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Land Rover 90 110 Workshop Rover Manual

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    2.5 LITRE PETROL ENGINE 1 
    RENEW EXHAUST  VALVE SEAT INSERTS 
    1. 
    2. 
    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. 
    Remove  any burrs  and swarf  from the pocket. 
    Failure 
    to do  this  could  cause the new  insert  to 
    crack  when  being  fitted. 
    NOTE:  Since no special  tool is available  for fitting  a 
    new  insert,  it is  recommended  that this work 
    is 
    entrusted to a cylinder  head overhaul  specialist. 
    FITTING 
    PISTONS AND  CONNECTING  RODS  Fit 
    rear  main 
    oil seal and flywheel  housing 
    2. 
    3. 
    4. 
    Check that the crankshaft  oil seal  journal is 
    undamaged  and clean.  Make sure the scal  housing 
    is  clean  and dry and  free  from  burrs. 
    Do not touch 
    the  seal  lip and 
    ensurc that thc outside  diameter  is 
    clean  and dry. 
    The 
    P.T.F.E seal Part No ETC 5369 which  should 
    be  used  is supplied  with a former  to maintain  the 
    correct  shape and 
    must not be removed  until the 
    seal 
    is to be  fitted. 
    Using  special 
    seal rcplacer 18G 134-1 1 and with  the 
    lip  side  leading  drive
    -in the  seal  as far as the  tool 
    allows. 
    If the tool is  not  available fit the seal to the 
    bottom of the housing  to ensure squarcness. 
    The  delection of the oil spray  hole in the connecting  rod 
    precludes  the necessity 
    of fitting  this towards  the 
    camshaft  side of the  engine.  See page 
    18 instruction 5. 
    REMOVE  AND REFIT FLYWHEEL HOUSING  AND 
    REAR 
    MAlN OIL  SEAL 
    1. Remove  the eight  bolts securing the flywheel 
    housing  to the  cylinder  block and remove  the 
    housing  and rcar  main  bcaring  oil seal. 
    4 ST1 842M 
    ST1 699M  
    						
    							2.5 LITRE PETROL ENGINE 
    5. Apply  a bead of Hylogrip 2000 sealant to the  rear 
    face 
    of the flywheel  housing  to the dimensions and 
    configuration  as illustrated  below. The illustration 
    has been  produced  full  size 
    so that a template may 
    be  made  to facilitate  the  application of the sealant. 
    The 
    bead should  be 53 mm wide and 0,25 mm 
    thick. 
    6. Examine  the seal  guide  number 18G 1344 and 
    repair  any damage  that could destroy  the seal lip. 
    7. Lubricate  the  outside  diameter  of the  seal  guide 
    and  the scal  journal  with concentrated  Oildag 
    in a 
    25% solution  with clean engine  oil. 
    8. Place the seal  guide  on  the  crankshaft  flange  and, 
    using  the two  dowels  protruding  from the cylinder 
    block  rear face 
    as a guide  to ensure  initial 
    squareness, 
    fit the  flywheel  housing and remove 
    the  seal  guide.  Secure 
    the flywheel  housing  evenly 
    tightening  the retaining bolts. 
    50  
    						
    							2.5 LITRE PETROL ENGINE I 12 1 
    FITTING SUMP 
    1. Clean the sump and cylinder block mating  faces. 
    2. Apply  a bead of RTV HYLOSILL 102  black 
    approximately  7 
    mm wide to the cylinder  block or 
    sump mating face. 
    3. 
    Fit the  sump  within  30 minutes  of applying  sealant 
    and  secure  with the bolts  and  tighten  evenly 
    to the 
    correct  torque. 
    NOTE:  RTV Liquid  Sealant is available  under part 
    number  RTC 
    3254 from Land  Rover  Parts and 
    Equipment  Ltd. 
    SKEW GEAR 
    I. To renew the bush, hold thc gear firmly in a vice 
    without  damaging  the teeth. 
    If possibie  insert a 
    scrap  drive shaft 
    in the gear  internal  splines  and 
    grip  the shaft. 
    2. Turn  the locknut clockwisc (left-hand thread) to 
    remove  and withdraw  the thrust washer and bush. 
    3. Fit a new bush removing  any burrs before  hand  and 
    ensure  that the location 
    hole is towards the lower 
    end 
    of the  gear. 
    4. Fit a new  thrust  washer, if the  original is worn or 
    scored. Apply Loctite 601 to the thread  and fit the 
    locknut  turning anti
    -clockwise  and  tighten to 27 - 
    34 Nm (20 - 25 Ibf.tt). 
    1 
    I 
    -4 
    5. The gear should revolvc freely in the bush with  a 
    clearance  of 0,051 
    to 0,203 mm (0,001 to 0,007 in) 
    between thrust washer  and bush. 
    51  
    						
