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 dangerous. 
Always  have a fire  extinguisher  containing FOAM 
CO? GAS, or POWDER  close at hand when handling or draining 
fuel,  or when  dismantling 
fucl systems  and in areas  where  fuel containers  arc stored. 
Always  disconnect  the vehicle  battery BEFORE  carrying out dismantling 
or draining  work on a fuel  system. 
Whenever 
petrol/gasoline is  being  handled,  drained or stored,  or when  fuel systems  are being  dismantled  all forms of 
ignition  must be extinguished  or removed,  any head-lamps  used must  be flameproof  and kept  clear of spillage. 
,‘ , 
.’I + . ,i 
NO  ONE  SHOULD  BE PERMITTED TO REPAIR  COMPONENTS  ASSOCIATED WITH PETROL/ 
GASOLINE  WITHOUT FIRST HAVING  HAD SPECIALIST  TRAINING. 
FUEL TANK DRAINING 
WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED  OR DRAINED  FROM ANY VEHICLE WHILST 
IT IS STANDING  OVER A PIT. 
Draining or extracting petrol/gasoline from  vehicle  fuel tank  must bc carried  out in a well  ventilated  area. 
The  receptacle  used to contain  the 
petroUgasoline must be more  than adequate  for the  full  amount of Fuel to be 
extracted  or drained.  The receptacle  should be clearly  marked  with its contents,  and 
placcd in a safe storagc area 
which  meets the requirements  of local  authority  regulations. 
WHEN 
PETROL/GASOLINE HAS  BEEN  EXTRACTED  OR DRAINED  FROM A FUEL  TANK THE 
PRECAUTIONS  GOVERNING NAKED LIGHTS  AND JGNITION  SOURCES SHOULD BE MAJN‘I’AINED. 
-- 
FUEL TANK  REMOVAL 
On vehicles  where the fuel line is sccurcd  to the  fuel  tank  outlet  by a spring  steel clip, it is recommended that such 
clips are  released  before the fuel  line is disconnected  or the fuel tank  unit is removed. This procedurc will avoid lhc 
possibility  of residual  petrol fumes in the fuel  tank  being  ignited  when the clips  are released. 
As  an added  precaution  fuel tanks  should  have a 
PETROL/GASOLJNE VAPOUR  warning label attached  to them 
as soon  as they  are removed  from the vehicle. 
FUEL TANK REPAIR 
Under no circumstances  should a repair  to any  tank  involving  heat treatment  bc carried out without  first rendcring 
the tank SAFE,  by using one of the  following  methods: 
STEAMING:  With 
the filler cap and  tank  unit removed,  empty the tank.  Steam the tank for at least  two hours 
with  low pressure  steam. Position  the tank 
so that  condensation  can drain  away freely,  ensuring  that any 
sediment  and sludge  not volatised  by 
the steam, is washed out during  the steaming proccss. 
BOILING:  With the filler  cap and  tank  unit removed,  empty the tank. Immersc the tank  completely in boiling 
water  containing  an effective  alkaline degreasing  agent  or a detergent,  with 
the water filling  and also 
surrounding  the tank  for at least  two hours. 
After  steaming  or boiling  a signed  and dated  label 
to this effect  should be attached  to the  tank. 
SPECIFICATION 
Purchasers  are advised  that the specification  details set out in this  Manual  apply to a range of vehicles  and not to any 
one.  For the specification  of a particular vehicle,  purchasers should consult  their Distributor  or Dealer. 
The  Manufacturers  reserve the right  to vary  their  specifications  with 
or without notice, and at such  times  and in such 
manner  as they  think  fit. Major  as well  as minor  changes  may be involved 
in accordance  with the Manufacturer’s 
policy 
of constant  product improvement. 
Whilst  every effort  is made  to ensure 
the accuracy of the  particulars  contained in this Manual,  neither the 
Manufacturer 
nor the  Distributor  or Dealer,  by whom  this Manual  is supplied,  shall in any circumstanccs be held 
liable fer ;~j: inaccuracy the consequences ihe,-pof, 
COPY RIGHT 
@ Land  Rover  Limited 1984 
All rights  reserved.  No part of this  publication  may be produced,  stored in a retrieval  system or transmitted in any 
form,  electronic,  mechanical,  photocopying,  recording or other  means  without  prior written  permission  of Land 
Rover  Limited,  Service Department,  Solihull, England. 
.. 
... Ill  
						

