Land Rover 2.6L 6 Cylinder Engine User manual

Land Rover 2.6L 6 Cylinder Engine User manual
 SE—CI
2.6 litre — 6 cylinder Engine
9£—T1
2.6 litre — 6 cylinder Engine
DISTRIBUTOR AND OIL PUMP
DRIVE SHAFT
Remove and refit 12.10.22
Removing
I Remove the distributor and short drive
shaft. 86.35.20.
2 Remove the side rocker cover.
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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.
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Refitting
6 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 fuliy closed (ie. No, 1
cylinder commencing firing stroke).
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7 Fit the oi 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
carnshaft,
8 Tum the drive shaft using a suitable
screwdriver, until the offset drive slot
in the end of the shaft is positioned as
illustrated.
9 Fit the distributor housing to the
engine and locate and secure with the
oil feed bolt and lock washer.
10 Reverse | and 2.
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CAMSHAFT
Remove and refit
12.13.01
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Service tools: 530101 Extractor for cam- E
shaft X er
507231 Extractor for chain- ин НК
wheel №
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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.
Remove the camshaft chainwheel and
timing chain. Extractor 507231.
Remove the camshaft thrust plate.
Remove the side rockers and shafts.
12.29.36.
Remove the distributor and short drive
shaft. 86.35.20.
Remove the oil pump and distributor
gear drive shaft. 12.10.22.
10 Remove the six camshaft bearings
locating screws.
Il Withdraw the camshaft until the bear-
ings are clear of the housing. Extractor
53010%.
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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Refitting
15 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, |
16 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.
17 [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.
18 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 wehs.
19 Fit the rear bearing into the housing.
20 Place a suitable distance between the
first and second intermediate hearings.
The width of the distance piece to be
approximately the distance between
the bearing housings but allowing suf-
ficient clearance for withdrawal.
21 Tap the camshaft rearwards until the
bearings are fully home in their respec-
tive housings and the locating holes are
aligned.
22 Remove the distance piece.
23 Lubricate the bearings through the
locating bolt holes then fit the bear-
ings fixings.
24 Fit the camshaft thrust plate.
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DATA
Camshaft end float
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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,
26 Temporarily 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 1 to 4.
0,11 ta 0,76 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 te
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.
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
gE—T1
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
où 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.
il 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 foliowing 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.
JT RCT792
Overhauling pistons
Original Pistons
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.
10
El
Check the piston diameter at the
bottom of the skirt at right angles to
the gudgeon pin.
Check the bore diameter at approxi-
mately half way down.
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 thrust 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.
IRC798
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12
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
résistance 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, degiaze 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
Ings Вар 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).
Oil contro! 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.
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Reboring
16
17
18
19
20
The cylinder head is inclined at an
angle of 272 ; 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 realipnment 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 15
level with the bottom of the exhaust
valve pocket. Bland to the shape of the
cylinder block.
Bore lo Lhe selected diameter to suit
pistons. Liners may be bored to a maxi-
mum of 1,01 mm (0.040 ın.).
Assembling
21 Fit the oil control ring to the piston.
22 {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.}).
23 Fit the two compression rings to the
piston with the sides marked ‘T° or
‘Top’ uppermost.
24 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.).
IRC798
IRC799
21
Connecting rods
25
26
27
28
29
30
3l
Check the alignment of the connecting
rod.
Check the gudgeon pin clearance in
the connecting rod bush. Clearance
limits: 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 dencted 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 Ibf. 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
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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 Ibf. 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.
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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 haif of the crank-
shaft journal. 605238.
36 Fit the connecting rod complete with
bearings to the applicable journal.
Torque 2,8 kgf. m (20 Ibf. 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.
IRC 282A
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
PIStonS. ....e.ermarerarenrerer.
Piston rings
Compression (2)
TYPE eK
Gap in boten
Clearance in groove . ..........-..
Oil control
Type ........ecemmeadanierraa.
Gap in borre ........e mee: eena
Clearance in groove . . .. ..........
Gudgeon Pin
Clearance in connecting rod .........
Fit in piston ....e.o_co.eersssreremera.
Connecting rods
(Clearance, bearing to crankpin .......
End float on crankpin ..............
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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CRANKSHAFT REAR OIL SEAL
Remove and refit 12.21.20
Service tool:
600963 Engine lifting sling
Removing
Et Remove the bonnet. 76.16.01,
2 Remove the front floor. 76.10.12.
3 Remove the engine assembly. 12.41.01.
4 Remove the starter motor. 86.60.01.
5 Remove the oil sump. 12.60.44.
6 Remove the clutch = assembly.
33.10.01.
Remove the flywheel. 12,53.07.
Remove the flywheel housing.
Remove the oil seal ring.
Remove the rear main bearing cap.
Remove the dowei located lower haif
of the oil seal retainer from the rear
main bearing cap.
|2 Remove the dowel located upper half
of the oil seal retainer from the cylin-
der block.
—
270304 Guides for oil seal
13 Remove the oil seal from the crank-
shaft.
Refitting
Id Assemble the garter spring on the
crankshaft journal by engaging the
hook and eye. Do mot 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.
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 iocated in the retainer recess.
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23 Secure the upper half of the oil seal
retainer with the three inner bolts,
leaving the outer belts at each end
finger tight at this stage.
LR886
24
25
26
27
28
25
30
31
32
33
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,
Apply Silicone Grease M54 to the ‘T"
seals and fit them to the rear main
bearing cap.
Trim the top edges of the ‘T’ seals to
prevent them from fouling the cylin-
der block when being fitted.
Fit the seal guides to the crankcase.
270304.
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.
Check that the seal is correctly located
in the Tetainer recess.
Tighten the bearing cap bolts ensuring
that there is no buckling of the split
seal or misalignment of the butt joint;
Torque: 10 kgf. m (75 Ibi. ft.).
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.
Trim the ends of the “T° seals to leave
0,8 mm (0.030 in.) protruding from
the bearing cap.
Reverse 1 to 19.
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CRANKSHAFT
Remove and refit 12.21.33
Removing
Remove the bonnet. 76.16.01.
