Land Rover part 2 engine Workshop Manual

11-01
(20) Air cleaner—all Models
Attention to the air cleaner is extremely
important, especially under dusty condi-
tions, as engine wear generally will be
seriously affected if the vehicle is run with
an excessive amount of sludge in the
cleaner oil bath.
In cases where the vehicle is operated
under dusty road or field conditions, atten-
tion must be more frequent, even to the
extent of a daily oil change; under ex-
tremely bad conditions, cleaning twice
daily may be called for.
Proceed as follows:
1 Slacken wing nut and release the
clamping strap securing the complete
air cleaner.
2 Disconnect the outlet elbow from the
carburetter intake pipe and remove the
cleaner from the vehicle.
3 Remove the oil bowl from the bottom
of the cleaner by releasing the three
securing clips.
4 Clean all dirty oil and sludge from the
bowl and refill with fresh engine oil to
the level indicated by a ring formed in
the pressing; the capacity is approxi-
mately 0,85 litre (1.5 Imperial pints).
5 Clean the filter in the cleaner body by
swilling the complete body in petrol or
paraffin and shake off the surplus.
6 Replace the bowl and refit the com-
plete unit in the vehicle.
21) Flywheel housing drain plug
The flywheel housing can be com-
pletely sealed to exclude mud and
water under severe wading conditions,
by means of a plug fitted in the
bottom of the housing.
2 The plug is screwed into a hole
adjacent to the drain hole and should
only be fitted when the vehicle is
expected to do wading or very muddy
work.
3 When the plug is in use it must be
removed periodically and all oil
allowed to drain off before the plug is
replaced.
RAGGA ——
-—— A, AR RY RTA TE
(22) Check injectors for burst pressure, and
spray
NOTE: Absolute cleanliness is essential
when handling any component of the fuel
injection system.
The use of a test pump is essential
when servicing injectors; it is recom-
mended therefore, that servicing of in-
jectors is carried out by a Rover
Distributor or Dealer or CAV Agent.
WARNING: Great care should be
taken to prevent the hands getting into
contact with the spray, as the working
pressure will cause the fuel to
penetrate the skin with ease.
IGNITION
(23) & (24) Sparking plugs—Petrol models
The sparking plugs are fitted with
plastic covers.
To gain access to the plugs for cleaning
and gap-setting, pull up the plug covers
without detaching them from the high
tension leads.
3 Check or replace the sparking plugs as
applicable. If the plugs are in good
condition, they should be cleaned,
preferably using an approved spark
plug cleaning machine.
4 Test the plugs in accordance with the
plug cleaning machine manufacturer’s
recommendations.
5 If satisfactory set the electrode gap to
0,75 to 0,80 mm (0.029 to 0.032 in.)
and replace.
It is important that only the recommended
sparking plugs are used for replacements:
4-cylinder models 8,0:1, use Cham-
pion UN12Y
4-cylinder models 7,0: 1 (optional), use
Champion N8
6-cylinder models, use Champion №5
La
21-01
(25) Distributor contact points
Check and adjust the contact points clear-
ance as follows. (4-cylinder distributor
illustrated)
t2
Remove the distributor cap and rotor
arm; then turn the engine, using the
starting handle, until the contacts are
fuily open.
The clearance should be 0,35 to 0,40
mm (0.014 to 0.016 in.) with the
feeler gauge a sliding fit between the
contacts.
If necessary, slacken the screw which
secures the adjustable contact.
Adjust by the adjuster slot until the
clearance is correct; re-tighten the
retaining screw.
Replace the rotor arm and distributor
cap.
{26) Distributor maintenance
Lubricate as follows:
]
2
3
Remove the distributor cap and rotor
arm.
Lightly smear the cam with clean
engine oil.
Add a few drops of thin machine oil to
lubricate the cam bearing and distri-
butor shaft.
Add a few drops of thin machine oil
through the side of the contact
breaker base plate, to lubricate the
automatic timing control.
Removing the plastic clip (4-cylinder
models) or the nut (6-cylinder models)
on the terminal block and lift off the
spring and moving contact, also
remove adjustable contact secured
with a screw. Ensure that the contacts
are free from grease or oil; if they are
burned or blackened, clean with a fine
carborundum stone and wipe with a
petrol-moistened cloth.
Add a smear of grease to contact pivot
before replacing the contacts. Then
adjust as detailed in previous opera-
tion.
Wipe the inside and outside of the cap
with a soft dry cloth; ensure that the
small carbon brush works freely in its
holder.
Replace rotor arm and distributor cap.
High tension leads
1
bo
A careful examination should be
carried out on all high tension leads
including the coil to distributor lead.
Look for any signs of corrosion,
insulation cracking or deterioration,
particulariy of the end contacts.
Renew any faulty leads.
(27) Ignition timing— Petrol models
]
Should the distributor have been dis-
turbed, the ignition timing must be reset as
follows:
Set the contact breaker point gap to 0,35
to 0,40 mm (0.014 to 0.016 in.) with the
points fully open.
3
244 litre Petrol models
The timing pointer represents 6°
B.T.D.C., 3% B.T.D.C. and T.D.C.
respectively.
Rotate the engine until the mark on the
crankshaft pulley is in line with the pointer
as follows:
Note that three types of timing marks are
in use, either a multiple pointer with a
single mark on the pulley or single pointer
with a scale of marks on the pulley.
The multiple pointers represent 6°
B.T.D.C., 3° B.T.D.C., T.D.C. and 6%
A.T.D.C. respectively.
The scale on the pulley represents 6°
B.T.D.C., 3% B.T.D.C., T.D.C., 3%
A.T.D.C. and 6% A.T.D.C.
See page 86— 19 for an alternative timing
mark and pointer.
8.0: 1 compression ratio
T.D.C. when using 90 octane fuel
3° A.T.D.C.* when using 85 octane fuel
7.0: 1 compression ratio (optional)
3° B.T.D.C. when using 83 octane fuel
T.D.C. when using 75 octane fuel
* Estimate this position on pulley on 3-
point pointer.
2.6 litre 6-cylinder models
5
Rotate the engine until the appropriate
mark on the crankshaft pulley is in line
with the pointer as follows:
7.8: 1 compression ratio
2° A.T.D.C. when using 90 octane fuel
7.0: 1 compression ratio (optional)
2° B.T.D.C. when using 83 octane fuel
T.D.C. when using 80 octane fuel
2° A. T.D.C. when using 78 octane fuel
The distributor rotor will now cor-
respond with No. 1 cylinder high
tension lead terminal.
Slacken the pinch bolt at the base of
the distributor head, rotate the distri-
butor bodily in the opposite direction
to the arrow on the side of the
distributor (4 cylinder models) or on
the rotor arm (6-cylinder models) until
the contact breaker points are just
opening with the fibre cam follower
on the leading side of the cam; re-
tighten the pinch bolt.
TRA5SA
£1—01
TRANSMISSION
(28) Check for oil leaks; rectify as necessary
(29) Clutch fluid reservoir
1 Check fluid level in reservoir by
removing cap.
2 Top up if necessary to bottom of filler
neck.
Use Castrol Girling Brake and Clutch Fluid
‘Crimson’ (Specification J. 1703).
If significant topping-up is required, check
for leaks at master cylinder, slave cylinder
and connecting pipe.
(30) Check tightness of all propeller shaft
coupling bolts
(31) Propeller shaft lubrication
1 Apply one of the recommended
greases at the lubrication nipple on the
sliding portion of the rear propeller
shaft.
2 To the lubrication nipples fitted to the
universal joints of both front and rear
shafts.
Front propeller shaft sliding portion
Lubricate the sliding spline on the front
propeller shaft, with one of the recom-
mended greases, as follows:
1 Disconnect one end of the propeller
shaft.
2 Remove plug in sliding spline and fit a
suitable grease nipple.
3 Important. Compress propeller shaft at
sliding joint to avoid overfilling, then
apply grease.
4 Replace grease nipple with plug and
reconnect propelier shaft.
/
©
(32) Main gearbox oil level
Check oil level daily or weekly when
operating under severe wading conditions.
1 The main gearbox and clutch with-
drawal mechanism are lubricated as
one unit. Check oil level and top up if
necessary to the bottom of the filler-
level plug hole.
2 If significant topping up is required
check for oil leaks at drain and filler
plugs, all joint faces and through drain
hole in bell housing.
(33) Transfer box oil level
Check oil level daily or weekly when
operating under severe wading conditions.
1 The transfer box and front wheel drive
housing are lubricated as one unit.
2 Check oil level and top up if necessary
to the bottom of the filler-level plug
hole. The filler-level plug is in the rear
face of the transfer box.
3 If significant topping up is required
check for oil leaks at drain and filler
plugs, all joint faces and through drain
hole in bell housing.
(34) Front differential oil level
1 Check oil level and top up if necessary
to the bottom of the filler plug hole
located at the front of the axle casing.
A second plug fitted at the rear of the
axle casing can be disregarded.
2 If significant topping up is required
check for oil leaks at plugs, joint faces
and oil seals adjacent to axle shaft
flanges and propeller shaft driving
flange.
(35) Rear differential oil level
1 Check oil level and top up if necessary
to the bottom of the filler plug hole.
2 If significant topping up is required
check for oil leaks at plugs, joint faces
and oil seals adjacent to axle flanges
and propeller shaft driving flange.
(36) Check hydraulic clutch pipes and hoses
visually for cracks, leaks and chafing
(37) Axle case breathers
1 Clean exterior of breathers.
2 Unscrew breathers from their tapered
threads in axle and wash in petrol.
3 Shake breather to ensure ball valve is free.
4 Lubricate balls with engine oil.
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STEERING AND SUSPENSION
(38) Steering ball joints
1 Check rubber boots daily when operat-
ing under arduous conditions.
2 The steering joints have been designed
to retain the initial filling of grease for
the normal life of the ball joints;
however, this applies only if the
rubber boot remains in the correct
position. Check to ensure that the
rubber boots have not become dis-
lodged or damaged, and check for
wear in the joint.
3 This can be done by moving the ball
joint vigorously up and down. Should
there be any appreciable free move-
ment the complete joint must be
replaced.
(39) Suspension fixings—Check security of all
suspension fixings, rectify as necessary
(40) Wheel alignment
Special equipment is required to check
wheel alignment and this work should be
carried out by a Rover Distributor or
Dealer.
For those owners who have suitable equip-
ment, the alignment should be 1,2 to 2,4
mm (0.046 to 0.093 in.) toe-in.
To adjust |
1 Set the vehicle on level ground with
the road wheels in the straight ahead
position and push it forward a short
distance.
2 Slacken the clamps securing the ball
joints at each end of the track rod.
3 Turn the track rod to decrease or
increase its effective length as neces-
sary until the toe-in is correct.
4 Push the vehicle rearwards turning the
steering wheel from side to side to
settle the ball joints, then with the
road wheels in the straight ahead
position, push the vehicle forward a
short distance.
5 Recheck the toe-in, if necessary carry
out further adjustment.
IRA 109A
6
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When the toe-in is correct, lightly tap
the track rod ball joints towards the
rear of the vehicle to the maximum of
their travel. This ensures full un-
restricted movement of the track rod.
Then secure the ball joint clamps.
(41) Check steering for oil leaks—investigate
and rectify as necessary
(42) Check shock absorbers for leaks and
rectify as necessary
(43) Steering relay unit
Check oil level and top-up if necessary
until the oil is visible at the base of the
filler and breather holes. If significant
topping-up is required, check joints for
leakage and fit new joint washers as neces-
sary. To check oil level and top up,
proceed as follows:
1 Remove the fixings and withdraw
radiator grille.
2 Remove two of the bolts securing the
relay top cover.
3 Using one of the holes as an oil filler
(the other acting as a breather hole)
fill the relay unit with the correct
grade of lubricating oil to the bottom
of the filler hole.
4 Whilst filling, it is probable that oil
will eject through the breather hole. If
this occurs do not assume that the
relay unit is full. Time must be given
to allow the oil to find its way to the
main chamber. Wait a few moments
until the breather hole is clear of oil,
then continue filling.
5 As the unit fills up, air is forced out
usually in the form of an oil bubble,
escaping through the breather hole,
again giving the impression that the
unit is full. Wait for the bubble to
subside, then continue filling in this
manner until the oil is clearly visible at
the base of the filler and breather
holes.
6 Replace the two top cover bolts.
Refit the radiator grille and name
plate.
(44) Steering box oil level
1 Check oil level and top up if necessary
to the bottom of the filler-plug hole
on the top of the cover plate. Access
to the plug is gained by lifting the
bonnet panel.
2 If significant topping up is required
check for oil leaks at joint faces and
rocker shaft oil seal.
IRA GIA
51-01
(45) Steering box
Check steering box mountings for security
and steering box for backlash. Rectify as
necessary.
(46) Swivel pin housing oil level
1 The front wheel drive universal joints,
swivel pins and front hubs receive their
lubrication from the swivel pin hous-
ings. Check oil level and top up if
necessary to the bottom of the filler-
level plug holes at the rear of the
housings.
2 If significant topping up is required
check for oil leaks at plugs, joint faces
and oil seals.
BRAKES
(47) Check visually hydraulic pipes and unions
for chafing, leaks and corrosion—rectify as
necessary
(48) Brake fluid reservoir
1 Check fluid level in brake reservoir by
removing cap.
2 Top up if necessary to level mark on
reservoir.
Use Castrol Girling Brake and Clutch Fluid
‘Crimson’ (Specification J. 1703).
If significant topping-up is required, check
master cylinder, wheel cylinders and brake
pipes for leakage; any leakage must be
rectified immediately.
ARC 3968
(49) Transmission brake adjustment
If hand brake movement is excessive,
adjust as follows:
1 Release the hand brake. The adjuster
protrudes from the front of the brake
backplate.
2 During rotation of the adjuster a click
will be felt and heard at each quarter
revolution. Rotate adjuster in a
clockwise direction until the brake
shoes contact the drum. Then unscrew
the adjuster two clicks and give the
hand brake a firm application to
centralise the shoes.
1RA B5A nia
(50) Foot and hand brake
1 Check operation of foot and hand
brake, ensure that the brake pedal
travel is not excessive and maintains a
satisfactory pressure under normal
working load.
2 Excessive pedal travel indicates worn
brake linings ог the necessity for
adjustment.
3 If the brakes feel spongy this may be
caused by air in the hydraulic system
and must be removed by bleeding the
system at each wheel cylinder.
4 Prior to this operation, all hydraulic
hoses, pipes and connections should be
checked for leaks and any leaks
rectified.
S Check operation of hand brake and
ensure that it holds the vehicle satis-
factorily.
Wheel brake adjustment
When the vehicle is used in deep muddy
conditions the brake drums must be
periodically removed and cleaned, at the
same time the brake shoes and anchor plate
should be thoroughly cleaned.
When used continuously under excep-
tionally wet and muddy conditions this
operation may be advisable once, or even
twice a week, to prevent the abrasive
action of packed mud rapidly wearing out
brake linings and drums.
When lining wear has reached the point
where the pedal travel becomes excessive,
it is necessary to adjust the brake shoes in
closer relation to the drum.
Proceed as follows:
88 Models
| Jack up each wheel in turn.
2 On the back face of the brake anchor
plate will be found a hexagon adjust-
ment bolt which operates a snail cam
bearing on the leading shoe. Only one
of these is fitted to each wheel brake
unit, thereby providing single-point
adjustment.
+ +
7 2
IRA 84A у с В
3 Spin the wheel and rotate the adjuster
bolt until the brake shoe contacts the
drum, then ease the adjuster until the
wheel again rotates freely.
4 Repeat for the other three wheels.
109 Models
5 Each shoe is independently set by
means of a hexagon adjustment bolt
operating through a serrated snail cam.
6 Apply the brakes and set the snail cam
adjusters so that the brake shoes are in
firm contact with the drums.
7 Slacken off each adjuster just suf-
ficiently for the drum to rotate freely.
8 Repeat for the other wheels in turn.
NOTE: The rear brake shoes should be
adjusted individually to obtain the best
results.
91—01
(51) Inspect brake linings for wear, drums for
condition, replace worn parts as necessary
(52) Handbrake linkage
The hand brake operates a mechanical
brake unit mounted on the output shaft
from the transfer box.
Lubricate the hand brake linkage and
check for worn parts. Take care not to
contaminate the hand brake linings with
oil.
(53) Servo hose(s) — check hose(s) for security
and condition, replace as necessary
ELECTRICAL
(54) Electrical and interior equipment
6 Check operation of all lamps, direction
indicators, warning lights, horn, instru-
ments and other equipment.
(55) Battery acid level
Check weekly when operating under severe
conditions. The battery is located under
the bonnet at the front right-hand side.