							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  existing 
tools  or standard  equipment.  The user 
is therefore  assured that the tool is necessary  and 
that  it will  perform  accurately,  efficiently and safely. 
Special  tools bulletins  will be issued  periodically  giving details  of new 
tools as they  are 
introduced. 
All orders  and enquiries  from the United  Kingdom  should be sent  direct  to V. L. 
Churchill.  Overseas orders should  be placed  with the local V. L. Churchill  distributor, 
where  one exists.  Countries  where there is 
no distributor  may order  direct  from V. L. 
Churchill  Limited, 
PO Box 3 Daventry,  Northants,  England 11 4NF. 
The  tools  recommended  in this  Workshop  Manual are listed 
in a multi-language,  illustrated  catalogue 
obtainable  from Messers. 
V. L. Churchill  at the  above  address  under publication  number 2217/2/84 or from 
Land  Rover  Ltd., under  part number 
LSM0052TC from  the following  address, Land Rover  Publication 
Service, 
P.O. Box 534, Erdington,  Birmingham B24 OQS.  
						

							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 - R0605022 
* Whilst these tools are now  not obtainable,  their use is 
described for workshops  that have  them  available. 
Remove  the engine  from the vehicle.  Clean the exterior 
secure  the engine 
to a recognised engine  stand. 
REMOVE ANCILLARY  EQUIPMENT 
Before commencing,  make a careful  note of the 
position 
of brackets,  clips, harnesses,  pipes, hoses, 
filters  and other  miscellaneous  items 
to facilitate  re- 
assembly . 
* 9’ 
T and in the  interests of safety  and efficient  working, 
12 
Petrol engine 
1. Disconnect  the spark plug leads,  release  the 
distributor  clamp bolt and withdraw 
the distributor 
complete.  Remove the adaptor  plate held by three 
bolts. 
2. Remove  the inlet  and exhaust  manifolds  complete 
with  carburetter.  Removal 
of the heat shicld will 
facilitate  this operation. 
L 
Diesel  engine 
.. 3. Release the fuel pipes  from the injectors. 
4. Rcmove the  nuts  securing  the injector  pump and 
withdraw  the pump  and the short  drive  shaft. 
5. Remove  the induction  and exhaust  manifolds. 
6. Remove  the six bolts  and withdraw  the oil filter 
tube 
(carly engincs only). At  the  same  time remove 
the two joint  washers  and the baffle  plate with the 
timing  pointer  attached. DO NOT disturb the two 
bolts  retaining  the timing  pointer.  Later engines 
have  a single  plate with timing  pointer. 
7. Remove  the vacuum  pump. 
Petrol and diesel  engines 
8. Remove  the six bolts  and withdraw the rear  side 
cover  complete  with fuel pump. 
9. Remove  the alternator  and drive  belt. 
10. Remove  the fan  and pulley. 
11. 
12. 
13. 
14. 
15. 
16 
17 
Remove  the seven -bolts- and  remove  the water 
pump. 
Drain the sump  and remove the dipstick. 
Remove  the starter  motor. 
Restrain  the flywheel,  remove the crankshaft 
pulley  nut and  withdraw  the pulley.  (Bolt 
on later 
engines). 
Evenly slacken  and remove the clutch  retaining 
bolts 
and withdraw  the clutch  assembly  and centre 
plate.  Remove 
the two  bolts  and remove  the oil filter 
assembly  complete  from the cylinder  block. 
Remove  the bowl  retaining  bolt, drain  the 
oil and 
discard  the element. 
Remove  the cylinder  head. 
REMOVE AND OVERHAUL  OIL PUMP 
1. 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. 
continued 
1  
						

							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 oil pump 
6. Examine the gears  for wear,  scores  and pits.  If the 
gears  appear  serviceable  check for end
-float  as 
follows: 
2 
7. Clean  the pump  body and assemble  the gears. 
Place  a straight  edge across  the 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 0,15 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, 
asscmble 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 i2,7 mm (0.500 in) 
diameter. 
continued 
12 
ST911M  
						