Remove the air cleaner. 19.10.04.
Remove the radiator and front panel
assembly. 26.40.01.
Remove the front floor. 76.10.12.
Remove the engine assembly,
12.41.01.
Remove the oil sump. 12.60.44.
Remove the oil pump. 12.60.26.
Remove the timing gear
12.65.01.
Remove the timing chain and ten-
sioner. 12.65.28.
10 Remove the
33.10.01.
11 Remove the flywheel. 12.53.07.
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pa 60 — 2
clutch assembly.
12 Remove the flywheel housing.
13 Remove the oil seal. '
14 Remove the connecting rod caps and
bearing lower halves. Retain in related
sets,
15 Remove the main bearing caps and lift
the crankshaft clear. Retain the bear-
ing halves and caps in related sets.
16 Remove the oil seal from the crank-
shaft.
17 Remove the upper half of the ой 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
22
23
24
25
IRC ASS
Insert a thrust washer at each side of
the rear upper main bearing shell with
the grooved faces towards the crank-
shaft webs.
locate the bearing lower halves into
numbers 1 to 6 main bearing caps. Fit
the caps but do not fully ‘tighten the
fixings at this stage.
Fit the crankshaft rear oil seal and
number 7 rear main bearing shell.
12.21.20.
Tighten the main bearing cap fixings.
Torque: 10,0 kgf. m (75 1bf. ft.).
Fit the appropriate bearing halves and
caps to the connecting rods, using
NEW securing nuts. Torque: 2,8 kgf.
m (20 bf. ft.).
26 Fit the oil seal ring to the flywheel
housing.
27 Refit the flywheel housing.
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 | to 9.
CRANKSHAFT
Overhaul 12.21.46
Inspecting
Remove the crankshaft. 12.21.33.
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 Bearings for the crankshaft main
journals and the connecting rod
journals are available in the following
undersizes:
0,25 mm (0.010 in.)
0,50 mm (0.020 in.)
0,76 mm (0.030 in.)
0,01 mm (0.040 in.)
4 Thrust washers for the crankshaft rear
main journal, to control the crankshaft
end float, are available in the following
OVEISIZES:
0,06 mm (0.0025 in.)
0,12 mm (0.005 in.)
0,18 mm (0.0075 in.)
0,25 mm (0.010 in.)
0,31 mm (0.0125 in.)
5 Fit the front main bearing cap, less
bearing halves, to the cylinder block.
Torque 10,4 kgf. m (75 1bf. 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.
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7 Repeat 5 and 6 for the remaining 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.
8 Locate the bearing halves into the
front main bearing cap and the cylin-
der block, and fit the cap to the block.
Torque: 10,4 kgf. m 475 Ibf. ft.).
9 Slacken the fixing on one side of the
cap only and check the clearance
between the joint faces. The clearance
must he 0,10 mm to 0,15 mm (0.004
in. to 0.006 in.).
10 The bearing nip can be corrected by
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.
11 Repeat 8 to 10 for the remaining main
bearings.
12 When the bearing nip has been
checked, remove the caps and bearing
shell bottom halves.
13 Position a standard size thrust washer
each side of the rear main bearing
shell, top half, with the grooved faces
away from the cylinder block. The
thrust washer thicknesses must agree
within 0,08 mm (0,003 in.).
14 Place the crankshaft in position on the
cylinder block.
15 Mount a dial test indicator to read off
the end of the crankshaft.
16 Check the crankshaft end float. The
correct end float limits are 0,05 mm to
0,15 mm (0.002 in. to 0.006 in.).
17 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.
TRC 631
18 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
shirn 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 bearing
clearance, 19 to 26. Do not rotate the
crankshaft while the Plastigauge is fitted,
or the reading will be impaired.
19 Locate the crankshaft in position on
the upper bearing halves in the cylin-
der block.
20 Place a piece of Plastigauge across the
centre of the lower half of the crank-
shaft journal. 605238.
DATA
Crankshaft
Journal diameter ........... cc. ...
Crankpin diameter. . ...............
End float (contrelled by thrust washers
at rear bearing) ........ 0.0...
Regrind permissible by 0,25 mm (0.010
Main bearing running clearance .......
Connecting rod bearing running clearance
21
22
23
24
25
26
27
28
Fit the bearing cap complete with the
lower bearing half. Torque: 10,5 kgf.
m (75 1bf. ft.).
Remove the bearing cap and lower half
bearing.
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.
The correct clearance with new or
overhauled components is 0,015 mm
to 0,050 mm (0,0006 in. to 0.002 in.).
If a new bearing is being fitted, use
selective assembly to obtain the
correct clearance.
Wipe off the ‘Plastigauge’ with an oily
rag. DO NOT scrape it off.
Retain all components in related sets.
Refit the crankshaft. 12.21.33.
67,0 mm — 0,0127 mm (2.6245 in. —
0.0005 in.)
47,63 mm + 0,018 mm (1.875 in. +
0.00075 in.)
0,05 mm to 0,15 mm (.002 in.
to .006 in.)
Undersize Journal dia. “Crankpin dia.
1,01 mm 65,63 mm 46,6 mm
(0.040 in.) (2.584 in.) (1.835 in.)
0,015 mm to 0,050 mm (0.0006 in. to
0.002 in.)
0,0114 mm to 0,043 mm {0.00045 in.
0.0017 in.)
CYLINDER PRESSURES
Check 12.25.01
Checking
1 Run the engine until it attains normal
= LA fa y hy
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
mator for several revolutions and note
the highest pressure reading obtain-
able.
If the pressure is appreciably less than
the correct figure, the piston rings or
valves may be faulty.
Low pressure in adjoining cylinders
may be due to a faulty cylinder head
gasket.
DATA
Compiessionratio .................
Compression pressure. ..............
Crankingspeed. ...................
IRC 828 7
7.8:1
11,95 kgf. cm?
(170 1bf. in.?)
300 rev/min
7.0: 1
9.84 kgf. cm?
(140 Ivf. in?)
300 rev/min
CYLINDER HEAD
Remove and refit
12.29.10
Removing
2
3
4
So 7 —] cr CH
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12
Drain the coolant at the radiator and
engine block.