The specific gravity of the electrolyte
should be checked at every maintenance
inspection. Readings should be;
Temperate climate below 26.5 C (80°F) as
commissioned for service, fully charged
1.270 to 1.290 specific gravity.
As expected during normal service, three-
quarter charged 1.230 to 1.250 specific
gravity.
If the specific gravity should read between
1.190 to 1.210, half-charged, the battery
must be bench charged and the electrical
equipment in the car should be checked.
Tropical climate above 26. 5°C (80°F) as
commissioned for service, fully charged
1.210 to 1.230 specific gravity.
As expected during normal service, three-
quarter charge 1.170 to 1.190 specific
gravity.
If the specific gravity should read between
1.130 to 1.150, half-charged, the battery
must be bench charged and the electrical
equipment on the car should be checked.
Check acid level as follows:
1 Wipe all dirt and moisture from the
battery top.
2 Remove the filler plugs or manifold
lid. If necessary add sufficient distilled
water to raise the level to the top of
separators.
Replace the filler plugs or manifold
lid.
3 Avoid the use of a naked light when
examining the cells.
4 In hot climates it will be necessary to
ton up the battery at more frequent
intervals.
5 In very cold weather it is essential that
the vehicle is used immediately after
topping up, to ensure that the distilled
water is thoroughly mixed with the
electrolyte. Neglect of this precaution
may result in the distilled water freez-
ing and causing damage to the battery.
IRA TTA 5
(56) Battery terminals
6 Remove battery
grease and refit.
7 Replace terminal screw; do not over-
tighten. Do not use the screw for
pulling down the terminal.
8 Do NOT disconnect the battery cables
while the engine is running or damage
to alternator semiconductor devices
may occur. It is also inadvisable to
break or make any connection in the
alternator charging and control circuits
while the engine is running.
9 It is essential to observe the polarity of
connections to the battery, alternator
and regulator, as any incorrect connec-
tions made when reconnecting cables
may cause irreparable damage to the
semiconductor devices.
terminals, clean,
(57 Headlamp beam setting
This operation requires special equip-
ment and should be carried out by a
Rover Distributor or Dealer.
2 In an emergency each headlamp can be
adjusted by means of a headlamp
horizontal adjusting screw.
3 The headlamp vertical adjusting screw.
The adjusting screws are accessible
through slots in the headlamp bezel.
(58) Windscreen wiper blades
Examine condition of wiper blades, replace
as necessary:
1 Pull wiper arm forward.
2 Lift spring clip and withdraw blade
from wiper arm.
3 To fit new blade reverse removal pro-
cedure.
EXHAUST AND FUEL PIPES
(59) & (60) Exhaust system, fuel, clutch and
brake pipes
1 Check exhaust system fixings for
security, paying particular attention to
heat shields, flexible mounting plates
and clamps.
2 Examine the system for signs of
leakage and blowing. Any silencers or
pipes found to be leaking or badly
corroded should be replaced:
3 At the same time check all fuel, clutch
and brake pipes, unions and hoses for
signs of leakage, corrosion, chafing or
damage.
21-01
WHEELS AND TYRES
(61) Check that tyres comply with manufac-
turer’s specification
(62) Tyre pressures
Maximum tyre life and performance will
only be obtained if the tyres are main-
tained at the correct pressures.
(63) & (65)
Whenever possible check with the
tyres cold as the pressure is about 0,1
kg/cm? (2 1b/sq. in.) 0,14 bars higher
at running temperature.
Always replace the valve caps as they
form a positive seal on the valves.
3 Any unusual pressure loss in excess of
0,05 to 0,20 kg/cm? (1 to 3 Ib/sq. in.)
0.07 to 0 ,21 bars per week should be
investigated and corrected.
4 Always check the spare wheel so that
it is ready for use at any time.
5 At the same time remove embedded
flints etc. from the tyre treads with
the aid of a penknife or similar tool
and check that the tyres have no
breaks in the fabric or cuts to sidewalls
etc. Clean off any oil or grease on the
tyres using white spirit sparingly.
6 Check that there are no lumps or
bulges in the tyres or exposure of the
ply or cord structure.
7 “Butyl” synthetic innertubes are fitted
and all repairs must be vulcanised.
8 It is an offence to run tyres when the
tread pattern of the tyre does not have
a depth of at least 1 mm throughout at
least three-quarters of the breadth of
the tread and round the entire outer
circumference of the tyre.
9 It is advisable to run-in new tyres by
driving at reasonable speeds for the
first 400 km (250 miles) or so before
driving at higher speeds.
|
(64) Road wheel nuts
Check road wheel nuts, tighten as neces-
sary.
(66) Changing wheel positions
The road wheels should be changed round
as illustrated to equalise tyre wear.
When cross-country tyres are used, the ‘V’
tread should be directed to the front at the
top.
WARNING: Do not touch the outer ring of
nuts on divided type wheels (optional
equipment) unless the wheel is removed
and the tyre fully deflated, or severe
personal injury may result.
IMPORTANT: As the Land Rover is fitted
with a transmission brake, it is necessary
before removing a road wheel to apply the
hand brake and engage four-wheel drive.
This will ensure that the hand brake is
operative on all four wheels.
Remember to engage two-wheel drive when
the road wheel has been replaced.
BODY
(67) (70) & (71) Door locks and mechanisms
9 Check operation of all door locks and
mechanisms, window controls, safety
catches, bonnet catch etc.; apply a few
spots of oil as necessary.
(68) (69) & (72) Seats, safety belts and rear view
mirrors
7 Check all seat fixings for security and
examine condition of safety harness.
Safety harness which have been used in an
accident or are frayed or cut, must be
replaced.
8 Check rear view mirror(s) for security and
examine mirror face for signs of cracks or
crazing.
(73) Check cleanliness of controls, door handles
and steering wheel
GENERAL
(74) Road or roller test
Give the vehicle a roller or road test and carry
out any further adjustments required including
brakes, clutch, throttle linkage etc.
Check steering and all gears in high and low
range including the high range four-wheel
drive control.
Check operation of all lights and instruments.
After test check for oil, fuel and fluid leaks at
all plugs, flanges, joints and unions.
PREVENTIVE MAINTENANCE
In addition to the recommended periodical
inspection of brake components it is advisable
as the vehicle ages, and as a precaution against
the effects of weat and deterioration, to make
a more searching inspection and renew parts as
necessary.
It is recommended that:
Brake linings, hoses and pipes should be exam-
ined at intervals no greater than those laid
down in the Maintenance Summary.
Rubber seals in brake system— Every 60 000
km (36,000 miles) or 36 months. Renew all
rubber seals in master cylinder, wheel cylinders
and servo until where applicable. This should
be done every three years if mileage travelled is
less than 60 000 km (36,000 miles). Refill with
correct fluid.
Fluid changing, brake system— Every 30 000
km (18,000 miles) or 18 months. All brake
fluid absorbs moisture from the air and as a
result its boiling point is lowered with a conse-
quent deterioration in performance. In a sealed
brake system, water absorption takes place
over a period and can, if not remedied reduce
brake performance to a dangerous level.
All the fluid in the brake system should be
changed every 30 000 km (18,000 miles) or 18
months. lt should also be changed before
touring in mountainous areas, if not done in
the previous nine months. Use only fluid
recommended in Section 09.
Care must be taken always to observe the fol-
lowing points:
a al times use the recommended brake
uid.
b Never leave fluid in unsealed containers.
it absorbs moisture quickly and can be
dangerous if used in your braking system
in this condition.
81-01
¢ Fluid drained from the system or used for
bleeding is best discarded.
d The necessity for absolute cleanliness
throughout cannot be over-emphasized.
Replacing Brake-Shoes
When it becomes necessary to renew the
brake shoes, it is essential that only
genuine shoes, with the correct grade of
lining are used. Always fit new shoes as
complete axle sets, never individually or as
a single wheel set. Serious consequences
could result from out-of-balance braking
due to mixing of linings.
Bleeding the brake system
When the fluid in the hydraulic system has
been changed or any components replaced
it will be necessary to remove the air by
bleeding the hydraulic system at each
wheel cylinder. Bleeding must always be
carried out at all wheels.
Proceed as follows:
1 Slacken the adjusters off on all brake
shoes.
2 Attach a length of rubber tubing to
the bleed screw on the wheel cylinder
furthest from the brake pedal and
place the lower end of the tube in a
glass jar containing brake fluid.
3 Slacken the bleed screw and depress
the brake pedal and release slowly.
Pause at each end of the return stroke
to allow the master cylinder to re-
cuperate. Continue pumping in this
manner until the fluid issuing from the
tube shows no signs of air bubbles
when the. tube is held below the
surface of the fluid in the jar.
The fluid in the reservoir should be re-
plenished throughout the operation.
Hold the tube under the fluid surface
and, with the foot brake fully de-
pressed, tighten the bleed screw. Do
not overtighten.
Repeat for the other three wheels in
turn, finishing at the one nearest the
brake pedal.
Pump brake pedal until rear shoes are
in firm contact with the brake drums.
While holding pedal depressed, adjust
rear adjuster up to the shoes.
Release pedal and slacken rear
adjusters until shoes are just clear of
the drums.
Adjust front shoes in the normal
manner.
61-01
SPECIAL OPERATING CONDITIONS
When the vehicle is operated on dusty, wet or muddy terrain, more frequent
attention, depending on the conditions, should be paid to the following:
Daily or Weekly
Check/top up engine oil
Empty, clean and refill air cleaner oil bath
Check/top up cooling system
Check/top up gearbox oil
Check/top up transfer box oil
Check/top up battery electrolyte
Check steering rubber boots for security
and damage
Clean out brake drums and adjust to
manufacturer’s instructions
Lubricate front and rear propeller shaft
grease points and front sliding joint
Clean fuel sedimentor (diesel)
Monthly
Renew gearbox oil
Renew transfer box oil
6 months: Renew air cleaner elements
Stationary Running
If the vehicle is used exclusively in low
transfer ratio or for stationary work,
maintenance intervals must be based on
either fuel consumption or hours running
time. Refer to the chart.
CONVERSION CHART
Kilometres and miles, fuel consumption and hours’ running time
Fuel consumption Hours’
Kilometres Miles Petrol Diesel Running
Litres Gallons Litres Gallons time
5000 3000 680 150 455 100 120
10000 6000 1,363 300 909 200 240
| 5000 9000 2,045 450 1,363 300 360
20000 12000 2,727 600 1,818 400 480
25000 15000 3,409 750 2,272 500 600
30000 18000 4,091 900 2,727 600 720
35000 21000 4,773 1.050 3,182 700 840
40000 24000 5,455 1.200 3,636 800 960
1-71
2% Litre— Three Main Bearing—4 Cylinder Petrol Engine
c-cl
24 Litre—Three Main Bearing— 4 Cylinder Diesel Engine
€E—Cl
2% litre — 4 cylinder Pétrol and Diesel
CAMSHAFT
Remove and refit 12.13.01
Service tools: 507231 Chainwheel extrac-
tor
530101 Camshaft extractor
Removing
1 Remove the bonnet. 76.16.01.
2 Remove the air cleaner. 19.10.04.
3 Remove the radiator and front panel
assembly. 26.40.01.
4 Remove the external oil filter assembly.
12.60.01.
Petrol Engines: Remove the distribu-
tor and drive gear. 86.35.20.
Diesel Engines: Remove the fuel injec-
tion pump. 19.30.07.
Remove the valve gear. 12.29.34.
Remove the cylinder head. 12.29.10.
Remove the tappets. 12.29.57.
0 Remove the timing gear cover.
12.65.01.
11 Remove the timing chain tensioner.
12.65.28.
12 Withdraw the timing chain.
13 Remove the fixings from the camshaft
chainwheel.
14 Extract the chainwheel from the cam-
shaft. 507231.
15 Remove the thrust plate from the cam-
shaft. Tab washers deleted on later
engines.
16 Extract the camshaft. 530101.
NOTE: For details of camshaft bearings,
refer to 12.13.13.
Refitting
17 Insert the camshaft into the cylinder
block.
18 Fit the thrust plate.
19 Fit the chainwheel to the camshaft but
do not engage the lockwasher at this
stage.
20 Mount a dial test indicator to read off
the end of the camshaft.
21 Check the camshaft end float. The
correct end float limits are 0,06 mm to
0,13 mm (0.0025 in. to 0.0055 in.). If
the end float is excessive, fit a new
thrust plate and/or camshaft.
22 Remove the dial test indicator.
23 Reset the valve timing. 12.65.22.
24 Reverse 1 to ll.
= NO CO 1 aN wn
1RC301
CAMSHAFT BEARINGS
Remove and refit 12.13.13.
Service tools: 605975 Bearing drift and
adaptor assembly compris-
ing:
274388 Bearing drift
531760 Adaptor
274389 Reamer for bearings
includes:
274394 Guide plug
NOTE: Prior to removing the camshaft
bearings, the engine must be removed from
the vehicle and be completely dismantled
until only the camshaft bearings remain in
the cylinder block.
Removing
1 Drift out the front and rear bearings
and withdraw them through the side
cover apertures. 274388.
CU TT я
e o rs A
Mun” 2 4 и
A NN
esos |
2 Drift the two centre bearings into the
distributor drive chamber and collapse
them to enable withdrawal. 274388.
Refitting
NOTE: The two centre and rear bearings
are of the same width, whereas the front
bearing is wider and has an additional oil
feed hole.
3 Position the cylinder block vertical,
rear face down.
4 Place a new bearing into the front
camshaft chamber and position it so
that it is above the second bearing
housing, counting from the front of
the block.
5 The chamfer on the bearing edge must
be towards the housing bore.
continued
MA AN
v—Cl
10
Align the oil hole in the bearing with
the innermost oil feed drilling in the
housing bore. Accuracy is essential
otherwise misalignment of the oil
holes may result and once the bearing
is in place it cannot be rotated to
correct any error.
Add pencil marks to the bearing outer
diameter and the cylinder block
adjacent to the housing to assist in
checking alignment.
Having visually aligned the bearing,
place inside it the adaptor. 531760.
Maintain the bearing in a level posi-
tion. Pass the drift through the front
bearing housing into the camshaft
chamber so that it rests on top of the
adaptor. Commence drifting the bear-
ing into the block. Ensure that the
bearing is not drifted in too far, and
that the oil feed holes are correctly
aligned.
Repeat 5 to 9 for the front bearing.
Note that the front bearing is wider
and has a small hole in addition to the
large oil feed hole. This small hole
aligns with a vertical drilling in the
block, which in turn feeds a horizontal
drilling for the tappet mechanism.
Drift this bearing in so that the outer
edge is just below the machined sur-
face of the front face. This is to ensure
that when the camshaft thrust plate is
fitted it will not stand proud on the
bearing edge.
11 Turn the cylinder block over so that
the rear face is uppermost.
12 Repeat the foregoing procedures for
the two remaining camshaft bearings.
Reaming the camshaft bearings
NOTE: No lubricant is necessary for the
reaming operation, best results are
obtained when the bearings are cut dry.
13 Locate the guide plug 274394, into
the front camshaft bearing and retain
using the thrust plate screws, but do
not tighten the screws at this stage.
14 Insert the reamer 274389 from the
rear of the cylinder block, locating it
through the guide plug at the front.
15 Locate the guide collar immediately in
front of the reamer cutter into the
rearmost bearing, then secure the
screws retaining the guide plug at the
front.
16 Position the cylinder block vertical,
rear face uppermost.
17 Ream the rear and two centre bear-
ings. As each bearing is cut the reamer
should be held steady by the operator
whilst an assistant, using a high pres-
sure airline, blows away the white
metal cuttings, before allowing the
reamer to enter the next bearing.
18 Remove the guide plug 274394, before
reaming the front bearing.
19 Ream the front bearing.
20 Remove the reamer handle and bolt.
21 Remove the reamer, turning it in the
same direction as for cutting.
22 Remove the plugs from the ends of oil
gallery passage and clean the gallery
and oil feed passages to camshaft and
crankshaft bearings, using compressed
air. Refit the plugs and lock in posi-
tion.
23 The hexagon-headed plugs at the rear
of the block should have new washers
fitted, and their threads coated with a
suitable jointing compound.
24 Clean the cylinder block ready for
engine reassembly.
1RC308
ON Laa Y —
CONNECTING RODS AND PISTONS
Remove and refit 12.17.01
Removing
Remove the bonnet. 76.16.01.
Remove the air cleaner. 19.10.04.
Remove the valve gear. 12.29.34.
Remove the cylinder head. 12.29.10.
Remove the oil sump. 12.60.44.
With two pistons at bottom dead
centre (BDC) remove the connecting
rod cap fixings.
7 Remove the caps and withdraw the
connecting rod bearing halves. Retain
the caps and bearings in related sets.
