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.