Disconnect the brake servo pipe from
the inlet manifold.
Remove the carburetter. 19.15.09.
Disconnect the accelerator control rod
and return spring at the bell crank lever,
Disconnect the two temperature trans-
mitter leads from the cylinder head.
Disconnect the rocker oil feed pipe at
the rear of the cylinder head.
Remove the sparking plugs.
Disconnect the radiator top hose.
Disconnect the hose from the engine
breather cap.
Remove the distributor. 86.35.20.
Remove the distributor vacuum pipe
and retaining clip from the thermostat
outlet pipe fixing.
Remove the special nuts and sealing
washers and lift off the top rocker
cover and joint washer.
13
14
13
16
17
Slacken the locknuts and screw back
the tappet adjusting screws.
Slacken the cylinder head fixings
evenly and remove them.
Lift off the cylinder head and discard
the cylinder head gasket.
Remove the *0' ring seal from the
connector by-pass to water pump.
Withdraw the tappet push rods and
retain them in their fitted order.
Refitting
18
19
Remove the side rocker cover and fit
the tappet push rods in their original
positions.
Smear a new cylinder head gasket with
oil and place on the face of the
cylinder block, with the side marked
*this side up’ uppermost.
IRC 760
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20
21
22
23
Use two old cylinder head bolts with
their heads sawn off to locate the
gasket and head. Cut a screwdriver slot
across the diameter of the bolts to
facilitate removal when the cylinder
head is in position.
Position the cylinder head onto the
block, at the same time position the
‘DY ring seal onto the by-pass con-
nector.
Ensure that the tappet push rods
remain correctly seated.
Tighten the cylinder head bolts in the
order shown and to the following
torques:
a. Bolts A”? kgf, m (50 Ibf. ft.)
b. Bolts ‘B’ 4 kof. m (30 1bf. ft.)
24
25
26
27
28
Set the inlet valve tappet clearances to
0,15 mm (0.006 in.) in the following
order:
Set No. 1 tappet with No. 6 valve fully
open.
Set No. 2 tappet with No. 5 valve fully
open.
Set No. 3 tappet with No. 4 valve fully
open.
Set No. 4 tappet with No. 3 valve fully
open,
Set No. 5 tappet with No. 2 valve fully
open,
Set No. 6 tappet with No. | valve fully
open.
Refit the side and top covers.
Fit the distributor. 86.35.20.
Reverse 1 to 6.
With the engine at normal running
temperature, check the cylinder head
fixings tightness, then the inlet valves
tappet clearances, and tighten and
reset as necessary.
CYLINDER HEAD
Decarbonise and top overhaul 12.29.21
Service tools: 262749 Rocker shaft ex-
tractor
276102 Valve Spring com-
pressor
274401 Exhaust valve guide
rémover
274400 Inlet vaive guide
remover
600959 Exhaust valve guide
replacer
601508 Inlet valve guide
replacer
263050 Protection plate,
insert removal
530625 Exhaust valve seat
replacer
Cylinder head and inlet valves
Dismantling
Remove the cylinder head. 12.29.10.
2 Remove the thermostat housing and
thermostat.
3 Remove the inlet valve rockers and
shafts. 12.29.35.
4 Remove the inlet valve assemblies,
using spring compressor 276102, and
retain the components in sets related
to their parent cylinder.
IRC763 ‘
‘RL 764 To
10
11
Withdraw the oil seals from the valve
guides.
Remove combustion deposits from the
cylinder head, valve ports and piston
crowns, using only soft metal tools.
If necessary, remove the inlet valve
seat inserts by grinding sufficient to
weaken the insert, then prising out.
Drive out the inlet valve guides from
the combustion chamber side, using
remover 274400,
[Inspect the valve spring pairs which
must be an interference fit with each
other.
Inspect the valve split cones and spring
caps for general condition.
Inspect the cylinder head for general
condition and for damage to threads.
Assembling
12
If replacement inlet valve scat inserts
are to be fitted, warm the head evenly
for a few minutes at 66°C (150°F)
approximately (the normal operating
temperature of a degreaser), enter the
seat squarely into the cylinder head
recess and press into position.
13 Lubricate and fit the inlet valve guides,
together with the valve spring seating
washers, using replacer 601508.
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14 Face the inlet valve seats, both original
and replacements, to 30° + 4°, using
the valve guides as pilots.
15 Check, and if necessary, Jeface the
inlet valve faces to 30 — 4 .
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16 Lap each valve into its respective seat
then thoroughly wash the assembly.
17 Lubricate the valve stems and reverse
4,
18 Reverse 2 and 3.
19 Place the cylinder head assembly aside
pending refitting.
Dismantling the exhaust valves arrange-
ment
20 Remove the
30.15.10.
21 Remove the side rocker cover and
joint washer.
22 Mark the exhaust valves [or refitting in
Correct sequence.
23 Slacken the tappet adjusting screws
right off and set each rocker back on
its cam.
24 Remove the exhaust valve assemblies,
using spring compressor 276102, and
retain the components in sets related
to their parent cylinder,
exhaust manifold.
25 Remove the combustion deposits from
the valves and ports.
26 Fxamine the valve seat inserts and
valve guides, If replacement is neces-
sary, first remove the exhaust valve
rockers and shafts. 12.29.36.
NOTE: In installations where access is
restricted, to replace valve guides on No. 5
or No. 6 cylinders may first require engine
removal.
EF Ci
27 If necessary, remove the valve seat
inserts, 28 and 29.
WARNING: Due to the extreme hardness
of the seat inserts, take great care to avoid
possible injury due to fragmentation.
28 Reduce the insert to a minimum thick-
ness by grinding.
29 Secure the protection plate 263030
over the cylinder block face and break
the seat insert, Using a suitable chisel
applied through the hole in the plate.
30 If necessary, drift out the exhaust
valve guides, using remover 274401.
t valves, seats and guides, refitting
next exhaust seat inserts are to be
fitted, clean the seat recess and pull
the new insert into position, using
special tool 530625. It is not necessary
to heat the block or freeze the insert,
but light taps on the tool may be
required to ensure that the insert
enters smoothly. Continue precautions
against fragmentation, by fitting the
protection plate 2630350 and leaving it
in position for a few minutes.