1RC274
8 Withdraw the pistons and attached
connecting rods from the top of the
bore.
9 Position the remaining pistons at BDC
and repeat the removal procedure.
10 Retain the removed components in
related sets. The correct cap for each
connecting rod is denoted by the
number stamped near the joint faces.
This number also indicates the crank-
shaft journal to Which it must be
fitted.
Refitting :
NOTE: If replacement components are to
be fitted, the checks detailed in 12.17.10
must be carried out.
11 Position the crankshaft with two
crankpins at BDC.
12 Insert the appropriate connecting rod
and piston assemblies into their respec-
tive bores, noting that the oil hole in
the connecting rods must be towards
the camshaft.
13 Petrol engines: Position the piston
rings so that their gaps are staggered
around the piston thrust face (cam-
shaft side of the engine).
IRC 275
14 Diesel engines: Position the piston
compression rings so that their gaps
are staggered around the piston thrust
face (camshaft side of the engine).
15 Diesel engines: Position the oil control
ring so that the ends of the expander
butt, but do not overlap and are in line
with the gudgeon pin. Position the gap
in each rail 25 mm (1 in.) to the left of
the butted ends of the expander.
16 Using a piston ring compressor, locate
the pistons into the cylinder bores.
— TT
IRC 365
17 Lubricate the journals and bearing
halves and fit the appropriate bearing
halves to the connecting rods and caps.
18 Fit the connecting rod caps using NEW
securing nuts. Torque 3,5 kgf. m (24
Ibf. ft.).
19 Repeat 11 to 19 for the remaining
connecting rod and piston assemblies.
20 Reverse 1 to 5.
CONNECTING RODS AND
PISTONS-— Petrol
Overhaul 12.17.10
Dismantling |
NOTE: During the following procedures
retain all components in related sets to
facilitate subsequent assembly. If the same
pistons are to be refitted, add location
marks to ensure reassembling in the same
relative position.
1 Remove the connecting rods and
pistons. 12.17.01.
2 Remove the piston rings.
3 Remove the circlips from the gudgeon
pin bosses.
4 Withdraw the gudgeon pins from the
pistons.
‘Overhauling pistons
Original pistons
5 Remove the carbon and deposits,
particularly from the ring grooves.
6 Examine the pistons for damage or
excessive wear — see under ‘New
pistons’ for clearance dimensions — fit
new replacements as necessary.
New Pistons
Original pistons fitted to new engines at the fac-
tory are specially graded to facilitate assembly.
The grading letter on top of the piston crown
must be ignored when ordering new pistons.
Genuine Land-Rover service standard size
pistons are supplied 0,025 mm (0.001 in) over-
size to allow for production tolerances on new
engines. When fitting a new piston to a stan-
dard size cylinder block the bore must be honed
to accommodate the piston with the correct
clearances.
The clearance limits with new standard size
pistons and a new cylinder block are 0,058
mm to 0,068 mm (0.0023 in. to 0.0027
in.).
The clearance limits with new oversize
pistons and a newly rebored cylinder block
are 0,043 mm to 0,055 mm (0.0017 in. to
0.0022 in.).
The temperature. of the piston and cylinder
block must be the same to ensure accurate
measurements.
7 Check the piston diameter at the
bottom of the skirt at right angles to
the gudgeon pin.
8 Check the bore diameter at approxi-
mately half way down.
9 If gauge equipment is not available,
the piston clearance can be assessed
using long feeler gauges. 10 to 12.
10 Insert a long suitably sized feeler gauge
down the right hand side of the
cylinder bore.
11 Insert the correct piston, inverted, into
the cylinder bore and position it with
the gudgeon pin parallel with the axis
of the crankshaft.
12 Push the piston down the cylinder
until the piston reaches its tightest
point in the bore, at this point with-
draw the feeler gauge — a steady
resistance should be felt.
IRC 7 >
13 If service standard size pistons are being
fitted, check the diameter of the piston, as
already described, and hone the cylinder
bore, as necessary, to obtain the correct
clearance.
continued
9-71
14 If new piston rings are to be fitted
without reboring, deglaze the cylinder
walls with a hone, without increasing
the bore diameter. A deglazed bore
must have a cross-hatch finish.
15 Check the compression and oil control
ring gaps in the applicable cylinder,
held square to the bore with the
piston. Gap limits: 0,38 mm to 0,5
mm (0.015 in. to (0.020 in.). Use a
fine cut flat file to increase the gap if
required. Select a new piston ring if
the gap exceeds the limit.
ED
IRC279 \ “№5
16 Fit the oil control ring to the piston.
17 Check the oil control ring clearance in
the piston groove. Clearance limits:
0,038 mm to 0,089 mm (0.0015 in. to
0.0035 in.).
18 Fit the two compression rings to the
piston with the sides marked “T” or
‘Top’ uppermost.
19 Check the compression ring clearance
in the piston grooves. Clearance limits:
0,046 mm to 0,097 mm (0.0018 in. to
0.0038 in.).
19
1RC280
Where maximum permitted boring tole-
rance is not sufficient to reclaim the bores,
cylinder liners must be fitted.
Fitting the cylinder liners conforms to
normal practice. Machine the cylinder
block bores to 94,425 mm + 0,012 mm
(3.7175 in. + 0.0005 in.) diameter. This
will provide the liner with 0,076 mm to
0,114 mm (0.003 in. to 0.0045 in.) inter-
ference fit.
Press the liners into the cylinder block. The
liners must not be proud of, or more than
0,254 mm (0.010 in.) below, the top face
of the cylinder block.
Cylinder liners should be bored to standard size
of 90,47 mm (3.562 in.) diameter.
Liners may be rebored to a maximum of 1,01
mm (0.040 in.) oversize. |
Connecting rods
20 Check the alignment of the connecting
rod.
21 Check the gudgeon pin clearance in
the connecting rod. Clearance limits:
0,007 mm to 0,015 mm (0.0003 in. to
0.0006 in.).
22 If a new connecting rod small! end
bush is required, ensure that the oil
holes are aligned when pressing in the
replacement, then ream the bush to
obtain the correct clearances, as above.
1RC373
23 Check the fit of the gudgeon pin in the
piston, the pin must not fall through
either boss but be capable of being
fitted by hand at normal room tem-
perature 20 C (68 F.).
24 Select the correct cap for each con-
necting rod as denoted by the number
stamped near the joint faces. This
number also indicates the crankshaft
journal to which it must be fitted.
25 Assemble the caps, less bearing halves,
to the respective connecting rods.
Torque 3,5 kgf. m (25 1bf. ft.).
26 Slacken the fixing on one side of the
cap only and check that there is no
clearance at the joint face. If there is
clearance, a new assembly must be
fitted.
Connecting rod bearing nip and clearance
NOTE: New bearing halves are supplied
with a protective coating and must be
degreased, prior to fitting, to remove the
coating.
27 Fit the bearing halves to the connect-
ing rod and cap, and secure the assem-
bly. Torque 3,5 kgf. m (25 1bf. ft.).
28 Slacken the fixing on one side of the
cap only and check the clearance
between the joint faces. The clearance
must be 0,10 mm to 0,20 mm (0.004
in. to 0.008 in.). The bearing nip can
be corrected by selective assembly of
the bearing shells; these are available in
slightly varying thicknesses. Do not
file or machine the caps or connecting
rods to vary the bearing nip.
26827 nn PE ENE 26828
27
24
IRC 281 |
29 Make a final check to prove the
bearing clearance, using a 0,063 mm
(0.0025 in.) shim paper. The connect-
ing rod should resist rotation when
fitted to the crankshaft with the shim
paper fitted between the journal and
one half of the bearing shell, and move
freely by hand with the shim paper
removed.
NOTE: As an alternative, Plastigauge may
be used to check the connecting rod
bearing clearance. 30 to 36.
Do not rotate the connecting rod or
crankshaft while the Plastigauge is fitted,
or the reading will be impaired.
30 Place a piece of Plastigauge across the
centre of the lower half of the crank-
shaft journal. 605238.
31 Fit the connecting rod complete with
bearings to the applicable journal.
Torque 3,5 kgf. m (25 Ibf. ft.).
32 Remove the connecting rod cap and
lower half bearing.
33 Using the scale printed on the Plasti-
gauge packet, measure the flattened
Plastigauge at its widest point. The
graduation that most closely cor-
responds to the width of the Plasti-
gauge indicates the bearing clearance.
34 The correct clearance with new or over-
hauled components is given in DATA at
the end of this operation.
35 If a new bearing is being fitted, use selec-
tive assembly to obtain the correct
clearance.
L—el
36 Wipe off the Plastigauge with an oily
rag. DO NOT scrape it off.
Connecting rod end float
37 Fit the connecting rods complete with
bearings to their applicable journals.
Torque 3,5 kgf. m (25 Ibf. ft.).
38 Check the end float between the end
face of the connecting rod and the
journal shoulder. End float limits:
0,20 mm to 0,30 mm (0.007 in. to
0.012 in.).
39 Remove the connecting rods from the
crankshaft and retain all parts in
related sets.
Assembling
40 Assemble the pistons to their respec-
tive connecting rods.
DATA
Pistons
Clearance in bore, measured at bottom
of skirt at right angles to gudgeon pin.
Standard size pistons ............
Oversize pistons. ...............
Piston Rings
Compression (2)
Gapinbore....................
Clearance in groove . . . . . .. oo... ..
Oil control
Сар тм Боге... .................
Clearance in groove ..........e...
Gudgeon pin
Clearance in connectingrod .........
Fit in piston .....................
Connecting Rods
Clearance, bearing to crankpin ..........
End float on crankpin ..................
Ww
~
Au
А
y
41 Fit new circlips to retain the piston
gudgeon pins.
42 Refit the connecting rods and pistons
12.17.01.
0,058 mm to 0,068 mm (0.0023 in. to
0.0027 in.)
0,043 mm to 0,055 m (0.0017 in. to
0.0022 in.)
0,38 mm to 0,50 mm (0.015 in. to
0.020 in.)
0.046 mm to 0.097 mm (0.0018 in.
to 0.0038 in.)
0,38 mm to 0,50 mm (0.015 in. to
0.020 in.)
0,038 mm to 0,089 mm (0.0015 in.
to 0.0035 in.)
0,007 mm to 0,015 mm (0.0003 in.
to 0.0006 in.)
Push fit by hand
“a 19 mm to 0,068 mm (0.00075 in. to 0.0027
in.
0,20 mm to 0,30 mm (0.007 in. to 0.012 in.)
CONNECTING RODS AND
PISTONS — Diesel
Overhaul 12.17.10
Dismantling
NOTE: During the following procedures
retain all components in related sets to
facilitate subsequent assembly. If the same
pistons are to be refitted, add location
marks to ensure reassembling in the same
relative position.
1 Remove the connecting rods and
pistons. 12.17.01.
2 Remove the piston rings.
3 Remove the circlips from the gudgeon
pin bosses.
4 Withdraw the gudgeon pins from the
pistons.
Overhauling Pistons
Original Pistons
5 Remove the carbon and deposits,
particularly from the ring grooves.
6 Examine the pistons for damage or
excessive wear — see under ‘New
pistons’ for clearance dimensions — fit
new replacements as necessary.
New Pistons
Original pistons fitted to new engines at the fac-
tory are specially graded to facilitate assembly.
The grading letter on top of the piston crown
must be ignored when ordering new pistons.
Genuine Land-Rover Service standard size
pistons are supplied 0,025 mm (0.001 in) over-
size to allow for production tolerances on new
engines. When fitting a new piston to a stan-
dard size cylinder block the bore must be honed
to accommodate the piston with the correct
clearances.
The clearance limits with new standard size
pistons and a new cylinder block are 0,111
mm to 0,134 mm (0.0044 in. to 0.0053
in.).
The clearance limits with new oversize
pistons and a newly rebored cylinder block
are 0,111 mm to 0,157 mm (0.0044 in. to
0.0062 in.).
The temperature of the piston and cylinder
block must be the same to ensure accurate
measurements. |
7 Check the piston diameter at the
extreme bottom and at right angles to
the gudgeon pin.
8 Check the bore diameter at approxi-
mately half way down, at right angles
to the gudgeon pin.
continued
IRC 368
8—cCl
10
11
14
15
If gauge equipment is not available,
the piston clearance can be assessed
using long feeler gauges. 10 to 12.
Insert a long, suitably sized feeler
gauge down the right hand side of the
cylinder bore.
Insert the correct piston, inverted, into
the cylinder bore and position it with
the gudgeon pin parallel with the axis
of the crankshaft.
La
Push the piston down the cylinder
until the piston reaches its tightest
point in the bore, at this point with-
draw the feeler gauge — a steady
resistance should be felt.
If service standard size pistons are being
fitted, check the diameter of the piston, as
already described, and hone the cylinder
bore, as necessary, to obtain the correct
clearance.
If new piston rings are to be fitted
without reboring, deglaze the cylinder
with a hone, without increasing the
bore diameter. A deglazed bore must
have a cross-hatch finish.
Check the compression and oil control
ring gaps in the applicable cylinder,
held square to the bore with the
piston. Gap limits: Upper compression
ring (chromed): 0,35 mm to 0,50 mm
(0.014 in. to 0.019 in.). Middle and
lower compression rings: 0,25 mm to
0,38 mm (0.010 in. to 0,015 in.). Oil
control ring, upper and lower rail:
0,38 mm to 1,14 mm (0.015 in. to
0.045 in.).
IRC279 NS
16 Fit the expander for the oil control
ring into the groove immediately
above the gudgeon pin. The ends of
the expander must butt but not over-
lap and be in line with the gudgeon
pin.
17 Fit the lower rail from the bottom of
the piston and locate it into the
groove, beneath the expander. Position
the ring gap 25 mm (1 in.) to the left
of the butted ends of the expander.
18 Fit the upper rail from the top of the
piston and locate it into the groove,
above the expander. Position the ring
gap 25 mm (1 in.) to the left of the
butted ends of the expander.
IRC 369
19 Check the oil control ring clearance in
the piston groove. Clearance limits:
0,038 mm to 0,064 mm (0.001 5 in. to
0.0025 in.).
20 Fit the compression rings marked “T”
or “TOP” with the marking uppermost
to the middle two grooves.
21 Fit the chrome edged compression ring
to the top groove.
22 Check the compression ring clearance
in the piston grooves. Clearance limits:
0,06 mm to 0,11 mm (0.0025 in. to
0.0045 in.).
22
1RC373
Where the maximum permitted boring tole-
rance is not sufficient to reclaim the bores,
cylinder liners may be fitted. Fitting the
cylinder liners conforms to normal prac-
tice. Machine the cylinder block bores to
94,425 mm + 0,012 mm (3.7175 in. +
0.0005 in.) diameter. This will provide the
liner with 0,076 mm to 0,0114 mm (0.003
in. to 0.0045 in.) interference fit.
Press the liners into the cylinder block. The
liners must not be proud of, or more than
0,05 mm (0.002 in.) below the top face of
the cylinder block. |
Cylinder liners should be bored to standard size
of 90,47 mm (3.562 in.) diameter.
Liners may be rebored to a maximum of 1,01
mm (0.040 in.) oversize.
Connecting rods
23 Check the alignment of the connecting
rod.
24 Check the gudgeon pin clearance in
the connecting rod. Clearance limits:
0,002 mm to 0,02 mm (0.0001 in. to
0.0009 in.).
25 If a new connecting rod small end
bush is required, ensure that the oil
holes are aligned when pressing in the
replacement, then ream the bush to
obtain the correct clearance, as above.
26 Check the fit of the gudgeon pin in the
piston, the pin must not fall through
either boss but be capable of being
fitted by hand at normal room tem-
perature 20 C (68 F).
27 Select the correct cap for each con-
necting rod as denoted by the number
stamped near the joint faces. This
number also indicates the crankshaft
journal to which it must be fitted.
28 Assemble the caps, less bearing halves,
to the respective connecting rods.
Torque 3,5 kgf. m (25 1bf. ft.).
29 Slacken the fixing on one side of the
cap only and check that there is no
clearance at the joint face. If there is
clearance, a new assembly must be
fitted.
Connecting rod bearing nip and clearance
NOTE: New bearing halves are supplied
with a protective coating and must be
degreased prior to fitting to remove the
coating.
30 Fit the bearing halves to the connect-
ing rod and cap and secure the assem-
bly. Torque 3,5 kgf. m (25 1bf. ft.).
31 Slacken the fixing on one side of the
cap only and check the clearance
between the joint faces. The clearance
must be 0,10 mm to 0,20 mm (0.004
in. to 0.008 in.). The bearing nip can
be corrected by selective assembly of
the bearing shells; these are available in
slightly varying thicknesses. Do not
file or machine the caps or connecting
rods to vary the bearing nip.