    							1121 2.5 LITRE DIESEL ENGINE 
    ST1922M 
    2.5 LITRE DIESEL  ENGINE 
    p7 *.: ..... ”.’ ,,” _... .. 
    52  
    						
    							2.50 LITRE DIESEL ENGINE 
    DISMANTLE AND OVERHAUL 
    Special  tools: 
    274400 
    - Drift  inlet valve  guides 
    274401 
    -Drift  exhaust  valve guides 
    600959 
    -Drift exhaust  valve guide 
    601508 
    - Drift  inlet valve  guide 
    MS621 -Seal cutter 
    530625 
    - Insert  replacer 
    R0605022 - Clutch  centralising tool 
    270304 - Cork-seal  guide 
    18G 1344 -Seal guide - rear main  bearing 
    18G 134-11 -Seal replacer  rear main  oil seal 
    530102A - Crankshaft  nut spanner 
    18G 1457/1- Dist.  pump  remover 
    18G 
    1464/2/6 - Crankshaft  pulley remover 
    18G 1456 -Crankshaft  oil seal  replacer 
    18G  1482 
    -Camshaft  oil seal  replacer 
    18G  1458 
    - Dist.  pump  timing  tool 
    MS47 
    - Press 
    18G705-1A - Collets 
    LST107 - Flywheel  timing pin 
    REMOVE 
    ANCILLIARY EQUIPMENT 
    Remove the engine  from the vehicle.  Clean the exterior 
    and 
    in the  interests  of safety  and  efficient  working, 
    secure  the engine  to 
    a recognised engine  stand. 
    Before  commencing,  make 
    a careful note of the 
    position  of brackets,  clips,  harnesses,  pipes,  hoses, 
    filters  and  other miscellaneous  items to  facilitate  re
    - 
    assembly . 
    Removal  of the  following  components  is a reversal of 
    the  fitting  procedure  described in engine assembly. 
    1. Remove the alternator  and mounting  brackets. 
    2.  Remove 
    the power steering pump and bracket. 
    3. 
    Rcmove the  fan and  pulley. 
    4.  Remove  the inlet  and exhaust  manifolds. 
    5. Disconnect  and remove  the  fuel supply pipes  from 
    the  injectors  and D.P.S.  pump and  cover the ports. 
    6. Disconnect  coolant by-pass  hose  from  the water 
    pump,  release 
    the seven bolts and remove the 
    water  pump. 
    7. Drain  the sump  and remove the  dipstick. 
    8. Remove the starter motor. 
    9. Restrain  the flywheel,  remove  the  crankshaft 
    pulley  bolt and withdraw 
    the pulley. 
    10. Evenly slacken  and remove  the  clutch  retaining 
    bolts  and  withdraw 
    the clutch  assembly  and centre 
    plate. 
    11. Remove  the two  bolts  and remove  the oil filter 
    assembly  complete from  the cylinder  block. 
    Unscrew 
    the filter element and discard. 
    12. Remove  the six bolts  and  withdraw  the  rear side 
    plate  complete  with fuel pump. 
    REMOVE AND OVERHAUL  CYLINDER HEAD 
    Remove  the cylinder  head 
    1. Remove injectors  complete with  spill rail. 
    2. Disconnect  the heater  plug electrical  connections. 
    3. Remove the engine  lifting brackets. 
    4.  Disconnect  oil gallery  pipe at rear  of engine. 
    5. Remove  three  bolts and lift-off the  thermostat 
    housing, elbow  and thermostat. 
    6. Remove  the  rocker  cover  and  slacken the tappet 
    screw  lock nuts.  Turn  the  adjusting screws to 
    release  them from 
    the push rods. 
    7. 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, see instruction  25, page  34 2.25  litre 
    Petrol and Diesel  engine. 
    8. Withdraw the push  rods and retain  them in 
    numbered sequence. 
    9. Evenly slacken  the remaining  cylinder  head 
    retaining bolts and  lift
    -off the cylinder head. 
    10. Remove the engine  lifting eyes. 
    11. Using valve spring  compressor 276102 or a suitable 
    alternative, remove  the valve 
    and spring assemblies 
    keeping  them identified  with their  original 
    locations  for possible  refitting. 
    12. Discard the valve  spring  and valve  guide  oil seals. 
    Remove  carbon deposits  from the valves  and 
    combustion  chambers and degrease 
    all parts  ready 
    for  examination. 
    Examine  components 
    13. Examine  the  cylinder head  for  cracks and 
    14.  Burnt,  pitted  and  pocketed seats must be repaired. 
    15. In addition,  worn or damaged  valve seats should  be 
    distortion. 
    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  remove  either the 
    injector shrouds 
    or the hot  plugs. 
    Small surface  cracks in the hot  plug,  extending  from the 
    opening  to approximately 
    8,O mm (0.312  in) in length 
    can  be ignored.  However, 
    if any severe  cracks appear 
    on the face of the  hot plugs 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  should be scrapped. 
    53  
    						