32 Lubricate the exhaust valve guides and
carefully drift them into position,
using replacer 600959.
SEAT
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RC 772 ©
33 Use the valve guide as a pilot and cut
the valve seat ta 45° + 4°. о
34 Face the exhaust valves to 45 and lap
each valve into its respective seat,
using suitable equipment.
34 ah
IRC TTA
35 Wash each valve, seat, port and guide
in clean paraffin.
36 Lightly oil the valve stems and reverse
24.
37 If removed, reverse item 26, during
which the valve timing must be re-set
as necessary.
38 Reverse 20 and 21.
39 Refit the cylinder head. 12.29.14.
INLET VALVE ROCKERS AND
SHAFTS
Remove and refit 12.29.35
Service tool: 262749 Extractor for rocker
shafts
Removing
| Remove the radiator and grille panel.
26.40.01.
2 Disconnect the sparking plugs leads
and remove the distributor cap.
3 Disconnect the hose at the engine
breather cap.
Remove the special nuts and sealing
washers and lift off the top rocker
cover and joint washer.
Slacken the locknuts and screw back
the tappet adjusting screws.
Remove the nuts, washers and screw
retainer plates from the rocker spacers.
Remove the special set screws and
washers securing the rocker shafts.
Remove the end plug and sealing
washer from the front of the cylinder
head.
continued
12 Reverse 6 and 7 for the rear shaft. 6 Remove the top rocker cover and
13 Repeat 10 and 11 for the front slacken the inlet tappet adjusting
(shorter) shaft. SCrews.
14 Reverse 6 and 7 for the front shaft.
15 Set the tappet clearances to 0.15 mm
(0.006 in.) in the following order:
Set No. 1 tappet with No. 6 valve fully
9 Extract the front and rear rocker
shafts and withdraw the valve rockers,
springs and spacers as they are re-
leased. Extractor 262749,
Refitting
10 Enter the rear (longer) shaft into the
head, with the tapped holes aligned open.
with the set screw holes in the housing Set No. 2 tappet with No. 5 valve fully
webs, and with the cil holes facing open.
away from the valves. Set No. 3 tappet with No, 4 valve fully
11 Push the shaft rearwards, fitting a open.
spring, valve rocker, spacer, valve Set No. 4 tappet with No. 3 valve fully
rocker and spring for each cylinder. 'RC755 ; open.
Set No, 5 tappet with No. 2 valve fully
open.
Set No, 6 tappet with No, 1 valve fully
open.
16 Reverse I to 4.
17 Caeck the inlet valve tappet clearances 7 Remove the side rocker cover and
with the engine at normal runnin лей
temperature. Reset to 0,15 mm (0,006 slacken the exhaust tappet adjusting
in.) as necessary. 8 Remove the camshaft retaining plate
and remove the end plug from the
front end of the rocker shaft.
EXHAUST VALVE ROCKERS AND
SHAFTS
Remove and refit 12.29.36
Service tool: 262749 Extractor for rocker
shafts
Removing
pW | Remove the radiator and grille panel.
26.40.01.
2 Remove the exhaust manifold.
DATA _ 30.15.10.
Inlet valve tappet clearance ............ 0,15 mm (0.006 in.) with engine 3 move the timing gear cover.
at normal running temperature. 4 Remove the timing chain tensioner.
12.65.28.
5 Remove the timing chain and gears.
12.65.12.
OF ¿1
9 Remove the two locating screws secur-
ing front and rear rocker shafts.
10 Remove the oil feed bolt locating the
distributor housing.
RC782
11 Engage the extractor 262749 into the
front rocker shaft.
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12 Withdraw the rocker shaft.
13 Lift out the exhaust valve rockers,
inlet cam followers, springs and
spacers. Note the sequence of assem-
bly. —-
14 Repeat 11 and 12 on the rear rocker
shaft arrangement.
IRC 784
Refitting
15 Fit a suitable siave bolt and packing
washer into the tapped hole at front
end of camshaft. This will enable the
camshaft to be rotated as required to
position the cam lobes away from the
rocker assembly being fitted.
16 To aid reassembly, lay out the six
spacer washers to be fitted between
the inlet cam followers and exhaust
valve rockers as follows:
Thick, thin, medium, medium, thin,
thick.
17 Reverse 14 in the order removed,
noting the fitted positions of the
spacing washers. Items 18 to 20.
18 Thick washers.
19 Medium washers.
20 Thin washers.
21 Feed in the rear rocker shaft. Ensure
that the locating screw hole in the
shaft is to the front; use the extractor
tool to align the hole with the hole in
the block.
22 Secure the shaft with the locating
screw and lock washer.
23 Reverse 12 and 13 in the order re-
moved.
24 Feed in the front rocker shaft. Ensure
the locating screw hole in the shaft is
to the rear and in line with the hole in
the block.
IRC785
DATA
Tappet clearances:
Inlet 0. ie
25 Reverse B and 9.
26 Reverse 3, 4 and 5 setting the valve
timing as described,
27 Set the tappet clearances te 0,15 mm
(0.006 in.) for inlet valves and 0,25
mm (0.010 in.) for exhaust valves in
the following order:
Set No, | tappet with No, 6 valve fully
open.
Set No. 2 tappet with No. 5 valve fully
open.
Set No. 3 tappet with No. 4 valve fully
open.
Set No. 4 tappet with No. 3 valve fully
open.
Set No. 5 tappet with No. 2 valve fully
open
Set No, 6 tappet with No. 1 valve fully
open.
28 Reverse ! and 2 and fit the rocker
COVETS.
29 (Check, and if necessary, reset the iniet
valves tappet clearances with the
engine at normal running temperature.
0,15 mm {0.006 in.).
0.25 mm {0.010 in.).
Г
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=
INLET VALVE ROCKERS
Replace Bush 12.29.55
Replacing bush
| Remove the rockers and shafts.
12.29.35.
