2.5 n/a diesel

[SafeAirOne]

Also, I asked the same thing about the 2.5 timing pins on the series forum. See the third post in this thread for a link to a french site that detils how to make the pins (includes photos).

EDIT: Disregard, I see you bought the expensive ones or already made your own in another post.

[GeoffWillis]

Also, I asked the same thing about the 2.5 timing pins on the series forum. See the third post in this thread for a link to a french site that detils how to make the pins (includes photos).

EDIT: Disregard, I see you bought the expensive ones or already made your own in another post.

Yes they were expensive and now having done the job once I can see how I could have saved some $$$ by drilling out a plug and using an 1/8" drill bit to locate the timing mark, but live and learn! The good news is that as of tonight the injection pump is off!!!! Only took six weeks!! Had a bit of a scare when using a gear puller to get the gear off the injection pump. It was VERY tight and was afraid the puller would break first, but it made an expensive sounding noise and let loose with no damage. The pump is in my hands. I used a few water balloons to seal up the injection lines while the pump is out, kinda looks like tiny condoms! Anyway, I'll be taking the pump to the local diesel shop and see if they can rebuild it. Hopefully the re-assembly will be easier.
More to follow.
Geoff

Injection pump missing...

http://www.flickr.com/photos/31277813@N06/4207769150/

Injection pump in hand!

http://www.flickr.com/photos/31277813@N06/4207009169/

[SafeAirOne]

Funny--I've got my 2.5 apart for a rebuild in my garage right now. I removed the entire timing case with the injector pump still mounted to the timing case, thinking I wouldn't need to fiddle around with it when it came time to reinstall it.

However, upon rethinking the whole thing, I'll probably end up pulling the pump and bringing it to my local diesel shop for a checkout. No point in rebuilding the engine and not having the pump and injectors at least tested.

I'll have to keep in mind the scary sound of the pulley breaking free of the shaft when I get around to removing mine.

Geoff, what caused you to have your pump rebuilt in the first place (sorry, I don't often check the defender forum)?

When you get it done, could you please post how much it cost you and what was done to it? I'd appreciate it! That way, I know how many pennies I'll have to start saving...

PS: Wow-- I just had a look at your pix on Flickr. Nice Rover! I wish ANYTHING on my rover looked as clean as the inside of your timing case. What was the tool you fabricated used for?

[GeoffWillis]

How I got here

I'm having the pump rebuilt as my son filled the rover with gas one day and about a month later (After draining the gas and filling with diesel) the pump just started leaking fuel all over and the engine wouldn't run smoothly (Fuel leaking out, air leaking in...). I've been told the rebuild will cost anywhere from $500 to $900 (That's a lot of pennies...) and I can buy a rebuild unit for about $1100, so it ain't cheap! I'll keep you posted.
The tool I had fabricated was to hold the crankshaft pulley while loosening the crankshaft bolt. Basically the wrench bolts to the pulley (4 bolts) and the large hole in the middle allows a 41 mm socket to fit inside, while the handle rests on the frame rail, and break the darn thing loose. It worked quite well, and I imagine it will really be useful when trying to torque the thing back on to 200 ft/lbs. I'd be happy to loan it out if others need it, it makes short work of the crankshaft bolt.
I'm glad to see other 2.5 NAD fans out there. Seems everybody wants a 200/300 tdi (Hey so would I) but I really enjoy the simplicity of this engine. Whats been your experience with the engine? I've only had the vehicle a year, and I was laid up for most of that time with 4 shoulder surgeries so I haven't had much of a chance to drive it. While not quick, I really think it will be perfect for bashing around the boonies, and the RoverDrive makes it livable on the paved roads, got it up to 110 kph once with a tail wind!
Geoff

[SafeAirOne]

Whats been your experience with the engine?

Well, I got my right-hand-drive 109 6 years ago--It had a dead 6cylinder engine in it. As I was moving to the desert, I figured I'd put a diesel in it for the increased range, reliablility and simplicity, so I got a used ex-MoD 2.5 from Rovers North. I did a little chasis repair and relocted the engine mounts and installed the 2.5, then a week later, drove it 3000 miles from one corner of the country to the other.

Though definitely slow in a 109 (or 110 as you know) this engine has been ultra-reliable. The only engine-related mechanical failure I've experienced in 60,000+ miles is a cracked fuel line from the injector pump to the #1 injector. Even then, I could easily have limped home if I didn't mind squirting diesel all over interstate 8 in extreme southern California.

My 2.5-powered 109 has, for the most part, been my daily driver since I installed the engine. I have since moved back to the northeast, and have found it increasingly hard to start my 2.5 during the cold months, plus it has developed a tapping noise, so I pulled the engine out last week for a rebuild. I have no idea how many miles are on this engine, but it looks like it'll be a simple rebuild--New bearings (they're worn, causing the tap, I believe) and a valve job (intakes not fully seating, causing the hard starts).

I'm the only one that drives the rover, but if I ever accidentally put gasoline in it, (and realize it in time) I'll have to remember not to start it up, but rather have it towed home and drained.

[GeoffWillis]

Got Pictures?

