Defender 90 / 110 / 130. Instruction - page 40

LITRE DIESEL ENGINE

2.

To

check t h e camshaft end-float, fit t h e woodruff

key and temporarily

fit

the cam-shaft pulley and

mount

a dial test indicator, as illustrated, so that

the stylus rests

i n

a loaded condition upon

t h e

machined face of the cylinder block.

Zero the dial

and move t h e camshaft back and forward and
the reading. The end-float should

within

to

(0.0025 to

in). I f the end-float is

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

t h e

two bolts.

FIT TAPPETS,

GUIDES AND ROLLERS

1. If the same parts are being refitted ensure that

are returned to

their

original positions. Ensure that

t h e

tappet slides move freely i n the guides.

Insert the tappet guides into the cylinder block and

align

locating screw holes.

3.

Fit the tappet rollcrs ensuring that they are fitted

in

accordance with the marks made during removal.
N e w

rollers,

however, may be fitted either way

round.

4.

fitting the tappet

make sure the

are clear

to

the tappet bearing surface, the

cross drilling and the oil feed

to

the push rod.

5. Insert the tappet

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

used on engines where

screws

originally wired for security.

FIT THE SKEW GEAR

Lubricate and insert the skew gear and coupling

assembly into mesh with

camshaft gear. Align

t h e

location hole

in the bush and

fit

a

new location

screw into

ihc

cylinder block.

I

FIT THE FLYWHEEL

1

Examine the

flywheel

and crankshaft mating faces

and remove any burrs or imperfections that could
prevent

t h e

flywheel locating correctly. Check that

the

dowel is

in position.

continued

79

2.50 LITRE DIESEL

ENGINE

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

(4.5 in).

4.

Turn

t h e

flywheel, and check that the run-out does

not exceed 0.05 to 0.07

(0.002

to

0.003 in).

Should the run-out be excessive, remove the
flywheel. and check again for irregularities o n
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

1456, until

seal is

approximately 0,5

below the inner face

of the

cover.

Front

cover

-

camshaft seal

4.

Drive

in

a new seal, lip side leading until flush

o r

approximately

below the inner surface

using special tool

continued

25

2.50

LITRE DIESEL ENGINE

Fit distributor pump

(D.P.S.)

8

5. Fit

the camshaft front inspection cover complete

with

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.

M

Fit D.P.S. pump pulley, and loosely secure with

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

diameter

bolt,

plain washer and nut.

Fit crankshaft timing pulley

9. Apply Loctite 518

to

the pulley face as illustrated;

d o not allow sealant

to

contact

face.

Lightly

oil the crankshaft and pulley

and

fit

the pulley, with timing dot outwards, and drive into
position using a suitable tube as a drift.

81

2.50

LITRE DIESEL ENGINE

2.

3.

4.

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

E.P. mark

on

t h e

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.

a dial type torque wrench to

to

(21 to

17

ft)

and whilst holding

it

vertically,

the drive peg into

square hole in the

tensioner base plate. Tension the

and tighten

the clamp nuts

to

the correct torque.

Check that the dot

the crankshaft pulley and

cast-on arrow on the rear cover line-up.

Fit the timing belt tensioner assembly and loosely

secure with the two nuts (strap deleted o n later
models).
Turn the

D.P.S. pump pulley clockwise

until

the

dot lines

up exactly with arrows in

t h e

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

over

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

i t

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

correct torque.

CAUTION: The double tensioning procedure is
imperative, otherwise the belt

could fail resulting in

serious engine damage. See CAUTION Page 84 and

11.

Rotate the crankshaft until, the E . P . mark o n the
flywheel and the pointer line-up.

12.

that the dots on the pump and camshaft

pulleys coincide exactly with their respective
arrows.

If

there is any misalignment

procedure

must be repeated.

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