2 Press out the bush from the rocker.
INC ZEN
3 Press in the replacement bush to
0,25 mm to 0,50 mm (0.010 in. to
0.020 in.) below the thrust face of
the rocker.
4 Using the holes in the rocker as
guides, drill oil holes 1,58 mm
(0.062 in.) and 2,77 mm (0.109 in.)
diameter in the bush,
5 Ream the bush to 12,5 mm + 0,025
mm (0.500 in. + 0.001 in.).
6 Reverse 1.
ENGINE ASSEMBLY
Remove and refit 12.41.01
Removing
1 Remove the bonnet. 76.16.01.
2 Disconnect the battery earth lead.
3 Remove the radiator and grille panel.
26.40.01.
4 Remove the gearbox tunnel cover.
76.25.07.
7 Disconnect the front exhaust pipe
from the manifold.
6 Remove the exhaust heat shield,
7 Disconnect the starter lead at the
solencid.
8 Disconnect the oil pressure and water
temperature wires from the multi-plug
on the main harness by the clutch
pedal box, remove from the clip and
release the harness clip from the air
pipe.
9 Disconnect the engine earth cable at
the chassis side-member.
10 Where fitted, disconnect the heater
hoses.
11 Where fitted, disconnect the control
cable at the heater water valve.
12 Disconnect the switch lead and HT
lead at the ignition coil.
13 Disconnect the fuel feed at the filter.
14 Release the accelerator return spring.
15 IMsconnect the accelerator linkage at
the spring loaded bell crank lever.
16 Remove the fixings securing the clutch
hose and speedometer cable bracket at
the flywheel housing.
17 Disconnect the cold start
cables at the carburetter.
18 Detach the servo hose at the manifold
pipe.
19 Remove the alternator lead from the
solenoid,
20 Untape and remove the white wire
from the throttle jack.
21 Remove the ignition coil from the
bulkhead.
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22 Support the engine weight, using a
suitable lifting sling.
23 Remove the engine front mountings
upper and lower fixings.
24 Support the gearbox, using suitable
packing blocks or a jack, and remove
the bell housing to flywheel housing
fixings.
25 Pull the engine forward sufficient io
disengage the drive from the gearbox.
YR 819
26 Ensure that all cables, pipes etc. are
clear then hoist the engine from the
vehicle.
Refitting
27 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.
28 Engage a gear to prevent gearshaft rota-
tion and offer the engine to the gearbox. If
necessary, Totale the engine sufficient to
align the gearbox primary pinion with the
clutch plate splines.
29 When aligned, push the engine fuily to the
rear and secure the bell housing to the fly-
wheel housing, tightening the fixings
evenly.
30 Lift the engine sufficient to remove the
packing or jack from beneath the gearbox
and insert the engine front mounting
rubbers.
3} Reverse 11023.
FLYWHEEL
Remave and refit 12.53.07
Removing
1 Remove the front floor. 76.10.12.
2 Remove the seat base. 76.70.06.
3 Remove the engine assembly. 12.41.01.
4 Remove the clutch assembly.
33.10.01.
5 Remove the flywheel,
Refitting
6 Fit the flywheel to the crankshaft and
tighten the securing belts. 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 | to 4.
FLYWHEEL
Overhaul 12.53.10
Procedure
Wear or scoring on the flywheel pressure
face may be corrected by machining, pro-
viding that the overall thickness of the
flywheel is not reduced below 30,5 mm
(1.204 in.).
1 Remove the flywheel. 12.53.07.
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
refaced as follows:
4 Remove the dowels.
5 Reface the flywheel over the compiete
surface,
6° Check the overall thickness of the
-- flywheel to ensure that it is still above
the minimum thickness.
7 Fit the dowels,
X Refit the flywheel, 12.53.07.
IRC BZ5A
1RC 8274
IRC 828
STARTER RING GEAR
Remove and refit 12.53.19
Removing
1 Remove the flywheel, 12.53.07.
2 Drill an 8 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 fragments.
WARNING: Take adequate precautions
against fragments as the starter ring may
break asunder when being split.
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.
& Locate the heated starter ring gear in
position on the flywheel with the
square edge of the teeth against the
flywheel flange.
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IRC 309
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.
Ar
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SPIGOT BEARING
Remove and refit 12.53.20
Removing
1 Remove the flywheel, 12.53.07
2 Press the spigot bearing from the
flywheel.
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.
OIL FILTER ASSEMBLY, EXTERNAL
Remove and refit 12.60.01
Removing
Remove the fixings, oil filter adaptor
to cylinder block.
2 Withdraw the oil filter assembly com-
plete with adaptor.
3 Withdraw the front and rear joint
washers.
4 If required, remove the fixings and
detach the filter body from the
adaptor; withdraw the joint washer,
Refitting
5 Reverse das necessary. Torque 3,45 kgf m
(25 lof ft).
6 Reverse 1 to 3,
7 Replenish the lubricating oil as necessary.
OIL STRAINER
Remove and refit 12.60.20
Removing
l Remove the oil sump. 12.60.44.
2 Remove the strainer fixings.
3 Withdraw the strainer from the oil
pump.
Refitting
4 Wash the strainer, using clean fuel.
5 Reverse 1 to 3.
RC IN
IRC787
OIL PUMP
Remove and refit 12.60.26
Removing
1 Remove the oil sump. 12.60.44,
2 Remove the relief valve retainer and
joint washer.
NOTE: Take care to retain the steel ball
which is freed from the oil pump relief
outlet.
3 Withdraw the spring and plunger.
4 Remove the oil pump locating screw.
5 Withdraw the oil pump and strainer
assembly from the engine.
Refitting
6 Offer the oil pump assembly to the
engine and align the pressure relief
valve housing and the locating screw
bore with the respective tappings in
the engine block.
7 Reverse 1 to 5.
OIL PUMP
Overhaul 12.60.32
Dismantling
| Remove the oil pump. 12.60.26,
2 Remove the oil pump strainer.
3 Remove the oil pump body.
4 Lift out the pump gears.
Inspecting and replacement
5 Clean all parts and examine for wear.
6 If required, unscrew and replace the
idler gear spindle in the pump cover.