Cool, a 109 with a 2.5 NAD, what year? Got any photos? I always liked the series II in particular. I had a 62 88" with safari and soft top but a 2.25 petrol. Wonderful vehicle, but I'm do love diesels. I can bet that its hard to start up north, it's hard enough here in TX where cold means 35 deg f. Must have been cool to do the engine transplant, I thought about pulling the engine to do the injection pump. I really wanted to "Clean up" the engine compartment, plus I could justify buying an engine hoist and stand...., but the cost of special tools and the pump rebuild put that off. I'm a little concerned about the engine mounts, the rubber on the front looks old, but I really want to get it back on the road as it's finally cool enough here to be tolerable in traffic. I'll definately buy a bucket of lock-tite when putting things back on as that crankshaft pully comming of could be real expensive! I'll be glad I have that wrench when I torque that crankshaft back on.
Geoff

[SafeAirOne]

Cool, a 109 with a 2.5 NAD, what year? Got any photos?

It's a '73 Series III RHD 109. Here's some photos from the Series forum here on the RN board:







And finally...a shot of the 2.5 in its current state, mid-rebuild:

[GeoffWillis]

Beautiful Truck

I think your truck is awesome, are you using the Series III transmission or did you swap it out also? I'm quite pleased with the overall condition of my Rover, the only thing I think will need attention in the near future are the door sills. Its a good solid truck, no rust anywhere on the frame and until the unfortunate gasoline incident it ran like a top. I found a shop to rebuild the pump, they won't even give me an estimate till I drop it off, sounds expensive! It will have to wait till after the new year as we're off to visit family in West Virginia. Happy holidays all.
Geoff

[SafeAirOne]

Yeah, I'm using the original Series III transmission--No problem, since the 2.5 is rated at less horsepower thant the 2.25 Petrol and the 2.6, 6-cylinder that was originally fitted.

Interesting to know that Gasoline (or more likely the alcohol in today's gasoline) would have that sort of an effect on the injector pump.

If I were you, I'd be pleased with the overall condition of your truck too! I don't think I've ever seen an ex-MoD rover look as good as yours! It looks like it just rolled off the assembly line. I'll be candid and admit that I aspire to own a Rover just like you have and, in fact, I covet yours .

[Terrys]

I would be more suspect of the ultra-low sulpher diesel as the culprit in leaky injector pump seals. I began having hard starting issues and loss of prime (air in) issues a few months ago on my '87 300TD merc (Non of my land rovers are oil burners) and found all the instruction (and confidence) from Russell at Dieselgiant.com. Read his comments on his website regarding seal detioration when using ULow S Diesel.
I rebuilt my MB (6 cyl) pump last week for $18.00 in parts, and $33.00 for a special socket. The car starts, and runs like new now, and no loss-of-prime issues.

[SafeAirOne]

That's a tough call...I've been driving for the last 6 years on whatever is spewing out of the local diesel pumps in California and New Hampshire, presumably ULS diesel in both places. I haven't experienced the almost instantaneious failure that Geoff experienced after a single instance of gasoline contamination.

I wish they'd put a biodiesel pump within convenient driving distance of my house. Adding some biodiesel does wonders for the lubricating properties (or lack thereof) of ULS diesel.

[GeoffWillis]

Yeah, I'm using the original Series III transmission--No problem, since the 2.5 is rated at less horsepower thant the 2.25 Petrol and the 2.6, 6-cylinder that was originally fitted.

Interesting to know that Gasoline (or more likely the alcohol in today's gasoline) would have that sort of an effect on the injector pump.

If I were you, I'd be pleased with the overall condition of your truck too! I don't think I've ever seen an ex-MoD rover look as good as yours! It looks like it just rolled off the assembly line. I'll be candid and admit that I aspire to own a Rover just like you have and, in fact, I covet yours .

Thanks for the kind words, I do love my Rover, it was quite a find and until the gasoline screw up it needed absolutely nothing. I found a shop to give me an estimate on rebuilding the pump, I hope to be able to swing by Friday and let them check it out. Maybe I'll get real lucky and the pump will be fine and I'll find it was a leaky fuel line (Don't think this is the case but one can only hope). I certainly know much more about my vehicle than I did this summer! I'd owned a few diesels in the past (VW Jetta's), but never worked on them, so it's been quite fun to get my hands dirty on this. This forum has been a tremendous resource for me, thanks to all who helped, and I'll let you know what I find out and how it goes back together.

[junkyddog11]

I'd be surprised if the gasoline caused the pump failure and would suspect it to be coincidental.
I run about 10% gasoline in B10 this time of year to prevent gelling and up in the really cold parts of the world they will run an even higher blend. I've actually been burning up 10 gallons of surplus 2stroke mix from this summers motorcycling in all my diesel trucks 2.5n/a 300tdi (2) and a 7.3 powerstroke. Never had any issues with filters freezing etc.

sorry to chip in then disapear but I'm off (tonight) to the tropics for a few weeks. Good luck with all the rebuilds guys.

[Maryland 110]

there is a fellow named Dave Lucas selling a 70k original mile 2.5 natural diesel on the D90 Source board. His engine may be cheaper than an injection pump rebuild

[Jim-ME]

I've been using Opti-Lube XPD year round in my 2.5 NAD at 1/2 oz/g. My pump has also started to leak but the engine still runs great. I've found a brand new OEM pump in England for less than $600 which is about half of a Lucas recon from the same place plus I won't have a core charge to deal with. RDS has a brand new pump for 1275.00 which is not too bad all said and done.
Jim