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Defender 90 / 110 / 130. Manual - part 20

GENERAL

vapour

is highly flammable and in confined spaces is also very explosive and toxic.

When

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

potentially very dangerous.

Always have a fire extinguisher containing FOAM

GAS, o r POWDER close at hand

handling

or draining

fuel, or when dismantling

systems and in areas where fuel containers arc stored.

Always disconnect the vehicle battery B E F O R E carrying out dismantling

or draining work on a fuel system.

Whenever

is being handled, drained or stored, o r 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.

N O ONE S H O U L D B E PERMITTED

REPAIR COMPONENTS ASSOCIATED WITH PETROL/

GASOLINE WITHOUT FIRST HAVING H A D SPECIALIST TRAINING.

FUEL TANK DRAINING

WARNING:

MUST NOT

BE EXTRACTED OR DRAINED FROM ANY VEHICLE

WHILST

IS STANDING OVER A PIT.

Draining

or extracting

from vehicle fuel tank must

carried out in a well ventilated area.

The receptacle used to contain the

must be more than adequate for the full amount

to be

extracted or drained. The receptacle should be clearly marked with its contents, and

in a safe

area

which meets the requirements of local authority regulations.
WHEN

HAS BEEN EXTRACTED O R DRAINED FROM A FUEL TANK

THE

PRECAUTIONS GOVERNING NAKED LIGHTS A N D JGNITION SOURCES S H O U L D BE

- -

FUEL TANK REMOVAL

On vehicles where

the fuel line is sccurcd to the fuel tank outlet by a spring steel clip,

is recommended

that

such

clips are released before the fuel line is disconnected or the fuel tank unit

is removed.

This

will

avoid

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

VAPOUR warning label attached to them

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

t h e

tank SAFE, by

using one of the following methods:

STEAMING: With

filler cap and tank unit removed, empty the tank. Steam

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
BOILING: With the filler cap and tank unit removed, empty the tank.

the tank completely

in boiling

water containing an effective alkaline degreasing agent o r a detergent, with

t h e water filling and

also

surrounding the tank for at least two hours.
After steaming o r boiling a signed and dated label to this effect should

attached to the tank.

SPECIFICATION

Purchasers are advised that the specification details set out

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 o r Dealer.

The Manufacturers reserve the right to vary their specifications with

or without notice, and at such times and

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

this Manual, neither the

Manufacturer

nor the Distributor or Dealer, by whom this Manual is supplied, shall

i n

any

be held

COPY RIGHT

Land Rover Limited

1984

of this publication may be produced, stored

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.

...

Special

Service

The use of approved special service tools is important. They are essential

if service

operations are t o 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

n o

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 o r standard equipment. The user

is therefore assured that the

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
Churchill. Overseas orders should be placed with the local

L. Churchill distributor,

where o n e exists. Countries where there is

no distributor may order direct from

V. L .

Churchill Limited,

PO Box 3 Daventry, Northants, England

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

o r from

Land Rover Ltd., under part number

from the following address, Land Rover Publication

Service,

P.O. Box 534, Erdington, Birmingham B24 OQS.

2.25

LITRE

PETROL

AND DIESEL ENGINE

DISMANTLE ANDOVERHAUL

Special
Chain wheel extractor

507231

Tappet guide remover

*Camshaft bearing remover

274388

adaptor

531760

guide plug

274394

”

reamer

274389

Cork-seal guide

270304

Seal guide rear main bearing

1344

Seal replacer

rear main oil seal

134

Diesel engine timing gauge

Clutch centralising tool

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

and in the interests

of safety and efficient working,

Petrol engine

1. Disconnect the spark

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

will

facilitate this operation.

Diesel engine

the fuel pipes from the injectors.

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

only). At the same time remove

the two joint washers and the baffle plate with
timing pointer attached.

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

Remove the six bolts and withdraw

the rear side

cover complete with fuel pump.

Remove the alternator and drive belt.

10. Remove the fan and

pulley.

12.
13.

14.

Remove the seven

and remove the water

Drain

the sump and remove t h e dipstick.

Remove the starter motor.
Restrain the flywheel, remove the crankshaft

pulley nut and withdraw the pulley. (Bolt

later

engines).
Evenly slacken and remove t h e 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

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

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.

Overhaul the oil pump

6. Examine the gears for wear, scores and pits. If the

gears appear serviceable check for end-float as

follows:

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:

Idler gear

(0.003 to

0.006

in).

9. Driven gear

(0.002 t o 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

spindle by drilling-out

the peened over end

of t h e spindle

so that the

spindle can be withdrawn from the pump body.

ensure squareness when fitting t h e new spindle,

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

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
(0.125 in) and ream the bush

(0.500

in)

diameter.

continued

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