7 Tf required, replace the drive shaft
bush at the top of the pump body.
Press the replacement bush into the
body and ream in position to 14,28
mm + 0,02 mm (0.5625 in, + 0.001
in.). Ensure correct alignment with the
bore at the bottom end of the pump
body; the bush should be a light drive
fit.
8 If required, replace the bush in the
idler gear. Drill the oilway 3,0 mm
{0.125 in.) diameter then ream the
bush, in position, to 12,7 mm + 0,02
mm (0.500 in. + 0.001 in.) in dia-
meter.
2 Fit the idler gear to the spindle.
10 Fit the driving gear with the plain part
of the gear bore uppermost.
il Using a straight edge and feeler gauges,
check the gears end-float which should
be:
Driving gear: 0,05 to 0,12 mm (0.002
to 0.005 in.).
Idler gear: 0,07 to 0,15 mm (0.003 to
0.006 in.).
12 Reverse | to 3.
OIL SUMP
Remove and refit 12.60.44
Removing
1 Remove the sump plug and drain off
the lubricating oil.
2 Withdraw the dipstick.
3 Remove the fixings at the sump flange.
4 Lower the sump to clear the oil
strainer and withdraw.
5 Withdraw the sump joint washer.
Refitting
6 Reverse 4 and 5, using a new sump
joint washer.
7 Reverse 3, fitting the two 5/16 in.
UNC bolts into the timing gear cover
tappings.
6 Reverse 1 and 2.
9 After 1600 km (1000 miles) running,
recheck sump bolts for correct torque as
follows:
IO Slacken each bolt in turn approximately
one flat, then retighten to 1.65 kgf m {12
li ft).
TIMING GEAR COVER AND OIL
SFAL
Remore and refit
Gear cover 1 to 9 12.65.01
Oil seal 12.65.05
Service tool: 530102 Spanner for starter
dog
NOTE: On initial assembly of the engine,
the mud shield around the oil seal is
rivetted in position but after removal in
service the rivets are substituted with self
tapping drive screws.
Where drive screws are fitted, it may be
possible to renew the seal without remov-
ing the timing gear cover.
AT 7, if the mud shield is fitted with drive
screws, the screws may be removed and the
oil seal extracted.
On fitting a new seal, the mud shield
should be allowed to finally pull the seal
into position to ensure a positive location.
Removing
i Remove the bonnet. 76.16.01,
2 Remove the fan blades and radiator front
panel assembly. 26.40.01.
3 Stacken the air pump fixings and
remove the drive belt.
4 Slacken the alternator fixings and
remove the fan belt.
Remove the alternator adjusting link.
Remove the starter dog using 530102.
Withdraw the crankshaft pulley.
At this point, see note above and if the
mud shield is rivetted:
Remove the timing cover fixings,
including those at the sump front face.
Taking care not to damage the sump
joint, carefully withdraw the timing
cover and gasket,
10
11
12
13
14
Drill out the rivets securing the oil seal
mud shield.
Press out the oil seal and clean the
mating surfaces.
Smear the outside diameter of a new
oil seal with Hylomar Pl 32/M jointing
compound.
Press the oil seal into the timing cover,
Coat the drive screws with Hylomar
and fit and secure the mud shield.
continued
F= LH
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Refitting
15 Smear general purpose grease on both
sides of the cover joint washer.
16 Reposition the cover on the engine
and refit the fixings.
17 Fit the starter dog. Torque: 27,65 kgf.
m (200 Ibf. ft.).
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18 Fit the alternator adjusting link.
19 Refit the fan belt and adjust.
20 Refit the air pump drive belt and
adjust.
21 Reverse 1 to 3.
IRC 84 3A
TIMING CHAIN GEARS
Remove and refit 12.65.12
Service tool: 507231 Extractor for chain-
wheel
Removing
I Remove the radiator and front panel.
26.40.01.
Remove the timing gear cover. 12.65.01.
Remove the timing chain tensioner.
12.65.28.
Remove the camshaft chainwheel fix-
ings.
5 Extract the camshaft chainwheel,
using 507231, together with the crank-
shaft chainwheel.
6 Withdraw the chain from the chain-
wheels.
7 Replace the chain vibration damper if
the rubber facing is worn.
+ LD by
Refitting, including valve timing procedure
Temporarily fit the timing gear cover,
using fixings sufficient to retain it on
the dowels,
9 Fit the timing pointer to the cover.
10 Temporarily fit the pulley to the
crankshaft, engaging the keyway and
key.
11 Rotate the crankshaft to align the
TDC mark on the pulley with the
timing pointer.
0 o oe | я <
WN A 1 tE > IF i AD
a A
6 a EF
IRC 776
12 Remove the crankshaft pulley and
timing gear cover without disturbing
the crankshaft position.
13 Temporarily fit the camshaft chain-
wheel, engaging the keyway marked
‘PF,
14 Rotate the camshaft to position the
groove marked ‘A’ in line with the
centre line of the top fixing hole for
the gear cover. Remove the chainwheel
without disturbing the camshaft posi-
tion.
15 Fit the crankshaft chainwheel, cham-
fered bore first, to just engage the
crankshaft inner key.
14
IRC 77B
DATA
Clearance, timing chain to chain vibration
damper .......... 1120
16 Position the chain on the chainwheels,
aligning the keyway *P” with the cam-
shaft key and with ‘no slack’ at the
driving side of the chain.
17 Fit the camshaft chainwheel and
chain.
18 Lightly tap home the chainwheels.
NOTE: It is important that the timing
chain has no slack at the driving side.
Slightly offset keyways are provided in the
camshaft chainwheel to enable adjustment
to be made, if required, provided that the
crankshaft and camshaft relationship is not
disturbed.
19 Fit and lock the camshaft chainwheel
fixings.
20 If required, adjust the chain vibration
damper position to allow 0,05 mm to
0,25 mm (0.002 in. to 0.010 in.)
clearance with the chain.
21 Reverse 2 and 3. Torque load for
starting dog fixing is 27,5 kgf. m (200
Ibf. ft.}.
22 Reverse |.
0,05 mm to 0,25 mm (0.002 in.
to 0.010 in.)