28130 ——. ER
IRC 370
6-C1
32 Make a final check to prove the
bearing clearance, using a 0,063 mm
(0.0025 in.) shim paper. The connect-
ing rod should resist rotation when
fitted to the crankshaft with the shim
paper fitted between the journal and
one half of the bearing shell, and move
freely by hand with the shim paper
removed.
NOTE: As an alternative, Plastigauge may
be used to check the connecting rod
bearing clearance.
Do not rotate the connecting rod or
crankshaft while the Plastigauge is fitted,
or the reading will be impaired.
33 Place a piece of Plastigauge across the
centre of the lower half of the crank-
shaft journal. 605238.
34 Fit the connecting rod complete with
bearings to the applicable journal.
Torque 3,5 kgf. m (25 Ibf. ft.).
35 Remove the connecting rod cap and
lower half bearing.
36 Using the scale printed on the Plasti-
gauge packet, measure the flattened
Plastigauge at its widest point. The
graduation that most closely cor-
responds to the width of the Plasti-
gauge indicates the bearing clearance.
37 The correct clearance with new or over-
hauled components is given in the DATA
at the end of this operation.
38 If a new bearing is being fitted, use
selective assembly to obtain the
correct clearance.
39 Wipe off the Plastigauge with an oily
rag. DO NOT scrape it off.
Connecting rod end float
40 Fit the connecting rods complete with
bearings to their applicable journals.
Torque 3,5 kgf. m (25 tbf. ft.).
41 Check the end float between the end
face of the connecting rod and the
journal shoulder. End float limits:
0,20 mm to 0,30 mm (0.007 in. to
0.012 in.).
==
1RC372
42 Remove the connecting rods from the
crankshaft and retain all parts in
related sets.
Assembling
43 Assemble the pistons to their respec-
tive connecting rods.
44 Fit new circlips to retain the piston
gudgeon pins.
45 Refit the connecting rods and pistons.
12.17.01.
DATA
Pistons
Clearance in bore measured at bottom
of skirt at right angles to gudgeon pin.
Standard size pistons ............
Oversize pistons ...............
Piston rings
Compression No. 1
TyDE
Gapinbore....................
Clearance in groove . .............
Compression Nos. 2 and 3
TYPE eG
Gapinbore....................
Clearance in groove ..............
Oil control No. 4
TYPE «oo ieee ee eee
Gapinbore....................
Clearance ingrove ...............
Gudgeon pin
Clearance in connectingrod ............
Fitinpiston ................. 0...
Connecting rods
Clearance, bearing tocrankpin ..........
End floatoncrankpin ..................
0,111 mm to 0,134 mm (0.0044 in. to
0.0053 in.)
0,111 mm to 0,157 mm (0.0044 in. to
0.0062 in.)
Square friction edge — chromium plated
0,35 mm to 0,50 mm (0.014 in. to
0.019 in.)
0,06 mm to 0,11 mm (0.0025 in. to
0.0045 in.)
Bevelled friction edge. Marked ‘T or
“TOP” on upper side.
0,25 mm to 0,38 mm (0.010 in. to
0.015 т.)
0,06 mm to 0,11 mm (0.0025 in. to
0.0045 in.)
Expander and rails
0,38 mm to 1,14 mm (0.015 in. to
0.045 in.)
0,038 mm to 0,064 mm (0,0014 in.
to 0.0025 in.)
0,002 mm to 0,020 mm (0.0001 in.
to 0.0008 in.)
Push fit by hand
0,019 mm to 0,068 mm (0.00075 in.
to 0.0027 in.)
0,20 mm to 0,30 mm (0.007 in. to
0,012 in.)
OI-CI
CRANKSHAFT REAR OIL SEAL
Remove and refit 12.21.20
Service Tools: 270304 Guides for oil seal
600963 Engine lifting sling
Removing
Remove the bonnet. 76.16.01.
Remove the front floor. 76.10.12.
Remove the engine assembly. 12.41.01.
Remove the starter motor. 86.60.01.
Remove the oil sump. 12.60.44.
Remove the clutch assembly.
33.10.01.
Remove the flywheel. 12.53.07.
Remove the flywheel housing.
Remove the oil seal ring.
Ln Ba Ua bh —
D 0 —
10 Remove the rear main bearing cap.
11 Remove the lower half of the oil seal
retainer from the rear main bearing
cap.
12 Remove the upper half of the oil seal
retainer from the cylinder block, by
rotating the crankshaft to align the
cut-out with the fixings.
13 Remove the oil seal trom the crank-
shaft.
Refitting
14 Assemble the garter spring on the
crankshaft journal by engaging the
hook and eye. Do not stretch the
spring.
15 Move the assembled spring along the
journal until it is against the thrower
flange.
16 Apply Silicone Grease MS4 to the
crankshaft oil seal journal and to both
end faces of the split oil seal.
17 Open the split seal sufficiently to
allow it to be fitted over the crank-
shaft oil seal journal. The recess in the
oil seal must be towards the thrower
flange and the garter spring.
LR882
NOTE: The oil seal must not be repeatedly
fitted and removed from the crankshaft, as
this can damage the sealing lip.
18 Position the garter spring so that the
hook and eye is located mid-way
between the split and hinge of the oil
seal.
19 Using a small screwdriver, ease the
spring into the recess in the oil seal.
20 Rotate the oil seal until the split is on
the vertical axis pointing towards the
cylinder head and in its approximate
running position on the journal; this
position is important.
NOTE: Do not degrease the seal retainer
halves with trichlorethylene, but wipe
clean with a dry cloth prior to applying
Hylomar.
21 Apply Hylomar PL 32/M jointing com-
pound, to the seal location diameter of
both retainer halves.
22 Locate one half of the oil seal retainer
onto the cylinder block dowels. The
oil seal should be compressed to assist
assembly, also ensure that it is cor-
rectly located in the retainer recess.
CAUTION: The seal must be held so that it
does not rotate when the crankshaft is
being rotated to fit the retainer securing
bolts.
23 Secure the upper half of the oil seal
retainer with the three inner bolts,
leaving the outer bolt at each end
finger tight at this stage.
24 Secure the lower half of the oil seal
retainer to the rear main bearing cap in
the same manner as described for the
upper half.
25 Apply Silicone Grease MS4 to the ‘T°
seals and fit them to the rear main
bearing cap.
26 Trim the top edges of the ‘T’ seals to
prevent them from fouling the cylin-
der block when being fitted.
27 Fit the seal guides to the crankcase.
270304.
“18 13
A
2726243
125 32
28 Fit the rear main bearing cap complete
with the seal retainer, “T” seals and
bearing shell to the crankcase until
there is an 0,8 mm (0.030 in.) gap
between the cap and the crankcase.
29 Check that the seal is correctly located
in the retainer recess.
30 Tighten the bearing cap bolts ensuring
that there is no buckling of the split
seal or misalignment of the butt joint.
Torque: Petrol engines: 11,5 kgf. m
(85 Ibf. ft.). Diesel engines: 13,8 kgf.
m (100 Ibf. ft.).
31 Fully tighten all the bolts securing the
retainer halves. Turn the bolt heads so
that the hexagon corners will not foul
the flywheel housing seal when fitting.
32 Trim the ends of the ‘T’ seals to leave
0,8 mm (0.030 in.) protruding from
the bearing cap.
33 Reverse | to9.
[1-71
CRANKSHAFT
Remove and refit 12.21.33
Removing
1 Remove the bonnet. 76.16.01.
2 Remove the air cleaner. 19.10.04.
3 Remove the radiator and front panel
assembly. 26.40.01.
4 Remove the front floor. 76.10.12.
5 Remove the engine assembly.
12.41.01.
6 Remove the oil sump. 12.60.44.
7 Remove the oil pump. 12.60.26.
8 Remove the timing gear cover.
12.65.01.
9 Remove the timing chain and ten-
sioner. 12.65.28.
Remove the
33.10.01.
Remove the flywheel. 12.53.07.
Remove the flywheel housing.
Remove the oil seal ring.
Remove the connecting rod caps and
bearing lower halves. Retain in related
sets.
[
<
clutch assembly.
jm um ju ju
«Es LD FH
15 Remove the main bearing caps and lift
the crankshaft clear. Retain the bear-
ing halves in related sets.
16 Remove the oil seal from the crank-
shaft.
17 Remove the upper half of the oil seal
retainer from the cylinder block.
18 If required, remove the chainwheel
and key from the crankshaft.
Refitting
NOTE: If replacement components are to
be fitted, the checks detailed in 12.21.46
must be carried out.
19 Locate the upper main bearing halves
into the cylinder block.
20 Lubricate the bearings and crankshaft
journals with clean engine oil, and
place the crankshaft in position.
21 Insert a thrust washer at each side of
the centre main bearing shell with the
unplated faces towards the cylinder
block.
22 Locate the bearing lower halves into
the front and centre main bearing
caps. Fit the caps but do not fully
tighten the fixings at this stage.
23 Fit the crankshaft rear oil seal.
12.21.20.
24 Tighten the front and centre main
bearing cap fixings. Torque: Petrol
engines: 11,5 kgf. m (85 lbf. ft.).
Pe engines: 13,8 kgf. m (100 1bf.
ft.).
25 Fit the appropriate bearing halves and
caps to the connecting rods, using
NEW securing nuts. Torque: 3,5 kgf.
m (25 1bf. ft.).
26 Fit the oil seal ring to the flywheel
housing.
27 Refit the flywheel housing.
128.27
1RC587
28 Refit the flywheel. 12.53.07.
29 Refit the clutch assembly. 33.10.01.
30 Reset the valve timing. 12.65.22.
31 Reverse 1 to 9.
CRANKSHAFT
Overhaul 12.21.46
CAUTION: DO NOT fit an undersize
crankshaft to a Diesel engine. When a
Diesel engine crankshaft is worn, a new
standard size replacement must be fitted,
carrying out the following checks (except
item 3).
1 Remove the crankshaft. 12.21.33.
Inspecting
2 Check each crankshaft journal for
ovality. If ovality exceeds 0,040 mm
(0.0015 in.), a reground or new crank-
shaft should be fitted.
3 Petrol Engines: Bearings for the crank-
shaft main journals and the connecting
rod journals are available in the follow-
ing undersizes:
0,25 (0.010 in.).
0,50 mm (0.020 in.).
0,76 mm (0.030 in.).
1,01 mm (0.040 in.).
4 Thrust washers for the crankshaft
main journal, to control the crankshaft
end float, are available in the following
oversizes:
0,06 mm (0.0025 in.).
0,12 mm (0.005 in.).
0,18 mm (0.0075 in.).
0,25 mm (0.010 in.).
5 Fit the front main bearing cap, less
bearing halves, to the cylinder block.
Torque: Petrol engines: 11,75 kgf. m
(85 Ibf. ft.). Diesel engines: 13,8 kgf.
m (100 Ibf. ft.).
6 Slacken the fixing on one side of the
cap only and check that there is no
clearance at the joint face. If there is
clearance, a complete new cylinder
block must be fitted.
7 Repeat $ and 6 for the centre and rear
main bearing caps.
Main bearing nip and clearance
NOTE: New bearing halves are supplied
with a protective coating and must be
degreased prior to fitting, to remove the
coating.
eT—cl
1RC 295
Locate the bearing halves into the
front main bearing cap and the cylin-
der block, and fit the cap to the block.
Torque: Petrol engines: 11,75 kgf. m
(85 1bf. ft.). Diesel engines: 13,8 kgf.
m (100 Ibf. ft.).
Slacken the fixing on one side of the
cap only and check the clearance
between the joint faces. The clearance
must be 0,10 mm to 0,15 mm (0.004
in. to 0.006 in.).
10 The bearing nip can be corrected by
11
12
13
14
15
16
selective assembly of the bearing
halves; these are available in slightly
varying thicknesses. Do not file or
machine the caps or cylinder block to
vary the bearing nip.
Repeat 8 to 10 for the centre and rear
main bearings.
When the bearing nip has been
checked, remove the caps and bearing
shell bottom halves.
Position a standard size thrust washer
each side of the centre main bearing
shell, top half, with the unplated faces
towards the cylinder block. The thrust
washer thickness must agree within
0,08 mm (0.003 in.).
Place the crankshaft in position on the
cylinder block.
Mount a dial test indicator to read off
the end of the crankshaft.
Check the crankshaft end float limits
are 0,05 mm to 0,15 mm (0.002 in. to
0. 006 in.).
17
IRC 296
18
The crankshaft end float can be
adjusted by fitting oversize thrust
washers. The variation of thrust
washer thickness at each side must not
exceed 0.08 mm (0.003 in.) to ensure
that the crankshaft remains centra-
lised.
Make a final check to prove the main
bearing clearance, using a 0,063 mm
(0.0025 in.) shim paper. Check each
bearing in turn by fitting both bearing
halves and the bearing cap, with the
shim paper between the crankshaft
and one half of the bearing. The
crankshaft should resist rotation with
the shim paper fitted, and move freely
by hand with the shim paper removed.
NOTE: As an alternative, Plastigauge may
be used to check the main hearing clearance
19 to 26. Do not rotate the crankshaft
while the Plastigauge is fitted, or the read-
ing will be impaired.
19
20
21
22
Locate the crankshaft in position on
the upper bearing halves in the cylin-
der block.
Place a piece of Plastigauge across the
centre of the lower half of the crank-
shaft journal. 605238.
Fit the bearing cap complete with the
lower bearing half. Torque: Petrol
engines: 11,75 kgf. m (85 1bf. ft.).
Diesel engines: 13,8 kgf. m (100 Ibf.
ft.).
Remove the bearing cap and lower half
bearing.
23 Using the scale printed on the Plasti-
gauge packet, measure the flattened
Plastigauge at its widest point. The
graduation that most closely cor-
responds with the width of the Plasti-
gauge indicates the bearing clearance.
1RC297 N
DATA
Crankshaft
Journal diameter ..................
Crankpin diameter .................
End float (controlied by thrust washers
at centre bearing)
. 4 #8 = = » = =: =» = = + = + = à
Regrind sizes:- Petrol Engines only:
Main bearing running clearance—Petrol ..
Main bearing running clearance— Diesel
Connecting rod bearing running clearance
(Petroland Diesel) ....................
24 The correct clearance with new or
overhauled components is 0,020 mm
to 0,055 mm (0.0008 in. to 0.0028
in.).
25 If a new bearing is being fitted, use
selective assembly to obtain the
correct clearance.
26 Wipe off the Plastigauge with an oily
rag. DO NOT scrape it off.
27 Retain all components in related sets.
28 Refit the crankshaft. 12.21.33.
63,5 mm — 0,012 mm (2.5 in. — 0.0005
in.)
58,7 mm (2.312 in.)
0,05 mm to 0,15 mm (0.002 to
0.006 in.)
Undersize Journal dia. Crankpin dia.
0,25 mm 63,24 mm 58,47 mm
(0.010 in.) (2,490 in) (2.302 in.)
0,50 mm 62,99 mm 58,22 mm
(0.020 in.) (2.480 in.) (2.292 in.)
0,76 mm 62,73 mm 57,96 mm
(0.300 in.) (2.470 in.) (2.282 in.)
1,01 mm 62,48 mm 57.70 mm
(0.040 in.) (2.460 in.) (2.272 in.)
0,20 mm to 0,072 mm (0.0008 in.
t0 0.00285 in.)
0,20 mm to 0,063 mm (0.0008 in.
to 0.0025 in.)
0,019 mm to 0,068 mm (0.00075
to 0.0027 in.)
ET—TI
CY LINDER PRESSURES — Petrol
Check 12.25.01
Checking
1 Run the engine until it attains normal
operating temperature.
Remove the sparking plugs.
Secure the throttle in the fully open
position.
Check each cylinder in turn as follows:
Insert a suitable pressure gauge into
the sparking plug hole.
Crank the engine with the starter
motor for several revolutions and note
the highest pressure reading obtain-
able.
7 If the pressure is appreciably less than
the correct figure, the piston rings or
valves may be faulty.
8 Low pressure in adjoining cylinders
may be due to a faulty cylinder head
gasket.
Compression ratio:
Compression pressure .................
ON ‘л + Wha
Crankingspeed .......................
CYLINDER PRESSURES—
Diesel
Check 12.25.01
See page 12—23.
CY LINDER SIDE COVERS - Petrol
Remove and refit
Front side cover 1 to 6,
10 and 11 12.25.14
Rear side cover 1, 2, 7 to 10 and
12 to 14 12.25.16
Removing
1 Remove the bonnet. 76.16.01.
2 Remove theair cleaner. 19.10.04.
3 Release the oil filler pipe bracket from
the cylinder block.