    							121 2.50 LITRE DIESEL ENGINE 
    16. To remove a hot  plug  support  the cylinder  head, 
    face  downwards 
    on two pieces of timber  and 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 scrapped. 
    STl422M 
    ST1428PJ A- Shroud B - Hot Plug 
    17. If the injector  shroud is damaged  using a 13 mm 
    (1.05 in) t~all bearing and drift,  drift the shroud out 
    towards  the injector  bore. 
    Fitting hot plugs 
    20. Fit the hot  plugs  by tapping  with a hide-faced 
    mallet,  and locate  with a new 
    roll pin.  If the  hot 
    plugs are  loose in the cylinder  head they may be 
    retained  with 
    a little grease. 
    21. When  fitted,  the hot plugs  must be checked  with a 
    dial test indicator to ensure  that they  do not 
    protrude  above the level 
    of the cylinder  head face 
    more  than 
    0,76 mm (0.003 in) and are not recessed 
    below  the level  of the  cylinder  head face more  than 
    0.025 
    mm (0.001  in). 
    22 
    17 
    , /- n ST1 429M 
    Fitting shrouds 
    18. Thoroughly  clean out the combustion  chamber. 
    Thc hole in the side of the injector  shroud is for 
    manufacturing  purposes only bur at the same  time 
    can  be 
    used as a guide  when rcfitting the shroud. 
    19. Turn  the cylinder  head lace down.  Smear  a little oil 
    on  the  shroud  and insert  into the cylinder  head with 
    the hole  pointing  towards the centre of the cylinder 
    hcad, and  drift into position.  22. 
    Check  the valve  guides 
    lor wcar 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. 
    23.  Inspect  the valves  and discard  any that  arc burnt, 
    bent 
    or distorted.  Check the stems for wear  by 
    the  valve.  Valve faces that are pitted 
    or ridged  but 
    otherwise  serviceable  may be refaced. 
    24. Renew  push rods that are bent or have worn or 
    scored  ball or socket ends. 
    inserting a new guide. !f *Area: is exces>;i.,re, discard 
    fJ .. ..._ .. .  .. ,-. . 
    f-:- . , 
    54  
    						
    							2.50 LITRE DIESEL ENGINE 
    Whilst  this is rarely neccssary the  procedure  is 
    nevertheless  as follows: 
    25. Using  an 8 mni taper tap, cut a thread 30 mm 
    (1,2 in) deep in the  combustion  face end of the 
    tube 
    to be removed. 
    26.  Screw  an appropriate  bolt into  the  tube  and  press 
    out  the 
    tube as illustrated. 
    27.  Smear  both ends 
    of a new  tube with silicone  rubber 
    sealant 
    ancl press it into  the cylinder  head. 
    12 
    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. 
    31. Lubricate ncw guides with engine  oil and  using 
    special  drift 600959  for the  exhaust  and 601508  for 
    the inlet valve  guides or suitable alternatives,  drive 
    in the new guides  until the shoulder  is flush with 
    the casting. 
    ST1444M Reface  cylinder  head valve seats 
    32. Damaged or worn  valve  seats can be refaced 
    provided  they are not  abnormally  wide due to 
    repeated  refacing operations.  See instruction 
    43. 
    Renew  valve guides 
    28. Support the cylinder  head, combustion  chamber 
    uppermost  on  pieces 
    of timber of sufficient I - - thickness  to allow  clearance  for the valve guides  to 
    be driven out. - 
    274401  for exhaust  guides or suitable  alternatives 
    29. Using  special  drift  274400 for inlet guides  and 
    drive  out the old guides  from the combustion  face A 
    I, I 
    ,. ”. ’. ii. , :,: e. ,.. ‘ ., - 
    side. 
    I 
    A. Correctly seated valve 
    B. Undesirable condition 
    C. Method of rectification 
    B 
    C 
    55  
    						