							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  AND OVERHAUL  THE TIMING  CHAIN, 
SPROCKETS  AND TENSIONER 
1. Remove  the timing  cover.  Before  removing  the 
timing  chain tensioner  notc the ratchet  position 
in 
relation  to the pawl which  will give  an indication of 
chain  wear.  If the  last  tooth of the ratchet  is engaged 
with  the pawl 
the chain is excessively  worn and 
should  be discarded. 
2. Remove  the ratchet  pivot bolt, plain  bolt and nut 
and withdraw  the timing  chain tensioner  complete. 
3.  Remove  the timing  chain and crankshaft  sprocket. 
4.  Remove  timing chain damper. 
Assemble 
the oil pump 
16. Fit the  idler  gear to the  spindle. 
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 
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. 
Later  engines  are fitted  with 
a bracket  to locatc the 
strainer. 
5. Remove  the camshaft  sprockct retaining  bolt and 
washer.  Withdraw  the sprockct  using chain  wheel 
extractor  507231 
or similar. 
Illustration 
A shows  the early  retaining  bolt and tab 
washer. 
Illustration 
B shows  the latest bolt and  special  washer. .. .. . 
A 
ST696M 
conriniicd 
3  
						

							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 
3. Cylinder  spring 
4. Ball 
5. Ball retaining  clip 
6. Ratchet and spring 
7. Ratchet  pivot bolt 
8. Pawl 
9. Jockey  wheel 
10. Timing  chain damper 
1. 
2. 
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. 
Using  long nosed  pliers or a suitable  bent length  of 
wire 
lift out  the tappet  slides and identify  them with 
their  respective  guides for possible  refitting. 
3.  Lift  out the tappet  rollers  and mark  the side  facing 
the front  of the engine for possible  reassembly. 
4. Lift out the tappet  guides  and retain  with their 
respective  slides and rollers. 
If the guides  are 
difficult  to remove  use special  tool 
530101A. 
f? 8. Assemble  the tensioner  as illustrated  and compress 5. Carefully examine all parts and discard any that are 
the assembly  ready for fitting  to the  engine. 
worn or damaged. .4 
ST699M 
4  
						

							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  into  the timing  cover, lip side  facing 
crankshaft. 
5. Coat  the drive  screws  with Hylomar  and secure  the 
mud  shield. 
12 
ST7OOM 
.. , . (. I ..::.::. . .. 
REMOVE  THE CAMSHAFT 
1. Remove  the skew  gear bush  retaining  scrcw and lift 
out  the skew  gear bush  assembly. 
Also withdraw 
the  distributor  pump (diesel) 
or ignition  distributor 
(petrol  engine)  drive coupling  with the skew 
gcar 
assembly. 
ST596M ’// I I1 
2. Since  the camshaft  sprockct has already  been 
removed,  bend back the lock  tabs,  remove  the two 
bolts  and the camshaft  thrust 
plate. Carefully 
withdraw  the camshaft. 
NOTE:  Lock tab washers  are not used on later 
engines 
Inspect the  camshaft 
3. Discard the camshaft if any of the  following  visual 
defects  are evident. 
4. Scored,  worn, pitted  or chipped  cams. Worn, 
corroded  and discoloured 
journals. Worn  and 
chipped  gear teeth. 
5  
						

							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 flywheel clutch face can be 
corrected  by machining  provided that the overall 
width 
of the  flywheel  is not  reduced  below the 
following  dimensions: 
Petrol  engines 
34,?2 mm (1.375 in). 
Diesel engines 36,96 mm (1.453 in). 
Check  that the flywheel  has not been  previously 
machined. 
Examine  the ring  gear  teeth  and 
if chipped or worn 
the  gear  can be renewed. 
Reface  the flywheel 
5. Remove the clutch location  dowels. 
removing 
only the  minimum  material necessary to 
achieve a smooth flat surface parallel  with the 
crankshaft  mating face and within  the above  width 
dimensions  and fit new  dowels. 
6, i$itcii;ne the fly.wheei the compieic face 
Renew  the ring  gear 
7. Drill  a 8,0 mm (A in) hole  between  the root of any 
two  teeth  and the inner  diameter 
of the starter  ring 
deep  enough  to weaken  the ring. 
Do not allow  the 
drill  to enter  the flywheel. 
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  the flywheel,  clutch face down, on a flat 
surface  and locate  the heated  flywheel  with the 
square  edge 
of teeth downward  towards the 
flywheel  clutch face and chamfered  edge 
of the 
teeth  uppermost.  This applies 
to both  petrol  and 
Diesel  engines. 
11. Press the starter  ring firmly  against  the flange  until 
the  ring  contracts  sufficiently 
to grip the flywheel. g??;: 
Allow  the ring  gear  to cool  naturally. Do not %i-. 
hasten  cooling  in anyway. 
5. 
10 
ST 928M 
6  
						