4 Remove the front side cover complete
with oil filler pipe.
Withdraw the baffle.
Withdraw the joint washers.
Disconnect the fuel pipes at the fuel
pump.
Withdraw the joint washer.
© —2 OX Л
1RC378
7.0:1
10,2 kgf/cm?
(145 1bf /1n*)
300 rev/min
80:1
11,2 kgf/cm?
(160 1bf/in?)
300 rev/min
Refitting
10 Smear both sides of a new joint washer
with general purpose grease.
11 Reverse 1 to 6. When fitting front the
side cover bolts first engage the tap-
ping nearest to the oil filter pipe.
12 Reverse 7 to 9.
13 Prime the fuel pump by operating the
hand prime lever until no resistance is
felt.
14 Reverse 1 and 2.
CYLINDER SIDE COVERS — Diesel
Remove and refit
Front side cover 1 to 6 and 10 to 12
12.25.14
Rear side cover 1,2, 7 to 10 and
13 to 15 12.25.16
Removing
1 Remove the bonnet. 76.16.01.
2 Remove the air cleaner. 19.10.04.
3 Release the oil filter pipe bracket from
the cylinder block.
4 Remove the front side cover complete
with oil filler pipe.
5 Withdraw the baffle.
6 Withdraw the joint washers.
7 Disconnect the fuel pipes at the fuel
pump.
8 Remove the rear side cover complete
with the fuel pump.
9 Withdraw the joint washer.
Refitting
10 Smear both sides of a new joint washer
with general purpose grease.
11 Reverse 1 to 6. When fitting the side
cover bolts, first engage the tapping
nearest to the oil filler pipe.
12 Align the timing pointer with the
timing mark scribed on the flange of
the fuel distributor pump.
13 Reverse 7 to 9.
14 Prime the fuel system. 19.50.01.
15 Reverse 1 and 2.
vI—TI
CY LINDER HEAD — Petrol
Remove and refit
12.29.10
Removing
‘© 00 ~J ON LA > We
ja — fd pd Ja
Fa Ww в ©
J
wn
16
17
18
19
20
21
Remove the bonnet. 76.16.01.
Remove the air cleaner. 19.10.04.
Disconnect the battery earth lead.
Drain the cooling system.
Disconnect the vacuum pipe at the
distributor.
Disconnect ihe distributor leads at the
ignition coil.
Disconnect the distributor leads from
the sparking plugs.
Remove the sparking plugs.
Remove the fan cowl shroud.
Disconnect the oil gallery pipe.
Disconnect the coolant by-pass hose.
Disconnect the coolant hoses from the
thermostat housing.
Disconnect the carburetter linkage at
the ball joint.
Disconnect the cold start cable at the
carburetter.
Disconnect the fuel inlet pipe at the
carburetter and release the pipe clip at
the cylinder head.
Remove the heat shield from the
manifold.
Disconnect the exhaust pipe at the
manifold.
Remove the valve gear. 12.29.34.
Slacken evenly and remove the remaining
cylinder head fixings.
Lift off the cylinder head.
Withdraw the gasket.
Refitting
CAUTION: If a non-retorque fabric type cylin-
der head gasket is being used it must be fitted
dry, without grease or any sealing compound.
25
22 1f a copper—asbestos gasket is being used,
smear clean engine oil on the cylinder
block and cylinder head gasket joint faces. 26
23 Position the gasket on the cylinder block
with the lettering ‘PETROL’ uppermost. 27
28
Place the cylinder head in position.
Engage all the cylinder head fixing
bolts except those also used to secure
the rocker shaft assembly.
NOTE: Plain washers are fitted between
the cylinder head bolts and the cylinder
head on later engines.
Place the push rods into position and
ensure that they bottom correctly into
the spherical seats in the tappet slides.
Fit the rocker shaft assembly and
engage the fixings.
Secure the cylinder head and rocker
shaft fixings in the sequence illus-
trated. Torque: 1/2 in. UNF bolts 8,9
kgf. m (65 Ibf. ft.). 5/16 in. UNF bolts
2,4 kgf. m (18 bf. ft.).
4
O o O O
O O O O ©
6 2 6 ° 3 \4 8 4 18
5 à Eb #4 К
I 3 5 13
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FRONT >
IRC228 ;
1-71
29
30
31
32
33
34
Set the tappet clearances to 0,25 mm
(0.010 in.) for all valves as follows:
Set No. 1 tappet with No. 8 valve fully
open.
Set No. 3 tappet with No. 6 valve fully
open.
Set No. 5 tappet with No. 4 valve fully
open.
Set No. 2 tappet with No. 7 valve fully
open.
Set No. 8 tappet with No. 1 valve fully
open.
Set No. 6 tappet with No. 3 valve fully
open.
Set No. 4 tappet with No. 5 valve fully
open.
Set No. 7 tappet with No. 2 valve fully
open.
Recheck the tappet clearances with
the locknuts tightened, and readjust if
necessary.
Place the joint washer for the engine
top cover in position.
Fit the engine top cover.
Reverse 1 to 17.
After the initial engine run, that is
with the engine at normal running
temperature, check the cylinder head
fixings to the correct torque load with
the sparking plugs removed.
\RC230
CYLINDER HEAD — Diesel
Service tool:
Remove and refit
12.29.10
606445 Spanner for cylin-
der head bolts
Removing
1 Remove the bonnet. 76.16.01.
2 Remove the air cleaner. 19.10.04.
3 Disconnect the battery earth lead.
4 Drain the cooling system.
5 Discoñnect the fuel spill pipes at the
XD ÓN
injector end.
Disconnect the oil gallery pipe.
Disconnect the electrical feed to the
heater plugs.
Disconnect the electrical lead from the
water temperature transmitter.
Disconnect the breather hose from the
engine top cover.
If a brake servo unit is fitted, dis-
connect the vacuum pipe and the
butterfly control rod from the induc-
tion manifold.
Disconnect the exhaust pipe at the
manifold.
continued
1RC 335
IRC337 —
91—CI
12
13
14
Disconnect the heater hoses if fitted.
Disconnect the coolant hose from the
thermostat housing.
Disconnect the coolant by-pass hose.
15
Slacken the fuel injector feed pipes at
the distributor pump and disconnect
them from the injectors.
18
19
Remove the valve gear. 12.29.34.
Slacken evenly and remove the remain-
ing cylinder head fixings.
Lift off the cylinder head.
Withdraw the gasket.
Refitting
CAUTION: If a non-retorque fabric type cylin-
der head gasket is being used it must be fitted
dry, without grease or any sealing compound.
Refitting
20
21
22
23
24
If a copper-asbestos type gasket is being
fitted, thinly coat both sides of the gasket
with Hylomar PL 32/M jointing
compound.
Position the gasket on the cylinder
block with the lettering ‘DIESEL’
uppermost.
Place the cylinder head in position.
Engage all the cylinder head fixings
except those that also secure the
rocker shaft assembly.
NOTE: Five main bearing engines and
later three main bearing engines have
plain washers fitted between the cylinder
head bolts and the cylinder head.
Place the push rods into their original
bores and ensure that they bottom
correctly into the spherical seats in the
tappet slides.
Fit the rocker shaft assembly and
engage the fixings.
IRC 340
25
26
Secure to 1/2 in. UNF cylinder head
fixings. 606445. Torque 12,5 kgf. m
(90 1bf. ft.).
Secure the 5/16 in. UNF rocker shaft
fixings. Torque 2,4 kgf. m (18 lbf. ft.).
7 26 & 33
© O O C À
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6 8 8
5 13
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18341
27
28
Set the tappet clearances to 0,25 mm
(0.010 in.) for all values, as follows:
Set No. 1 tappet with No. 8 valve fully
open.
Set No. 3 tappet with No. 6 valve fully
open.
Set No. 5 tappet with No. 4 valve fully
open.
Set No. 2 tappet with No. 7 valve fully
open.
Set No. 8 tappet with No. 1 valve fully
open.
Set No. 6 tappet with No. 3 valve fully
open.
Set No. 4 tappet with No. 5 valve fully
open.
Set No. 7 tappet with No. 2 valve fully
open.
Recheck the tappet clearances with
the locknuts tightened, and readjust if
necessary.
L1—T
29 Place the joint washer for the engine
top cover in position.
30 Fit the engine top cover.
Reverse 1 to 15.
31
32 Start and run the engine until it attains
33
normal operating temperature.
Remove the engine top cover, and
while the engine is hot, check/tighten
all the 1/2 in. UNF cylinder head
fixings in the order shown. 606445.
Torque 12,5 kgf. m (90 Ibf. ft.).
CY LINDER HEAD — Petrol
Service tools:
Overhaul
12.29.18
276102 Valve spring com-
pressor
274400 Inlet valve guide
remover
274401 Exhaust valve guide
remover
600959 Exhaust valve guide
replacer
601508
replacer
MS627 Inlet valve seat cutter
MS621 Exhaust valve seat
cutter
MS76 Hand set
MS150—8 Adjustable pilot
MS150—8.5 Adjustable pilot
Inlet valve guide
Dismantling
1
2
3
4
5
6
4 pr 7
IRC A
Remove the cylinder head. 12.29.10.
Remove the induction and exhaust
manifold assembly. 30.15.01.
Remove the thermostat housing com-
plete.
Remove the valve assemblies and
retain the components in related sets.
Compressor 276102.
Withdraw the oil seals from the valve
guides.
Clean the combustion chambers and
piston crowns with a soft wire brush.
7
8
Clean the valves.
Clean the valve guide bores.
IRC 236
10
11
12
13
Nu
Regrind or fit new valves as necessary.
The correct angle for the inlet valve
face is 30 — % .
The correct angle for the exhaust valve
face is 45 — YA.
The correct angle for the inlet valve
seat is 30 +%4 .
The correct angle for the exhaust vaive
seat is 45 +4 .
12
a$+4
30°+ 4
Учим,
14
16
17
18
19
20
IRC238 TN CA
Check the valve guides and fit replate-
ments as necessary. 15 to 17.
Drive out the old guides from the
combustion chamber side. 274400 and
274401.
Lubricate the new valve guides and
drive them into position. 600959 and
601508.
Check and if necessary, reface the
valves and seats, as previously des-
cribed.
Inspect the valve springs which are
provided as paired assemblies. The
springs must be an interference fit
with each other.
Inspect the valve split cones and valve
spring caps for general condition.
Inspect the cylinder head for general
condition and for damage to threads.
continued
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SIA NE ON
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8I—Tl
Assembling
21
22
23
24
25
26
27
28
29
Fit the oil seals, fitted with springs, to
the inlet valve guides.
Fit the oil seals, with external projec-
tions, to the exhaust valve guides.
Lubricate the valve stems and guides
with engine oil and fit each valve as
follows:
Insert the valve into its respective
guide.
Place the valve springs in position.
Locate the cap on the springs.
Compress the springs and fit the valve
collets. 276102.
Reverse 1 to 3.
After the initial engine run, that is
with the engine at normal running
temperature, check the cylinder head
fixings to the correct torque load with
the sparking plugs removed. Torque
1/2 UNF bolts 8,9 kgf. m (65 1bf. ft.).
о UNF bolts 2,4 kgf. m (18 lbf.
ft.).
DATA
Cylinder Head
Inlet valve seat angle ...............
Exhaust valve seat angle ............
Valves
Inlet valve .........oomroornedare.
Diameterofstem..................
Faceangle .......................
Exhaustvalve ....................
Diameterofstem..................
Face angle ........ooerecorrecoreoo.
Valve guides
Inlet bore size, after fitting ..........
Exhaust bore size after fitting ........
Valve Springs
Inner
Length, free ......................
Length, under 8,0 kg (17.7 1b) load . ...
Outer
Length, free. ................c.c....
Length, under 21 kg. (46 1b) load .....
1RC240
30° +4
45° + 4°
7,88 mm to 7,90 mm (0.3107 in. to
0.3112 in.)
30° — 4°
8,65 mm to 8,67 mm (0.3410 in. to
0.3415 in.)
45 —%
7,93 mm to 7,97 mm (0.3125 in. to
0.3140 in.)
8,73 mm to 8,77 mm (0.3435 in. to
0.3450 in.)
42,67 mm (1.680 in.)
37,13 mm (1.462 in.)
46,28 mm (1.822 in.)
40,30 mm (1.587 in.)
CYLINDER HEAD — Diesel
Overhaul
12.29.18
Service tools: 276102 Valve spring com-
pressor
274400 Inlet valve guide
remover
274401 Exhaust valve guide
remover
600959 Exhaust valve guide
replacer
601508 Inlet valve guide
replacer
530625 Exhaust seat insert
replacer
MS 621 Inlet and exhaust
valve seat cutter
MS 76 Hand set
MS 150—8 Adjustable pilot
MS 150—8.5 Adjustable pilot
Dismantling
A U BD FH
ms AD CO — ON
= ©
13
Remove the cylinder head. 12.29.10.
Remove the induction and exhaust
manifold assembly. 30.15.01.
Remove the injectors. 19.60.01.
Remove the thermostat housing com-
plete.
Remove the valve assemblies and
retain the components in related sets.
Compressor 276102.
Withdraw the oil seals from the valve
guides.
Clean the combustion chambers and
piston crowns with a soft wire brush.
Clean the valves.
Clean the valve guide bores.
Regrind or fit new valves as necessary.
The correct angle for jnlet and exhaust
valve faces is 45 — 4 .
The correct angle for „the inlet and
exhaust valve seats is 45 +4 .
Check the valve guides and fit replace-
ments as necessary. 14 to 16.
45%
{RC IA
non
61-21
14 Drive out the old guides from the
combustion chamber side. 274400 and
274401.
IRC 348
15 Lubricate the new valve guides and
drive them into position. 600959 and
601508.
16 Check and if necessary, reface the
valves and seats, as previously des-
cribed.
17 Inspect the valve springs which are
provided as paired assemblies. The
springs must be an interference fit
with each other.
18 Inspect the valve collets and valve
springs caps for general condition.
19 Check the exhaust valve seats and fit
replacements as necessary.
20
21
22
23
24
Remove the valve guides from the
applicable exhaust ports.
Remove the old seat inserts by grind-
ing them away until they are thin
enough to be cracked and prised out.
Place the new seat insert in position.
Locate the replacer tool 530625, onto
the seat insert.
Using a suitable nut and bolt, pull the
insert into the recess in the cylinder
head.
Fit the valve guides as previously
detailed. о о
Cut the valve seats to 45 +% .
Check the push rod tubes and seals
and fit replacements as necessary. 28
to 32.
Drive out the old push rod tubes from
valve gear side. Using a suitable drift.
29 Fit new sealing rings to new push rod
tubes and smear them with MS4 sili-
cone grease.
IRC 352 _
30 Insert the new tubes, chamfered end
first, from the combustion chamber
side.
31 Align the flat on the push rod tube at
right angles to an imaginary line
between the centre of the push rod
tube and the centre of the hot plug.
—
A
„“
32 Press the push rod tubes into position
ensuring that the alignment is main-
tained and that the chamfers on the
tubes and in the cylinder head are
fully engaged.
Hot plugs (combustion chamber) and in-
jector shrouds
When carrying out normal top overhaul
work on the cylinder 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 approxi-
mately 8,0 mm (0.312 in.) in length can be
ignored. However if any severe cracks
appear on the face of the hot plug, before
attempting to remove it, closely inspect the
cylinder head for signs of cracks, particu-
larly 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.
continued
Oc-—cl!
33
34
35
36
37
38
To remove a hot plug, insert a thin
soft metal drift through the injector
shroud throat and tap the hot plug
from the inside. Once removed the hot
plug is scrap.
If the injector shroud is damaged, drift
the shroud out towards the injector
bore.
Throughly clean out the combustion
chamber. The hole in the side of the
injector shroud is for manufacturing
purposes only but at the same time
can be used as a guide when refitting
the shroud.
Smear a little oil on the shroud and
insert into the cylinder head with the
hole pointing towards the centre of
the cylinder head, and drift into
position. 274399.
Fit the hot plugs by tapping with a
hide-faced mallet. :
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 0,025 mm (0.001 in.)
and are not recessed below the level of
the cylinder head face more than 0,05
mm (0.002 in.).
/
33, 37838
1RC354
NOTE: If the hot plugs are loose in the
cylinder head they may be retained with a
little grease.
Assembling
39
40
41
42
43
44
45
Fit the oil seals, fitted with springs, to
the inlet valve guides.
Fit the oil seals, with external pro-
jectors, to the exhaust valve guides.
Lubricate the valve stems and guides
with engine oil and fit each valve as
follows:
Insert the valve into its respective
guide.
Place the valve springs in position.
Locate the cap on the springs.
Compress the springs and fit the valve
collets. 276102.
