Land Rover 90 110 Workshop Rover Manual
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.7 . .: , ...._ ,, . : . ... .:: .. . . _.. . .- .. .... .. 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