using  long-nosed  pliers lift out thc skew gear 
1. Remove  the oil filter  housing  complete with filter 
2. Remove  the skew  gear bush  locating  screw. 
and 
joint washer. 
withdraw  the end  plate  and ‘0’ ring seal. 
e”” pump  body.  assembly. + ;; ::.; “4 
I 
8 ST868M 
66 
ST614M =// 1 \I  
						

							2.50 LITRE DIESEL ENGINE 1121 
{: :;;
						

							I 12 I 2.50 LITRE DIESEL  ENGINE 
4 Dismantle  also the old  coupling  and use the sleeve 
to manufacture  a  suitable press tool.  Use  a round 
section file to increase  the depth  of the cross-pin 
slot 
so that it will not  bear upon the cross-pin  when 
used  to press 
in the  new  coupling.  Weld a suitable 
length 
of steel  bar or tube to  the sleeve to complete 
the tool. 
5. Fill the  annular  groove round the splines of the 
coupling  with silicone  rubber sealant. 
6. Assemble the skew gear and coupling  with the 
manufactured  press  tool 
in position  inside the 
coupling 
and place  under  the press  and slowly  press 
in the new  coupling.  Clean off surplus sealant  and 
swarf  from  the internal  splines 
of the skew  gear. 
7. Reassemble  the new  coupling  as  described  under 
‘Coup1 i ng Overhaul ’ . 
REMOVE THE CONNECTING-RODS  AND PISTONS 0 
During the following  instructions  it is important that all 
components  are kept 
in related  sets and the pistons  are 
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  arc numbered  one to four. 
2. Push  each  piston  assembly  up the bore and 
withdraw  from  the  cylinder  block.  Assemble the 
caps  and  shells 
to the connecting-rods and place to 
one  side  for inspection  with the cylindcr  block at a 
later stage. 
REMOVE  AND INSPECT  CRANKSHAFT 
1. Remove  the  eight  bolts  securing  the  flywheel 
housing 
to the  cylinder  block  and  remove  the 
housing  and  rear main  bearing  oil seal,  and 
‘0’ 
ring. 
The 
‘0’ ring has  been deleted on later engincs. 
ST7 1 8M 
68