46 Reverse 1 to 4.
47
After the initial engine run, that is
with the engine at normal running
temperature, check the cylinder head
fixings to the correct torque load.
606445. Torque: 1/2 in. UNF fixings
12,5 kgf. m (90 1bf. ft.). 5/16 in. UNF
fixings 2,4 kgf. m (18.1bf. ft.).
DATA
Cylinder Head
Inlet valve seat angle ...............
Exhaust valve seat angle ............
Valves
Inlet valve
Diameterof stem ...............
Faceangle .....................
Exhaust valve
Diameter ofstem ...............
Faceangle .....................
Valve guides
Inlet guide bore size, after fitting .....
Exhaust guide bore, after fitting ......
Valve springs
Inner
Length, free ...................
Length, under 8,0 kg (17.7 1b.) load .
Outer
Length, free ...................
Length, under 21 kg (46 1b) load . ..
45° + 1°
45° + 44°
7,88 mm to 7,90 mm (0.3107 in. to
0.3112 in.)
45 —%
8,65 mm to 8,67 mm (0.3410 in. to
0.3415 in.)
45 — Ya
7,93 тт to 7,97 mm (0.3125 in. to
0.3140 in.)
8,73 mm to 8,77 m (0.3435 in. to
0.3450 in.)
42.67 mm (1.680 in.)
37,13 mm (1.462 in.)
46,28 mm (1.822 in.)
40,30 mm (1.587 in.)
IC-Cl
VALVE GEAR — Petrol
Remove and refit
12.29.34
Removing
> WN =
Remove the bonnet. 76.16.01.
Remove the air cleaner. 19.10.04.
Remove the engine top cover.
Slacken locknuts and turn tappet
adjusting screws to disengage from
push rods.
Remove fixings from rocker shaft
support brackets. Do not remove shaft
assembly at this stage.
Withdraw the rocker shaft assembly
complete, using the engine top cover
secured inverted to the rocker bracket
studs to retain the assembly.
Withdraw the tappet push rods and
retain them in numbered sequence
related to the tappet served.
Refitting
8
1RC 218
Fit the tappet push rods to their
original bores. Ensure that the bottom
end of the push rods locate in the
spherical tappet seats.
Refit the rocker shaft assembly,
located by spigots. Torque: 1/2 in.
UNF bolts: 8,9 kgf. m (65 Ibf. ft.).
5/16 in. UNF bolts: 2,4 kgf. m (18 Ibf.
ft.).
10 Check tighten all 1/2 in UNF cylinder
head fixings in the order shown.
Torque: 8,9 kgf. m (65 1bf. ft.).
10
/
707
2 5 % >
©
6
5
Ó
IRC217
DATA
11
12
13
14
Set the tappet clearances to 0,25 mm
(0.010 in.) for all valves, as follows:
Set No. 1 tappet with No. 8 valve fully
open.
Set No. 3 tappet with No. 6 valve fully
open.
Set No. 5 tappet with No. 4 valve fully
open.
Set No. 2 tappet with No. 7 valve fully
open.
Set No. 8 tappet with No. 1 valve fully
open.
Set No. 6 tappet with No. 3 valve fully
open.
Set No. 4 tappet with No. 5 valve fuily
open.
Set No. 7 tappet with No. 2 valve fully
open. .
Recheck the tappet clearances with
the locknuts tightened, and readjust if
necessary.
Place the joint washer for the engine
top cover in position.
Reverse 1 to 3.
0,25 mm (0.010 in.) inlet and exhaust.
CCC
VALVE GEAR — Diesel
Remove and refit 12.29.34
Service tool: 606445 Spanner for cylin-
der head bolts
Removing
| Remove the bonnet. 76.16.01.
2 Remove the air cleaner. 19.10.04.
3 Disconnect the breather hose from the
engine top cover.
4 Remove the engine top cover.
5 Slacken locknuts and turn tappet
adjusting screws to disengage from
push rods.
6 Remove fixings from rocker shaft
support brackets. Do not remove shaft
assembly at this stage.
7 Invert the engine top cover and secure
it to the studs on the rocker brackets.
Withdraw the rocker shaft assembly
complete, using the engine top cover
to retain the assembly.
8 Withdraw the tappet pushrods and
retain them in numbered sequence
related to the tappet served.
Refitting
9 Fit the tappet pushrods to their
original bores. Ensure that the bottom
end of the push rods locate in the
spherical tappet seats.
10 Fit the rocker shaft assembly, located
by spigots. Torque: 1/2 in. UNF bolts:
12,5 kgf. m (90 lbf. ft.). 5/16 in. UNF
bolts: 2,4 kgf. m (19 Ibf. ft.).
IRC 330
11 Check tighten all the 1/2 in. UNF
cvlinder head fixings in the order
shown. 606445. Torque: 12,5 kgf. т
(90 Ibf. ft).
11817
O
9
O
FRONT msi
IRCI32
O 575 O в
2 96/34 О
|
IRC 331
12 Set the tappet clearance to 0,25 mm
(0.010 in.) for all valves, as follows:
Set No. 1 tappet with No. 8 valve fully
open.
Set No. 3 tappet with No. 6 valve fully
open.
Set No. 5 tappet with No. 4 valve fully
open.
Set No. 2 tappet with No. 7 valve fully
open.
Set No. 8 tappet with No. 1 valve fully
open.
Set No. 6 tappet with No. 3 valve fully
open.
Set No. 4 tappet with No. 5 valve fully
open.
Set No. 7 tappet with No. 2 valve fully
open.
13 Recheck the tappet clearances with
the locknuts tightened, and readjust if
necessary.
E7—Tl
14
15
16
17
18
Place the joint washer for the engine
top cover in position.
Reverse | to 4.
Start and run the engine until it is hot.
Remove the engine top cover, and
while the engine is hot, check/tighten
all the 1/2 in. UNF cylinder head
fixings in the order shown. 606445.
Torque: 12,5 kgf. m (90 Ibf. ft.).
Refit the engine top cover.
DATA
Tappet clearance ..................
CYLINDER PRESSURES —
Diesel
Check
12.25.01
Checking
1
2
Run the engine until it attains normal run-
ning temperature.
Stop the engine and open the bonnet. Dis-
connect the inlet pipe from the fuel distri-
bution pump to prevent the engine starting
during the following check.
Remove the injector from the cylinder to
be checked. The three remaining injectors
must be securely fitted to the cylinder
head.
Secure the manifold butterfly valve
(accelerator) in the fully open position.
Insert a suitable pressure gauge into the
injector hele in the cylinder head.
Crank the engine with the starter motor
for several revolutions and note the high-
est pressure reading obtained. For a cylin-
der in good condition the pressure should
be 31,0 to 33,0 kgf/cm?
If the pressure is considerably less than the
minimum figure, the piston rings or valves
may be faulty.
0,25 mm (0.010 in.) inlet and exhaust.
50
Refit the injector and repeat the foregoing
check on the three remaining cylinders.
Low pressure in adjoining cylinders may
be due to a faulty cylinder head gasket.
Reconnect the inlet pipe to the fuel distri-
bution pump.
ROCKER SHAFT ASSEMBLY
Overhaul
12.29.55
Dismantling
Remove the valve gear. 12.29.34.
Remove the locating screw and washer
from the intermediate rocker bracket.
Withdraw all the components from the
rocker shaft.
Remove the tappet adjustment screws.
Inspecting
5
10
11
Rocker brackets. Ensure the oil feed
holes are clear. Inspect the locating
dowel spigots; the spigots must be
undamaged to ensure a correct fit on
the locating dowels in the cylinder
head.
Valve rockers:
a Valve rocker for 2% litre Petrol
engines.
b Valve rocker for 2% litre Diesel
engines.
c Visually inspect the rocker bushes
for wear. If necessary, press re-
placement bushes into the rockers
and ream to 13,5 mm + 0,02 mm
(0.530 in. + 0.001 in.). The oil
holes in the rocker bushes are
pre-drilled and must be aligned
with the oil holes in the valve
rocker when assembled.
Check that all oil passage drillings are
clear.
Tappet adjusting screws and locknuts.
Examine threads for damage. Check
that the oil relief drilling is clear.
Inspect the rocker shaft for wear and
scores; check that the oil feed holes
are clear.
Examine the rocker shaft springs,
spacing washers and the locating screw
for soundness and general condition.
Fit an intermediate rocker bracket to
the rocker shaft and engage the locat-
ing screw through the bracket and into
the larger hole in the shaft.
continued
2KC IN
PCI
12 Petrol engines — Assemble the com-
ponents to the rocker shaft as illus-
trated and note the assembled position
of the spacing washers and the handed
valve rockers.
13 Diesel engines — Assemble the com-
ponents to the rocker shaft as illus-
trated and note the assembled position
of the spacing washers and the handed
valve rockers.
14 Refit the tappet adjustment screws.
15 Refit the valve gear. 12.29.34.
1RC224
DATA
Rockers
Bush internal diameter, reamed in posi-
BOM. «ov PSN
Shaft clearance in rocker bush:
Petrolengines ..................
Diesel engines ..................
13,40 mm to 13,42 mm (0.530 in. to
0.531 in.)
0,013 mm to 0,038 mm (0.0005 in. to
0.0015 in.)
0,013 mm to 0,062 mm (0.0005 in. to
0.0025 in.)
TAPPETS
Remove and refit 12.29.57
Service tool: 530101 Tappet Guide re-
mover
Removing
1 Remove the bonnet. 76.16.01.
2 Remove the air cleaner. 19.10.04.
3 Disconnect the battery earth lead.
4 Remove the valve gear. 12.29.34.
5 Remove the cylinder head. 12.29.10.
6 Remove the tappet guide locating
bolts from the right hand side of the
cylinder block.
CAUTION: Do not remove the tappet
guides before the rollers have been with-
drawn, otherwise the rollers may fall
behind the camshaft.
7 Using long nose pliers or a suitably
made wire clip, withdraw the tappet
slides and retain in sequence.
8 Withdraw the tappet rollers and retain
with the related slides.
9 Withdraw the tappet guides and retain
in sequence, with the other related
parts.
10 If the guides are difficult to withdraw,
use Service Tool 530101.
:
4 , In
“lunar
1RC 247
Refitting
li Fit the tappet guides in the sequence
removed, aligning the locating holes.
12 Engage the locating bolts sufficient to
retain the guides.
so
1RC246
13 Fit the tappet rollers with the larger
chamfer towards the front of the
engine.
14 Fit the tappet slides with the marking
‘FRONT’ towards the front of the
engine.
15 Tighten the tappet guide locating bolts
and secure in pairs by wire-locking.
16 Reverse I to 5.
1RC248
Sa-cl
ENGINE ASSEMBLY — Petrol
Remove and refit 12.41.01
Service tool: 600963 Engine sling
Removing
I Remove the bonnet. 76.16.01.
2 Remove the air cleaner. 19.10.04.
3 Remove the radiator and front panel
assembly. 26.40.01.
4 Remove the bell housing cover.
76.10.71.
5 Disconnect the exhaust pipe at the
manifold.
1RC 180A
6 Disconnect the heater hoses and
trunion if fitted.
7 Disconnect the carburetter linkage at
the ball joint.
8 Disconnect the cold start cable at the
carburetter.
9 Disconnect the distributor leads from
the coil.
10 Disconnect the engine earth cable.
{ Ny TE
IRC185
11 Disconnect the fuel inlet pipe at the
fuel pump.
12 Release the clutch fluid pipe from the
clips at the rear of the engine.
13 Disconnect the starter motor leads at
the solenoid.
14 Disconnect the electrical leads from
the alternator.
15 Disconnect the engine electrical leads
at the multi plug adjacent to the dash.
IRCIBI /
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16 Release the disconnected electrical
leads from the retaining clips at the
dash panel.
17 Release the speedometer drive cable
from the clip at the engine.
18 Disconnect the vacuum pipe from the
distributor where applicable.
MY
|
19 Remove the upper fixings from the
engine mounting rubbers.
20 Attach a suitable lifting sling and hoist
to the engine lifting hooks. 600963.
21 Remove the bottom fixing from the
left hand engine mounting rubber.
22 Remove the support bracket fixings
from the right hand engine mounting
rubber. |
23 Tension the hoist sufficient to with-
draw the engine mounting rubbers,
then lower the engine to its original
position to maintain alignment with
the gearbox.
IRC182
24 Remove the fixings securing the bell
housing to the flywheel housing.
25 Move the clutch slave cylinder aside
without disconnecting the fluid pipe.
continued
IRC184
97—51
26 Support the gearbox assembly by insert-
ing a suitable piece of timber 25 mm thick
between the gearbox and cross-member.
27 Draw the engine forward to release it
from the dowelled location to the bell
housing, and to clear the primary
pinion from the clutch.
28 Lift the engine clear.
Refitting
29 Attach a suitable lifting sling and hoist to
the engine lifting hooks. 600963, and
smear the splines of the primary pinion,
the clutch centre, and the withdrawal unit
abutment faces with Molybdenum disul-
phide grease such as Rocol MTS 1000.
30 Lower the engine into position, locat-
ing the primary pinion into the clutch
and engage the bell housing dowels.
31 Secure the bell housing to the flywheel
housing.
32 Tension the hoist sufficient to remove the
timber support from the gearbox and
insert the engine front mounting rubbers.
33 Lower the engine and secure the
engine mounting upper and lower fix-
ings.
34 Remove the engine lifting sling.
35 Reverse 1 to 18.
36 Check, and if necessary replenish the
engine lubricating oil.
37 Check, and if necessary replenish the
gearbox lubricating oil.
38 Start the engine. Check that the oil
pressure warning light goes out, and
check the cooling system for leaks.
39 Check, and if necessary adjust, the
engine idle speed.
40 Check, and if necessary adjust, the
ignition timing.
41 When the engine is cold, check the
coolant level in the radiator and top
up if necessary.
ENGINE ASSEMBLY — Diesel
Remove and refit 12.41.01
Service tool: 600963 Engine sling
Removing
1 Remove the bonnet. 76.16.01.
2 Disconnect the battery earth lead.
3 Remove the air cleaner. 19.10.01.
4 Remove the radiator and front panel
assembly. 26.40.01.
5 Remove the front floor. 76.10.12.
6 Disconnect the exhaust pipe at the
manifold.
\ N
0900
7 Disconnect the heater hoses, if fitted.
8 Disconnect the starter motor leads.
9 Disconnect the alternator leads.
7
IRC 318
10 Disconnect the engine earth cable.
11 Disconnect the electrical feed to the
heater plugs.
12 Disconnect the fuel pipe to the fuel
pump.
13 Disconnect the fuel inlet pipe from the
distributor pump.
14 Disconnect the fuel spill pipe at No. 4
injector.
A
\
|
IRCHE ii |
15 Disconnect the electrical lead from the
oil pressure switch.
IRC 319
LT—t1
18
19
Disconnect the electrical lead from the
water temperature transmitter.
Disconnect the accelerator linkage at
the fuel distributor pump.
If a brake servo unit is fitted, dis-
connect the vacuum pipe and the
butterfly control rod from the induc-
tion manifold.
Remove the upper fixings from the
engine mounting rubbers.
20
21
22
23
Attach a suitable lifting sling and hoist
to the engine lifting hooks. 600963.
Remove the bottom fixing from the
left hand engine mounting rubber.
Remove the support bracket fixings
from the right hand engine mounting
rubber.
Tension the hoist sufficient to with-
draw the engine mounting rubbers,
then lower the engine to its original
position to maintain alignment with
the gearbox.
IRC 325
24 Remove the fixings securing the bell
housing to the flywheel housing.
25 Move the clutch slave cylinder aside
without disconnecting the fluid pipe.
1RC326
26 Support the gearbox assembly by insert-
ing a piece of timber 25 mm thick (1.0 in)
between the gearbox and cross-member.
27 Draw the engine forward to release it
from the dowelled location to the bell
housing, and to clear the primary
pinion from the clutch.
28 Lift the engine clear.
Refitting
29.
30
31
32
33
34
35
36
37
38
39
40
41
Clean the engine and bell housing mating
faces of old sealant. Re-coat the faces with
Hylomar PL.32 Sealant.
Attach a suitable lifting sling and hoist to
the engine lifting hooks. 600963, and
smear the splines of the primary pinion,
the clutch centre and the withdrawal unit
abutment faces with Molybdenum disul-
phide grease, such as Rocol MTS 1000.
Lower the engine into position, locat-
ing the primary pinion into the clutch
and engage the bell housing dowels.
Secure the bell housing to the flywheel
housing.
Tension the hoist sufficient to remove the
timber support from the gearbox and
insert the engine mounting rubbers.
Lower the engine and secure the
engine mounting upper and lower fix-
ing.