							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 the eight  bolts securing  the flywheel 
housing  to the  cylinder  block and remove 
the 
housing  and rear  main  bearing  oil seal,  and ‘0’ 
ring. 
. 
ST718M 2. Push each  piston  asscmbly  up the  bore  and 
withdraw  from the cylindcr  block. Assemble  the 
caps  and shell.?  to the  connecting
-rods  and place to 
one  side  for inspection  with the cylinder  block at a 
later  stage. 2. Remove the main  bearing  caps and shells  and lift 
out the crankshaft.  Collect the bearing  shells from 
the  bearing  saddles and the thrust  washers  from 
thc 
centre saddle. 
...,.. .. . .. . continued 
7  
						

							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  taper 
of each  main  bearing  journal and 
crankpin  as follows: 
6. 
Ovality - Take  two readings  at  right-angles to 
each other at  various intervals. 
The  maximum  ovality  must 
not exceed 0,040 mm 
(0.0015  in). 
7. Taper - Take two readings  parallel to each  other 
at  both  ends of the  main  bearing  journal  and 
crankpin. 
The maximum  permissable  taper must 
not exceed 0,025 mm (0.001 in). 
8. To check  for  straightness,  support  the  front and 
rear  main  bearing  journals 
in ‘V’ blocks and 
position  a dial  indicator 
to check the run-out at the 
centre  main bearing  journal.  Run
-out must not 
exceed  0,076 mm (0.003 in) taking into account 
any  ovality 
in the centre journal. 
The  overall  allowable  wear limit should  not exceed 
0,11,4 mm (0.0045 in)  for main  bearing  journals 
and  0,088 
mm (0.0035  in) for crankpins. 
A crankshaft  worn  beyond the limits  of maximum 
taper, ovality  and overall  wear can be  ground 
undersize for  which bearing  shells arc available  see 
data,  book 
1. 
When  grinding  the  crankshaft  main bearing  and 
crankpin  journals,  rotation 
of the  grinding  wheel 
and  crankshaft  must be 
in the  same  direction, 
anti
-clockwise,  viewed  from the flywheel  end of the 
crankshaft.  Final finishing  of the  journals should  be 
achieved  by 
using a  static tapping stone with the 
crankshaft  rotating 
in a clockwise direction  viewed 
from 
the flywheel  end of the crankshaft.  It is 
important 
to ensure  that, when  grinding,  the stone 
travels  beyond  the edge 
of the journal ‘A’ to avoid 
formation 
of a  step ‘R’ as  illustrated. Also care 
must  be taken 
not to machine or damage  the fillet 
radii.C. 
1 
EXAMINE  AND  OVERHAUL THE CYLINDER 
BLOCK 
1. Degrease  the cylinder  block  and carry out a 
thorough  visual examination  checking  for  cracks 
and  damage. 
To check  the  main  bearing  caps and 
saddles  for  distortion.  Fit the  main  bearing  cap 
without  bearing  shells and tighten  to the  correct 
torque.  Slacken  and remove the  bolt 
on one side  of 
each  bearing cap and  check with a feeler gauge that 
no clearance  exists at  the  joint face  between  the 
cap  and  saddle. 
Inspect cylinder bores 
2. Mcasure the cylinder  bores for ovality, taper and 
general  wear, using any  suitable  equipment. 
However,  an inside  micrometer  is best  for checking 
ovality  and a cylinder  gauge for taper. 
3. Check  the ovality of each  bore  by taking 
measurement  at the top of the  cylinder just  below 
the  ridge  at two  points  diametrically  opposite. The 
difference  between 
the two figures  is the ovality of 
the  top  of the  bore.  Similar  measurements  should 
be  made  approximately  50 
mm (2.0 in) up from the 
bottom 
of the  bore so that  the overall  ovality may 
be  determined. 
4. 
The taper  of each  cylinder  is determined  by taking 
measurements  at 
the top and bottom of each bore 
at  right  angles  to 
thc gudgeon  pin line.  The 
difference  between  the two  measurements  is 
the 
taper. 
5. To establish  maximum  overall bore  wear,  take 
measurements  at as many points 
possible down the 
bores  at right  angles 
to the  gudgeon  pin line.  The 
largest  recorded  figure  is the  maximum 
wcar and 
should  be compared  with 
the original diameter  of 
the  cylinder  bore. 
Maximum permissible ovality 
0,127 mm (0.005 in). 
Maximum permissible  taper 0,254 mm (0.010  in). 
ST1808M 
8 
Maximum  permissible  overall  wear  0,177 mm 
(0.007 in). 
con t I n ued 
pi 
F