TIMING CHAIN TENSIONER
Remove and refit 12.65.28
Removing
1 Remove the radiator and front panel.
26.40.01.
2 Remove the timing gear cover. 12.65.01.
3 Remove the tensioner retaining bolts
and spring washers.
4 Remove the tensioner and backplate
between the tensioner body and cylin-
der block.
Dismantling
5 Press in the slipper and remove it from
the tensioner body.
6 Remove the ratchet and spring.
Examination
7 Check the slipper pad for wear, and
renew if necessary.
8 Examine the ratchet for wear and
renew if suspect.
9 Check the spring and renew if broken
or suspect.
10 Examine the tensioner body and check
that the oil inlet hole is clear.
Reamembling
11 Insert the spring into the slipper bore.
12 Fit the ratchet into the bore and turn
clockwise with an Allen Key to lock it
in a retracted position.
13 Fit the slipper assembly to the ten-
sioner body.
NOTE: To prevent the tensioner releasing
while fitting, insert a spacer between the
tensioner body and the back of the slipper.
14 Fit the tensioner assembly and back-
plate to the cylinder block taking care
not to allow the tensioner to release.
Secure with the two bolts and spring
washers.
15 Ensure correct location of the chain
guide.
16 Reverse 1 and 2.
IRC?
PT2 20!
GROUP B
ENGINE ASSEMBLIES 2.6 Litre Petrol
ZEN
Engine complete assembly 7.0:1 N.L.S
Engine complete assembly 7.8:1 RTC2475N Detoxed
Complete with all ancillaries except flywheel and clutch
LAND ROVER 10 02 \51330,
aRDUP B GROUP B
ENGINE - Cylinder Block 2.6 Litre Petrol ENGINE - Cylinder Block Fixings 2.6 Litre Petrol
NLS
255206(2) TE606231L(5)
272452
WM600041L (2) 239449 602915
231218 Ne
NON
252622(2)
231219 252626 (21
6
ERCA935(6) 27941
“© 525497(2) 2572627(4)
52124(2)
279413
605157
524636 (2)
WM600081L (4)
272451(2) 252621
NLS
—8 © 2995(2) 562654
Stripped engine assembly new ro rade (up to Engine suffix 'B’ inclusive
Stripped enaine assembly new 7.8:1 N : API
Stripped engine assembly rebuilt 7.8:1 RTC2388R (From Engine suffix °C’ onwards
Short engine 7.0:1 RTC2643
Short engine 7.8:1 RTC2642
Stud and dowel kit for cylinder block 535708
Cylinder liner 516498{6)
Engine overhaul gasket kit 605106
Decarbonising gasket kit RTC3333
25 LAND ROVER 1D 03 2RE 36 | ao ROVER 10 03 2RE_37
3ROUP B
ENGINE - Crankshaft 2.6 Litre Petrol.
600177 Standard
600174 0,0025in
600175 0,005 in
600176 0,0075in
600178 0,010 in
600179 0,0125in
523240 @ RTC1720/10 US FQ)
246464(2) RTC1720/20 US
No “SHE04071L{10)
WM600041L (10)
— 542197 (2)
542622
546324
542623
(1) Engine Set
G)crankshaft oil seal and retainer assembly 542494 includes silicone grease 270656
J LAND ROVER _1D 04
2RE 51
GROUP B
Г р TTT TTT
| | |
| | |
Std RTC2411(6) |
| 0.020in OS RTC2411/20(6)(@
| | 0.040in OS RTC2411/40(6) |
| | |
| | | - >» |
| сова (12) |
| «a |
I
264569(4) |
| |
| ERC23375(6) Standard |
53726916) 0.020in 0S |
| 537271(6) 0.04015 05 |
ERC23395(6) Standard | —-
536273(6)-8-B20in 05 H(3)
536275(6) 0,040in OS
273163(6)
524492(6) |
ll RTC1721 Std |
50518100(12) — (7 (8 RTC1721/10 US —
Z RTC1721/20 US
ERCIO27(12)- —
(1) Engine Sei
(2) Engines with 7.8:1 compression ratio
(3) Engines with 7.0:1 compression ratio
(4) Piston ring set
Ó no ROVER 19 04 2RE 52
aRQUP B
INGINE - 0il Pump Body and Release Valve 9.6 Litre Petrol
52278
274084
2504
274928
521583. й
212309
542396
> NT605061L
274086
245940
255227(4) 504997
243971
WMG 4
00051L(4) 504995
011 pump assembly 90564334
Assembly does not include drive shafts on adjacent frame
a
e LAND ROYER 1D 05
2RE 43
GROUP B
ENGINE - Oil Pump Gears, Drive Shaft and Body, 2.6 Litre Petrol
2678291)
90502209
7 -
| 236257(2) 598214 (7)
240555
564335
90564217
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011 pump assembly 90564334
(1) Assembly does not include drive shafts
© am ROVER 1D 05
ZRE 50
ENGINE - Camshaft 2.6 Litre Petro!