Remove the engine lifting sling.
Reverse 1 to 18 and prime the fuel
system. 19.50.01.
Check, and if necessary replenish, the
engine lubricating oil.
Check, and if necessary replenish, the
gearbox lubricating oil.
Start the engine. Check that the oil
pressure warning light goes out, and
check the cooling system for leaks.
Check, and if necessary adjust, the .
engine speed settings.
When the engine is cold, check the
coolant level in the radiator and top:
up if necessary.
8C—CI
FLYWHEEL
Remove and refit 12.53.07
Removing
1 Remove the front floor. 76.10.12.
2 Removetheseat base. 76.70.06.
3 Remove the engine assembly. 12.41.01.
4
Remove the clutch assembly.
33.10.01.
5 Remove the flywheel bolts with the
aid of a flywheel trap.
Refitting
6 Fit the flywheel to the crankshaft and
tighten the securing bolts. Torque: 8,5
to 9,0 kgf. m (60 to 65 1bf. ft.).
7 Mount a dial test indicator to read off
the flywheel face.
8 Check the run-out on the flywheel
face, this must not exceed 0,05 mm
(0.002 in.).
9 If the run-out is excessive, remove the
flywheel and investigate the cause.
10 Reverse 1 to 4.
Overhaul 12.53.10
Procedure
1 Remove the flywheel. 12.53.07.
Wear or scoring on the flywheel pres-
sure face may be corrected by machin-
ing, providing that the overall thick-
ness of the flywheel is not reduced
below the following applicable dimen-
sion.
Petrol engines 34,72 mm (1.375 in.)
Diesel engines 36,957 mm (1.455 in.)
2 Check the overall thickness of the
flywheel, as it may have been pre-
viously machined.
3 If the flywheel is above the minimum
thickness, the clutch face can be
— refacedas follows:
4 Remove the dowels.
5 Reface the flywheel over the complete
surface.
6 Check the overall thickness of the
flywheel to ensure that it is still above
the minimum thickness.
7 Fit the dowels.
8 Refit the flywheel. 12.53.07.
ARC 604A
286
IRC 310
STARTER RING GEAR
Remove and refit 12.53.19
Removing
1 Remove the flywheel. 12.53.07.
2 Drill an 8,0 mm (0.312 in.) diameter
hole axially between the root of any
tooth and the inner diameter of the
starter ring sufficiently deep to
weaken the ring DO NOT allow the
drill to enter the flywheel.
3 Secure the flywheel in a vice fitted
with soft jaws.
4 Place a cloth over the flywheel to
protect the operator from flying frag-
ments.
WARNING: Take adequate precautions
against flying fragments as the starter ring
may fly asunder when being spilt.
5 Place a chisel immediately above the
drilled hole and strike it sharply to
split the starter ring.
Refitting
6 Heat the starter ring gear uniformly to
between 225 C and 250 C (437 F and
482 F) but do not exceed the higher
temperature.
7 Place the flywheel, flanged side down,
on a flat surface.
8 Locate the headed starter ring gear in
position on the flywheel with the
square edge of the teeth against the
flywheel flange.
9 Press the starter ring gear firmly
against the flange until the ring con-
tracts sufficiently to grip the flywheel.
10 Allow the flywheel to cool gradually
DO NOT hasten cooling in any way.
11 Refit the flywheel. 12.53.07.
1 RC 309A
SPIGOT BEARING
Remove and refit 12.53.20
Removing
1 Remove the flywheel. 12.53.07.
2 Press the spigot bearing from the
flywheel.
2—]
DA
Hi
IRC 311 |
Refitting
3 Press in the new spigot bearing flush
with the clutch side of the flywheel.
4 Ream the spigot bearing to 22,237
mm to 22,242 mm (0.8755 in. to
0.8757 in.).
5 Refit the flywheel. 12.53.07.
67—€CI
OIL FILTER ASSEMBLY
— EXTERNAL
Remove and refit 12.60.01
Removing
1 Prop open the bonnet.
2 Disconnect the electrical lead from the
oil pressure switch.
3 Remove the oil filter.
4 Withdraw the joint washer.
Refitting
5 Smear both sides of the joint washer with
general purpose grease.
6 Place the joint washer in the correct posi-
tion on the cylinder block and fit the filter,
pehtening the bolts to 3,45 kgf m (25 Ibf
t).
7 Reconnect electrical lead.
8 Check the sump oil level after a short
engine run and top up as necessary to the
‘high’ mark on the oil level dipstick.
OIL PUMP
Remove and refit 12.60.26
Removing
1 Remove the oil sump. 12.60.44.
2 Remove the oil pump.
3 Withdraw the oil pump drive shaft.
Refitting
4 Locate the longer splined end of the
drive shaft into the oil pump.
5 Apply Hylomar Sealant to joint face of
pump body and fit gasket. (Gasket fitted
on later engines.)
Offer up the pump and drive shaft and
engage the drive splines at the engine.
Secure the oil pump.
Fit the oil sump. 12.60.44.
Replenish the engine lubricating oil to
the ‘high’ mark on the oil level dip-
stick.
10 Check the sump oil level after a short
engine run and top up as necessary to
the ‘high’ mark on the oil level dip-
stick.
O00 —} CN
1RC207
OIL PUMP
Overhaul 12.60.32
Dismantling
Remove the oil pump. 12.60.26.
Straighten the lockwasher for the oil
filter union nut.
Unscrew the oil filter union nut.
Withdraw the oil filter.
Withdraw the sealing ring.
Remove the oil pump cover.
Withdraw the pump gears.
Remove the plug for the oil pressure
relief valve.
Withdraw the sealing washer.
0 Withdraw the oil pressure relief valve
spring, plunger and ball.
= NO 009 +3 ON tn A ND
Inspecting
11 If necessary the idler gear bush may be
renewed. Press the new bush into the
gear, drill the lubrication hole 3,175
mm (0.125 in.) diameter and ream
the bush to 12,7 mm (0.500 in.)
diameter.
12 Inspect the pressure relief valve ball
seating and renovate, if necessary,
using a locally manufactured lapping
tool consisting of a steel ball, Rover
Part No. 3748, soldered to suitable
tubing.
13 The lapping tool may be installed in a
drilling machine or hand brace and the
ball seating refaced, using coarse grind-
ing paste. The tool may then be
removed and used to ‘hand lap’ the
ball seating with fine grinding paste to
a good finish. The seat must then be
thoroughly cleaned.
continued
IRC 263
IRC264
0€—C1
14
15
16
17
18
19
20
21
22
Check the end float of the oil pump
gears, as follows 15 and 16, and fit
new parts as necessary.
Steel gear: 0,05 mm to 0,12 mm
(0.002 in. to 0.005 in.).
Aluminium gear: 0,07 mm to 0,15 mm
(0.003 in. to 0.006 in.).
Fit the pump gears to the body, with
the plain portion of the drive gear bore
uppermost.
Smear the joint faces with suitable
jointing compound and fit the pump
cover to the pump body, locating on
the dowels.
Assemble the pressure relief valve com-
ponents to the housing bore. When
fitting the plunger, insert the end with
the integral ball seating first.
Fit the oil filter to the pump.
Position the filter such that it will be
square to the sump baffle plate when
fitted and secure with the lock-washer.
Fit the oil pump to the engine.
12.60.26.
DATA
Pump gear end float
Steel gear .....................
Aluminiumgear ................
Relief valve spring free length ........
0,05 mm to 0,12 mm (0.002 in. to
0.005 in.)
0,07 mm to 0,15 mm (0.003 in. to
0.006 in.)
67,82 mm (2,670 in.)
OIL SUMP
Remove and refit
12.60.44
Removing
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[RC257 “+
Prop open the bonnet.
Remove the oil filler cap.
Remove the sump drain plug.
Allow the oil to drain, then refit the
drain plug and sealing washer.
Remove the sump.
Withdraw the joint washer.
*.
Refitting
Place a new joint washer in position.
Fit the sump, and tighten bolts to 1,65 kgf
m (12 1bf ft).
Replenish the engine lubricating oil to the
‘high’ mark on the oil level dipstick.
Reverse | and 2.
Check the sump oil level after a short
engine run and top up as necessary to the
‘high’ mark on the oil level dipstick.
After 1600 km (1000 miles) running,
recheck sump bolts for correct torque as
follows:
Slacken each bolt in turn approximately
one flat, then retighten to 1,65 kgf m (12
Ibf ft).
TIMING GEAR COVER AND
OIL SEAL
Remove and refit
Gear cover 1 to 14 and 18 to 24 12.65.01
Qil seal 1 to 24 12.65.05
Service tool: 530102 Spanner for starter dog
for three-bearing engine only;
530102A for three- and five-bear-
ing engines.
NOTE: On initial assembly of the engine
the mud shield around the oil seal is
nvetted in position on the timing gear
cover. If this has been removed in service
however, the rivets may have been sub-
stituted with self tapping drive screws.
In this case the oil seal may be changed
without removing the timing gear cover
provided that on refitting the mud shield is
allowed to finally pull the oil seal into
position to ensure a positive location.
Removing |
Open and prop the bonnet.
Remove the radiator and front panel
assembly. 26.40.01.
Slacken the alternator fixings and remove
the fan belt.
Remove the alternator adjusting link.
“a WwW N —
5 With the vehicle in gear with hand-
brake on,‘ slacken the starter dog.
1e—C1
10
11
12
13
Remove the starter dog. 530102.
Withdraw the crankshaft pulley.
If only the oil seal is to be changed,
see NOTE above.
Remove the fan blades and pulley.
Disconnect the by-pass pipe from the
thermostat housing.
Remove the timing cover fixings,
including those at the sump front
flange.
Withdraw the timing cover. NOTE:
Slacken front side sump bolts for ease
of timing cover removal.
Withdraw the joint washer from the
timing cover.
Withdraw the joint washer from the
water inlet.
14
15
16
Drill out the rivets and drive the oil
seal from the timing cover.
Smear the outside diameter of the new
oil seal with Hylomar PL32/M jointing
compound.
Press the oil seal into the timing cover
and substitute the rivets with the self
tapping drive screws supplied.
Refitting
NOTE: It is of advantage temporarily to
remove the fixing stud from the cylinder
block front face. This will enable the front
cover to be lifted sufficient to clear the
edge of the sump gasket when offering the
front cover to the engine.
17
18
19
20
21
22
Smear general purpose grease on both
sides of the front cover and water inlet
joint washers.
Reverse 7 to 13.
Fit the starter dog. Torque: Petrol
engines: 20,5 kgf. т (150 ibf. ft).
Diesel engines: 27,65 kgf. m (200 ibf.
ft.).
Fit the alternator adjusting link.
Adjust the fan belt to give 6,5 to 9,5
mm (0.250 to 0.375 in.) free move-
ment when checked midway between
the fan and alternator pulleys.
Reverse 1 to 3.
IRC2458
E—cel
TIMING GEARS — Petrol
Service tool:
Remove and refit
12.65.22
507231 Chainwheel extrac-
tor
Removing
da WW DD -—
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//
18С253
Remove the bonnet. 76.16.01.
Remove the radiator and front panel
assembly. 26.40.01.
Remove the timing gear
12.65.01.
Remove the timing chain tensioner.
12.65.28.
Withdraw the timing chain.
Withdraw the chainwheel from the
crankshaft.
Remove the fixings from the camshaft
chainwheel.
Extract the chainwheel from the cam-
shaft. 507231.
Cover.
Refitting
Check that the key for the chainwheel
is correctly located in the crankshaft
slot.
Fit the chainwheel, large shoulder
first, to the crankshaft.
9
10
IRC 254
11
12
13
14
Locate the timing gear cover in posi-
tion.
Fit the timing pointer.
Locate the crankshaft pulley in posi-
tion.
Rotate the crankshaft until the timing
mark in the crankshaft pulley is
aligned with the longest tongue on the
timing pointer (No. 1 piston at TDC).
Without the disturbing the crankshaft,
remove the pulley, timing pointer and
gear cover.
Fit the camshaft chainwheel, using
keyway marked “P”.
Rotate the camshaft chainwheel until
the groove marked ‘P’ is in line with
the centre of the tapped hole, as
illustrated.
Retaining the chainwheels in the set
positions, fit the timing chain ensuring
that there is no slack chain on the
driving side.
19
20
If it is not possible to obtain a taut
fit on the driving side of the chain
with the chainwheels in the set posi-
tions, withdraw the camshaft chain-
wheel without disturbing the set posi-
tion of the camshaft, and refit the
chainwheel using one of the alternative
keyways. This procedure may be
repeated until a taught chain is
obtained on the driving side with the
camshaft and crankshaft in their pre-
viously set positions.
Reverse 1 to 4.
E£E—CI
TIMING GEARS — Diesel
Remove and refit 12.65.22
Service tool: 507231 Chainwheel extrac-
tor
Removing
Remove the bonnet. 76.16.01.
Remove the radiator and front panel
assembly. 26.40.01.
Remove the timing gear cover.
12.65.01.
Remove the timing chain tensioner.
12.65.28.
Withdraw the timing chain.
Withdraw the chainwheel from the
crankshaft.
Remove the fixings from the camshaft
chainwheel.
Extract the chainwheel from the cam-
shaft. 507231.
HA w NM —
O ~~ ANA
Refitting
9 Check that the key for the chainwheel
is correctly located in the crankshaft
slot.
10 Fit the chainwheel to the crankshaft.
CAUTION: When turning the crankshaft
do not allow the pistons to foul the valves.
If necessary, turn the camshaft to enable
the crankshaft setting to be obtained.
vé
¢ |
11 Turn the crankshaft in the direction of
rotation until the EP mark on the
flywheel is aligned with the timing
pointer.
IRC 254
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RC357 — VS
12 Fit the chainwheel to the camshaft
using any keyway.
13 Remove the engine top cover.
14 Turn the camshaft until No. 1 cylinder
exhaust valve is fully closed and set
the tappet clearance to 0,25 mm
(0.010 in.).
15 Mount a dial test indicator to enable
the ‘fully open’ position of the valve
to be ascertained.
16 Turn the camshaft in the direction of
rotation until the rocker pad has
nearly opened the valve fully. Stop
camshaft rotation.
| Y 6
1RC 361
17 Suitably mark the chainwheel and rear
casing relative to each other.
18 Note the reading on the dial test
indicator, then continue turning the
camshaft in the direction of rotation
until the dial test indicator needle has
reached the same position as pre-
viously noted. Stop camshaft rotation.
19 Suitably mark the chainwheel adjacent
to the mark previously made on the
rear casing.
20 Make a third mark on the chainwheel
to bisect the angle between the two
previously made marks.
IRC 358» |. br LE Nu
21 Turn the camshaft against the direc-
tion of rotation and align the middle
mark on the chainwheel with the mark
on the rear casing. No. 1 exhaust valve
is now fully open.
22 Retaining the chainwheels in the set
positions, fit the timing chain ensuring
that there is no slack chain on the
driving side.
continued
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IRC362
vE—CI
23 If it is not possible to obtain a taut
fit on the driving side of the chain
‘with the chainwheels in the set posi-
tions, withdraw the camshaft chain-
wheel without disturbing the set
position of the camshaft, and refit the
chainwheel using one of the alternative
keyways. This procedure may be
repeated until a taught chain is
obtained on the driving side with the
camshaft and crankshaft in their pre-
viously set positions.
IRC359 ==
24 Secure the fixings for the camshaft
chainwheel and engage the lockwasher.
25 Remove the dial test indicator.
26 Refit the engine top cover.
27 Reverse 1 to 4.
TIMING CHAIN TENSIONER
Remove and refit 12.65.28
Removing
1 Remove the bonnet. 76.16.01.
2 Remove the radiator and front panel
assembly. 26.40.01.
3 Petrol engines: Turn the crankshaft in
the direction of rotation until the
timing mark on the crankshaft pulley
is aligned with the centre tongue of
the timing pointer. |
4 Diesel engines: Turn the crankshaft in
the direction of rotation until the EP
mark on the flywheel is aligned with
the timing pointer.
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IRC 356 у
5 Remove the timing gear cover.
12.65.01.
6 Remove the tensioner ratchet and
spring.
7 Remove the fixings from the piston
housing.
8 Compress the tensioner spring by hand
and withdraw the tensioner assembly
complete.
9 Clean the tensioner components in
clean fuel.
10 Fit a new piston and housing if unduly
worn.
11 If the tensioner cylinder bush is
unduly worn, fit a new cylinder and
bush complete.
12 Fit a new idler wheel and ratchet arm
if the bushes are unduly worn.
13 Fit a new chain vibration damper if
the rubber pad is grooved.
14 Ensure that all oil passage drillings are
clear.
15 Petrol engines: if required, remove the
non-return valve plug, spring and ball.