    							1121 2.50 LITRE DIESEL ENGINE 
    33. 
    34. 
    35. 
    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. 
    Select  the  correct  expandable collet for the  valvc 
    guide concerned  i.e. 
    8 mm for inlet guides  and 8,5 
    mm for exhaust. 
    Loosely  assemble  the collet,  expander  and  nuts. 
    Ensure  that the  chamfered  end 
    of the expander  is 
    towards  the collet. 
    ST1440 M 
    36. Insert thc assembled pilot  into the valve  guide lrom 
    the combustion  face side of the cylinder  head until 
    the shoulder contacts the  valve guide  and the whole 
    of the collet is inside  the valve  guide. 
    37. Expand  the  collet in the guide  by turning  the 
    tommy bar  clockwise  whilst holding  the  knurled 
    nut. 
    36 I 
    38. Use  cutter MS 621 and  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 of thc blade 
    contacts the area  of material 
    to be  cut. Use thc key 
    provided 
    in the  hand set MS 76. 
    ST1439M 
    39. Fit the wrcnch to  the culter head  and  turn 
    clockwise  using  only  very  light pressure.  Continue 
    cutting 
    to approximatcly thc centre of the  existing 
    seat. 
    40. 
    To check  the  effectiveness of the  cutting opcration 
    use  engineers’  blue 
    or a feelcr gauge maclc from 
    ceilophane. 
    41.  Smear a 
    mall quantity  of cngineers’ blue round thc 
    valve  seat and revolve 11 properly  ground  valve 
    against  the seat. 
    A continuous  fine line should 
    appear 
    round the  valve. If there  is a gap of not 
    more thar !2 mni it can be corrected  by lapping. 
    56  
    						
    							2.50 LITRE DIESEL ENGINE 1121 
    , : ... -4 :: 42. Alternatively,  insert a strip of cellophane  between .I . .,..., ..
    						
    							1121 2.50 LITRE DIESEL ENGINE 
    52. Continue  the operation until a continuous  matt 
    grey  band  round the valve  face is obtained. 
    To 
    check  that the lapping  operation  is successful,  wipe 
    off  the  valve  paste  from the valvc  and seat  and 
    make a scries of pencil  lines across the  valvc face. 
    Insert  the valve 
    into the  guide  and  while  pressing 
    the  valve  onto 
    the seat rcvolve the valve  a quarter 
    turn  a few  times. 
    If all the  pencil lincs are  cut 
    through  no further  lapping  is required. 
    53. Wash  all traces  of grinding  paste  from the valves 
    and  cylinder  head seats. 
    Assembly  valves to cylinder  head 
    54. 
    55. 
    . 
    56. 
    Insert the inlet  valves into the guides and fit new  oil 
    seals 
    ~ith the  plain  exterior.  Ensure  that  the seal 
    locates 
    in the  groove in the  valve  guide. 
    Insert  the exhaust  valves and 
    fit the oil seals  with 
    the 
    ste?ped exterior.  They are largcr than thc inlet 
    valve 
    scals. 
    Fit the doublc valve  spring and  cup to each valvc in 
    turn arid  using  valve spring  compressor,  276102 or 
    a suitable  alternative,  secure the assembly with the 
    multi-groove butting cotters. 
    56 A 
    54 
    55 
    ST1430M 
    OVERHAIJL ROCKER SHAFT ASSEMBLY 
    Dismantle  and inspection 
    57. Remo*:e the locating  screw and washer  from thc 
    number  two rocker  bracket  and  withdraw all the 
    componcnts from the  rocker  shalt. 
    58. Remove the locknuts  and adjustment screw5 from 
    the rockers. 
    ST1431M 
    59. Examine  the rocker  shaft for wear and discard if 
    the bearing  surfacc  is worn  more  than 0,025 mm 
    (0.001  in). 
    60.  Inspect 
    the rockers  and discard if the pads  arc 
    worn.  It is not  permissible 
    to grind  pads in an 
    attempt 
    to reclaim  the rockers. 
    61. Renew  bushes if the  clearance  betwecn  shaft  and 
    bush  is 
    in excess  of 0,101  to 0,127 mm (0.004  to 
    0.005 in). 
    62.  Press 
    in replacements  ensuring that thc prc-drilled 
    oil holes coincide  with the holes in the rockers. 
    The  following  cross  section 
    of a  rocker shows thc 
    oil drillings. 
    -e?. .. .ic- -4 ST1433M 
    63. Using  a A4 reamcr 133 nim + 0,2 mm (0.530 in + 
    0.001  in)  finish the bushes and  clear swarf from the 
    oil holes. 
    64.  Examine  the ball
    -end of the adjusting  screws and 
    discard  any that  are worn.  Regrinding  is not 
    permissable.  Check the 
    thrcads for damage  and 
    that  the oil  relief  drilling is clear. 
    Assemble  rocker shaft assembly 
    65.  Check  that thc oil-ways in the rocker shaft  are clcar 
    and 
    fit number two  rocker  shaft bracket to the shaft ,. ..A ,,r,:, ..,:+I. cl., I,,,+:,, I.--n.., ,>-A ..,,-,.h-- a11u 1GlUlll Wllll LIIL IuLnrlllt; 3ClGW LlllU WU311c.I. 
    58  
    						
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