Refitting
16 Petrol engines: If removed, refit the non-
return valve ball, spring and plug.
NOTE: On later petrol engines the diesel
type timing chain tensioner assembly is
fitted. |
17 Assemble together, the piston housing,
tensioner spring, cylinder and idler
wheel.
18 Compress the assembly against the
tensioner spring.
19 Fit the assembly to the engine, locat-
ing the piston housing onto the dowels
and the cylinder spigot into the slot.
20 Fit the ratchet and spring and allow
the idler wheel to take up the timing
chain slack.
21 If necessary, adjust the position of the
chain vibration damper to allow 0,25
mm (0.010 in.) maximum clearance
between the timing chain and the
vibration pad.
RC ‘Ho № их
22 Petrol engines: Temporarily, refit the
timing gear cover, timing pointer and
crankshaft pulley, and ensure that the
timing marks are still correctly aligned.
Then providing that ‘the camshaft has
not been rotated, the engine valve
timing should be correct. If there is
any doubt, check the valve timing.
12.65.22.
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23 Diesel engines: Check that the EP
mark on the flywheel is still aligned
with the timing pointer. Then provid-
ing that the camshaft has not been
rotated, the engine valve timing should
be correct. If there is any doubt, check
the valve timing. 12.65.22.
24 Fit the timing gear cover. 12.65.01.
25 Reverse 1 and 2.
& 22
sE—cCl
2.6 litre — 6 cylinder Engine
9€—TI
2.6 litre — 6 cylinder Engine
DISTRIBUTOR AND OIL PUMP
DRIVE SHAFT
Remove and refit 12.10.22
Removing
1 Remove the distributor and short drive
shaft. 86.35.20.
2 Remove the side rocker cover.
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IRC747
3 Remove the oil feed bolt and lock
washer locating the distributor housing
inside the rocker chamber.
Lift out the distributor housing.
Withdraw the drive shaft.
E
nda
Refitting
Rotate the engine in direction of
rotation until the TDC mark on the
crankshaft pulley aligns with the
timing pointer, with both valves on
No. 1 cylinder fully closed (i.e. No. 1
cylinder commencing firing stroke).
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IRC 749
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ИИ ИМ Анти
Fit the oil pump and distributor gear
drive shaft to the engine with the
lower splines engaged in the oil pump,
and the skew gear engaged with the
camshaft.
Turn the drive shaft using a suitable
screwdriver, until the offset drive slot
in the end of the shaft is positioned as
illustrated.
Fit the distributor housing to the
engine and locate and secure with the
oil feed bolt and lock washer.
Reverse 1 and 2.
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CAMSHAFT
Remove and refit 12.13.01
Service tools: 530101 Extractor for cam-
shaft
507231 Extractor for chain-
wheel
Removing
1 Remove the radiator and grille panel.
26.40.01.
Remove the
30.15.10.
2 manifold.
3 Remove the
4
exhaust
timing gear cover.
12.65.01.
Remove the timing chain tensioner.
12.65.28.
5 Remove the camshaft chainwheel and
timing chain. Extractor 507231.
6 Remove the camshaft thrust plate.
7 Remove the side rockers and shafts.
12.29.36. |
8 Remove the distributor and short drive
shaft. 86.35.20.
9 Remove the oil pump and distributor
gear drive shaft. 12.10.22.
10 Remove the six camshaft bearings
locating screws.
11 Withdraw the camshaft until the bear-
ings are clear of the housing. Extractor
530101.
12 Remove the bearings by separating the
bearing halves. Keep the halves in
related pairs as indicated by the figures
marked on the end faces.
13 Withdraw the camshaft clear of the
engine.
14 Withdraw the remaining bearing from
the rear housing, utilising the oil relief
holes for extraction purposes if re-
quired.
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IRC808
LE—TI
Refitting
15
16
17
18
19
20
21
22
23
24
Before attempting to fit the camshaft
bearings to the cylinder block, ensure
that the bearing halves fit together
correctly on the dowels by checking
that no light is visible between the
joint faces.
The bearings must be fitted dry and
should be a hand push fit in the
cylinder block; they must always be
renewed in paired halves and the
numbers stamped on one of the end
faces of the bearing halves must be
adjacent.
Insert the camshaft partly into the
cylinder block, allowing the distri
butor and oil pump drive gear to pass
through the first and second inter-
mediate housing webs.
Assemble the front and intermediate
bearings on to their respective journals
on the camshaft. Ensure that the
dowelled joint faces are tightly fitted
together and the locating holes in the
bearings are in line with the holes in
the housing webs.
Fit the rear bearing into the housing.
Place a suitable distance between the
first and second intermediate bearings.
The width of the distance piece to be
approximately the distance between
the bearing housings but allowing suf-
ficient clearance for withdrawal.
Tap the camshaft rearwards until the
bearings are fully home in their respec-
tive housings and the locating holes are
aligned.
Remove the distance piece.
Lubricate the bearings through the
locating bolt holes then fit the bear-
ings fixings.
Fit the camshaft thrust plate.
1ЕС 811
DATA
Camshaft end float
+ = + + & = + + 4&4 & 8 à + à = 2 + 4
ARE a
25 Temporarily fit the camshaft chain-
wheel and check the camshaft end-
float which must be 0,11 to 0,16 mm
(0.0045 to 0.0065 in.). Replace the
thrust plate if the end-float is exces-
sive.
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. . To +
ес ‚ i PESA ñ
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= 7 ST E
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IRCB12
26 Temporarilv remove the camshaft
chainwheel and “fit the side rocker
shafts. 12.29.36.
27 Fit the camshaft chainwheel and
timing chain and set the valve timing.
12.65.12.
28 Fit the oil pump and distributor gear.
12.10.22.
29 Fit the distributor and short drive
shaft. 86.35.20.
30. Reverse | to 4.
0,11 to 0,16 mm (0.0045 in. to
0.0065 in.).
CONNECTING RODS AND PISTONS
Remove and refit 12.17.01
Removing
NOTE: During the following procedures
retain all components in related sets to
facilitate re-assembly. If the pistons are not
to be replaced, add location marks to
ensure re-assembling in the same relative
positions.
1 Remove the cylinder head. 12.29.10.
2 Remove the oil sump. 12.60.44.
3 With two pistons at bottom dead
centre (BDC) remove the connecting
rod cap fixings.
IRC790
4 Remove the caps and withdraw the
connecting rod bearing halves. Retain
the caps and bearings in related sets.
5 Withdraw the pistons and attached
connecting rods from the top of the
bore.
6 Position the remaining pistons at BDC
and repeat the removal procedure.
continued
8E—TI
Refitting
NOTE: If replacement components are to
be fitted, the checks detailed in ‘overhaul’
12.17.10 must be carried out as necessary.
7 Position the piston rings so that the
end gaps do not align with each other
or with the gudgeon pin bore in the
piston.
8 Enter the connecting rods into the
appropriate cylinders and position the
oil hole in the connecting rod and the
flat on the piston crown away from
the camshaft side of the engine.
9 Carefully insert the pistons into the
cylinders, taking care not to damage
the rings.
10 Lubricate the journals and bearing
halves and fit the appropriate halves to
the connecting rods and caps. The
bearing halves are located by tongues,
these to be positioned at the same side
of the connecting rod in the grooves
provided. |
11 Fit new bearing cap nuts and tighten
to 2,8 kgf. m (20 Ibf. ft.).
12 Reverse ! and 2.
CONNECTING RODS AND PISTONS
Overhaul 12.17.10
Dismantling
NOTE: During the following procedures
retain all components in related sets to
facilitate subsequent assembly. If the same
pistons are to be refitted, add location
marks to ensure reassembling in the same
relative position.
1 Remove the connecting rods and
pistons. 12.17.01.
2 Remove the piston rings.
3 Remove the circlips from the gudgeon
pin bosses.
4 Withdraw the gudgeon pins from the
pistons.
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Overhauling pistons
Original Pistons
5 Remove the carbon and deposits,
particularly from the ring grooves.
6 [Examine the pistons for damage or
excessive wear — see under ‘New
pistons’ for clearance dimensions — fit
new replacements as necessary.
New Pistons
Original pistons fitted to new engines at the fac-
tory are specially graded to facilitate assembly.
The grading letter on top of the piston crown
must be ignored when ordering new pistons.
Genuine Land-Rover service standard size
pistons are supplied 0,025 mm (0.001 in) over-
size to allow for production tolerances on new
engines. When fitting a new piston to a stan-
dard size cylinder block the bore must be honed
to accommodate the piston with the correct
clearances.
The clearance limits between the pistons
and cylinder bores are 0,048 mm to 0,060
mm (0.0019 in. to 0.0024 in.), measured as
described subsequently.
The temperature of the piston and cylinder
block must be the same to ensure accurate
measurements.
7 Check the piston diameter at the
bottom of the skirt at right angles to
the gudgeon pin.
8 Check the bore diameter at approxi-
mately half way down.
9 If gauge equipment is not available,
the piston clearance can be assessed
using long feeler gauges, 10 to 12.
10 Insert a long, suitably sized feeler
gauge down the thrust side of the
cylinder bore.
11 Insert the correct piston, inverted, into
the cylinder bore and position it with
the gudgeon pin parallel with the axis
of the crankshaft.
TRL
IRC795
6£-C1
12
13
14
15
Push the piston down the cylinder
until the piston reaches its tightest
point in the bore, at this point with-
draw the feeler gauge — a steady
resistance should be felt.
If standard size pistons are being
fitted, select pistons from the range
available until the clearance is satisfac-
tory.
If new piston rings are to be fitted
without reboring, deglaze the cylinder
walls with a hone, without increasing
the bore diameter. A deglazed bore
must have a cross-hatch finish.
Check the compression and oil control
rings gaps in the applicable cylinder,
held square to the bore with the
piston.
Compression rings gap: 0,38 mm to
0,50 mm (0.015 in. to 0.020 in.).
Qil control ring gap: 0,40 mm to 0,80
mm (0.015 in. to 0.033 in.).
Use a fine cut flat file to increase the
gap if required. Select a new piston
ring if the gap exceeds the limit.
Reboring
16
17
18
19
20
The cylinder head is inclined at an
angle of 22 ; standard boring equip-
ment can be used in conjunction with
a special jig block 261288.
Where the maximum permitted boring
tolerance is not sufficient to reclaim
the bores, cylinder liners may be
fitted.
Fitting the cylinder liners conforms to
normal practice. Machine the cylinder
block bores to 81,28 mm + 0,025 mm
(3.200 in. + 0.001 in.) which will
provide the liner with 0,07 mm to
0,10 mm (0.003 in. to 0.004 in.)
interference fit.
Prior to pressing in the liner, allowance
must be made for unavoidable rotation
of up to 5 mm (0.187 in.), clockwise.
To facilitate realignment should the
liner not be positioned correctly at the
first attempt, scribe lines down the
sides of the liner from the two peaks,
and make corresponding marks on the
cylinder block.
Press in the liner, using a special press
block 246650, until the top edge is
level with the bottom of the exhaust
valve pocket. Bland to the shape of the
cylinder block.
Bore to the selected diameter to suit
pistons. Liners may be bored to a maxi-
mum of 1,01 mm (0.040 in.).
Assembling
21
22
23
24
Fit the oil control ring to the piston.
Check the oil control ring clearance in
the piston groove. Clearance limits:
0,05 mm to 0,10 mm (0.002 in. to
0.004 in.).
Fit the two compression rings to the
piston with the sides marked “T” or
‘Top’ uppermost.
Check the compression ring clearance
in the piston grooves. Clearance limits:
0,046 mm to 0,097 mm (0.0018 in. to
0.0038 in.).
1RC799
Connecting rods
25
26
27
28
30
31
Check the alignment of the connecting
rod.
Check the gudgeon pin clearance in
the connecting rod bush. Clearance
mes: zero to 0,0241 mm (0.00095
in.).
If a new connecting rod small end
bush is required, ensure that the oil
holes are aligned when pressing in the
replacement, then ream the bush to
obtain the correct clearance, as above.
Check the fit of the gudgeon pin in the
piston, the pin must not fall through
either boss but be capable of being
fitted by hand at normal room tem-
perature 20 C (68 F).
Gudeon pins of 0,025 mm and 0,076
mm (0.001 in. and 0.003 in.) oversizes
are available.
Select the correct cap for each con-
necting rod as denoted by the number
stamped near the joint faces. This
number also indicates the crankshaft
journal to which it must be fitted.
Assemble the caps, less bearing halves,
to the respective connecting rods.
Torque 2,8 kgf. m (20 1bf. ft.).
Slacken the fixing on one side of the
cap only and check that there is no
clearance at the joint face. If there is
clearance, a new assembly must be
fitted.
continued
Op CI
Connecting rod bearing nip and clearance
NOTE: New bearing halves are supplied
with a protective coating and must be
degreased, prior to fitting, to remove the
coating.
32 Fit the bearing halves to the connect-
ing rod and cap, and secure the assem-
bly. Torque 2,8 kgf. m (20 bf. ft.).
33 Slacken the fixing on one side of the
cap only and check the clearance
between the joint faces. The clearance
must be 0,05 mm to 0,10 mm (0.002
in. to 0.004 in.). The bearing nip can
be corrected by selective assembly of
the bearings shells; these are available
in slightly varying thicknesses. Do not
file or machine the caps or connecting
rods to vary the bearing nip.
GP
30 NY
am. aX J 31 & 33
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32 re N |
; 4 7 a = 29
uE queno
IRC 370A :
34 Make a final check to prove the
bearing clearance, using selected shim
papers fitted between the journal and
one half of the bearing shell. As the
bearing clearance is taken up, the
connecting rod will become stiff to
rotate about the journal. The correct
bearing clearance is 0,0114 mm to
0,043 mm (0.00045 in. to 0.0017 in.).
NOTE: As an alternative, ‘Plastigauge’ may
be used to check the connecting rod bear-
ing clearance. 35 to 41. Do not rotate the
connecting rod or crankshaft while the
Plastigauge is fitted, or the reading will be
impaired.
35 Place a piece of ‘Plastigauge’ across the
centre of the lower half of the crank-
shaft journal. 605238.
36 Fit the connecting rod complete with
bearings to the applicable journal.
Torque 2,8 kgf. m (20 bf. ft.).
37 Remove the connecting rod cap and
lower half bearing.
38 Using the scale printed on the “Plasti-
gauge” packet, measure the flattened
‘Plastigauge’ at its widest point. The
graduation that most closely cor-
responds to the width of the “Plasti-
gauge’ indicates the bearing clearance.
39 The correct clearance with new or
overhauled components is 0.0114 mm
to 0,043 mm (0.00045 in. to 0.0017
in.).
40 If a new bearing is being fitted, use
selective assembly to obtain the
correct clearance.
41 Wipe off the ‘Plastigauge’ with an oily
rag. DO NOT scrape it off.
Connecting rod end-float
42 Fit the connecting rods complete with
bearings to their applicable journals.
Torque 2,8 kgf. m (20 1bf. ft.).
43 Check the end float between the end
face of the connecting rod and the
journal shoulder. End float limits:
0,15 mm to 0,38 mm (0.006 in. to
0.015 in.).
44 Remove the connecting rods from the
crankshaft and retain all parts in
related sets.
Assembling
45 Assemble the pistons to their respec-
tive connecting rods.
46 Fit new circlips to retain the piston
gudgeon pins.
47 Refit the connecting rods and pistons.
12.17.01.
DATA
Pistons
Clearance in cylinder bore, measured at
bottom of skirt at right angles to
gudgeon pin. Standard size and oversize
р15к00$. a sa a eu a»
Piston rings
Compression (2)
Туре... ......................
Gap in Боге... .................
Clearanceingroove ..............
Oil control
Туре. ......................,.
Gapinbore....................
Clearance ingroove ..............
Gudgeon Pin
Clearance in connectingrod .........
Fitinpiston .....................
Connecting rods
Clearance, bearing to crankpin .......
End float on crankpin ..............
IRC 806 (ur
0,048 mm to 0,060 mm (0.0019 in. to
0.0024 in.)
Cast iron. Marked “T” or “TOP” on
upper side.
0,38 mm to 0,50 mm (0.015 in. to
0.033 in.)
0,046 mm to 0,097 mm (0.0018 in. to
0.0038 in.)
Slotted, square friction edge.
0,38 mm to 0,80 mm (0.015 in. to
0.033 in.)
0,05 mm to 0,10 mm (0.002 in. to
0.004 in.)
Zero to 0,0241 mm (0.00095 in.)
Push fit by hand
0,0114 mm to 0,043 mm (0.00045 in.
to 0.0017 in.)
0,15 mm to 0,38 mm (0.006 in. to
0.015 in.)
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