GROUP B
WM600041L(3)
255206(3)
276541
ENGINE - Camshaft Chain and Chainwheel 2.6 Litre Petrol
GROUP B
530481
2500(3)
502266
266667
2RE 35
1D 06
274116
9 LAND ROVER
ZRE 49
255206(3)
ply
RE pt
+ i ve
10 96
BH604111L(2)
LAND ROVER
SHEOBOZ1L
3ROUP B GROUP B
ENGINE - Valves and Push Rods 2.6 Litre Petrol ENGINE - Inlet Valve Rockers 2,6 Litre Petrol
NT605061L (6)
268293(12) 506816(6
268292(6) © © NT605061L (3)
7 =)
NI
(O) WF600051L (3) —— Es
№” 5 525910(3)
+ 238871 (3) Xx
EL 23301006) © m0 8
|
= 231344(3) o
|
e No 568786(6)
=) Exhaust
== 525124 (6) 230034 (6)
Es Inlet |
90512142(12) 90512144(6) 500609 (6)
2 90512143(6) Vo
Sp)
pd 506817(6)
568475(6)
NT6050611 (6) > 243959
- 536577
525911 (3)
231352 (3)
212161 (6) 231348
a
| |
Sum ROVER 1D 07 2RE. 39 ® LAND ROVER 10 07 2RE 40
GROUP B GROUP B
ENGINE ~ Exhaust Valve Rockers and Inlet Cam Followers 2.6 Litre Petrol ENGINE - Side Cover apd Sump 2,6 Litre Petro]
267828(4) 274091(4)
. y
542426
587923 598231
90500610{6)
N 274817
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273309 (2) NN A
505597(2) Thin , A
Shim ‘ | A
| WY,
NHE05041L
532387
- LL
231577
273308(2)
hick
Thic £31874(3) 4m
90517429(3)
536872(3) €
> /
y 90517429 (3)
273307 do >
Rear 7 ) 90517429(3)
536873(3)M
90517429(3)
531873(3) #9 RTC1964(2)
273306
Front
564215 e
SHSO5071L (2) U
RTC636 255227 (16) UNF
E
md |
| © 2
© wo ROVER 10 08 2RE 41 LAND ROVER 1D 08 RE 48
GROUP B
ENGINE - Front Cover and Engine Breather 2.6 Litre Petrol
587104
55
4260(3) 603330
587105
566957
/ WM600051L (2)
7 SHE05061L(2)
554924
WM600051L (10)
ко
BH605161L(10)
214058
W600041L S
564163 q —
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A +
ta ~~
\
542256 (8) 272835
542073 90516028
Tr
ET
|
Lan ROYER 10 09 ¿RE 47
aROUP Y
ENGINE - Water Pump 2.6 Litre Petrol Up to Engine Suffix 'B' inclusive
563037
564164
568301
564270
564197
ERC3978
Water Pump overhau? kit 605716
Es LAND ROVER 1D 09 2RE 45
GROUP B
GROUP B DETOXED ENGINE - Water Pump and Viscous Fan 2.6 Litre Petrol From Engine Suffix 'C' onwards
ENGINE - Water Pump Adaptor and Fan 2.6 Litre Petrol UU TUTTO
243969
er |
|
235208 598486 |
BHAQACBIL (3)! AN на SN |
BH604091L (2) | _ CC \ | NAN-----—— 5924e3-=-----———--
BH604141L < +. \ я . NAS
BH5O4181L
3X604221L (2)!
ERC1742
574044 (2)
26426
274737
© | 562915 @ |
CN100508L (1)
614739
BH604101L (4)
NY607041L.
WM600051L (4 (2)
BH6O4101L(4) (3) 5
| 557517()———1E:
587468 (2)
| D Not required after August 1974 when one piece moulded bottom hose is fitted
(2) Up to Engine Suffix 'B' inclusive
From Engine Suffix co frame 1D 10 RH
LAND ROVER 10 10 2ВЕ 46 LAND ROVER 10 10 SRE 218
GROUP B GROUP B
ENGINE - Thermostat and Oil Pipe 2,6 Litre Petrol ENGINE - Cylinder Head 2.6 Litre Petrol
90513171
506047(3)
205038 278164 243958
598006(2) 243972
252515(4)
251002 (3) A
WM702001L (3) а
NH6O4041L (3)
(D 518272 1" dia
(2) 525497 15/16" Dia
511834(6) -
230062(6)
532319
(1) 210492 (4)}" dia
238046 (4) 22.5mm Dj
232039(2) © “ mo
TT
(1) 230251(7) ,688" Dia
(2) ERCA709(7) 16.250 Dia
>
ERC4707
232037
253003
(1) 230250(2) 14" Dia
(2) ERC256(2) 31,5mm — 266321(6)
90519864
Dur to October 1972
CORE PLUGS
(2)From November 1972 onwards 3 plugs CHECK BEFORE ORDERING
© LAND ROVER 19 11 2RE 66 1D 11 ОКЕ 64
GROUP B
ENGINE - Cylinder Head Fixings 2.6 Litre Petrol SROUP B
ENGINE - Rocker Cover 2.6 Litre Petrol
546210 568397
ERC2275 ERC438/
SH505061L(2) SH506071L (2)
\
274089(3)
WM600051L{2)
90574103(3)
568391 (1)
ERC3343(@)
WM600061L (2)
274100
568725
ERC3325
WM600051L (2)
ERC3324 (®)
SH505061L(2)
ERC2280 RTC3308
(1) Un to Engine suffix 'B' inclusive
(2) From Engine suffix 'C' onwards
| LAND ROVER 10 12 CRE 651 [LAND ROVER 1D 12 2RE42/A
aROUP В
ENGINE - Di] Filter and Adaptor 2.6 Litre Petrol
587723
232041
274609
6027212
<) 602212
O
Y WM600051L (2)
Ú
BH605161L (2)
597722
BH60724 11
ETC5276
BH6072811
WM600071L (2) RTC3183
SH507101L (2
90513581
516885
608169
©
a LA"D ROVER 10 33 2RE 34
GROUP B
ENGINE - Exhaust Manifold 2.6 Litre Petrol
WB110061L
WM60006 1 L (4 }
587401
WM600051L (2)
NH605041L (2)
Ds
O LAND ROVER 1D 13 2RE 33
GROUP B
VE TOXED ENGINE - Air Injection Pump 2.6 Litre Petrol From Engine Suffix 'C' onwards
GE mensa
WM600051L
GROUP B
DETOXED ENGINE - Exhaust Manifold Adaptor 2.6 Litre Petro] From Engine Suffix 'C' onwards
BH605381L
RTC3497
=,
ERC2456 — |
TT Y
ERC1454(4) но A "A
ERCS169
WM600051L
№
NH6O5041L (2)
ERCT460
ERC3525 GT
x» Ue; =
9 Que UY >
y @
| ` Q | WM600051L
| ; ERC2659
| ; : 2266L
SE 253205(3) ERCES69
ERC1456
—y Y р ERC2658
ERC2662
; BH605381L
- N 22661
0 a
LAND ROVER 10 14 6RE 212] [LAND ROVER 10 14 6RE 211/A
GROUP B
GROUP B
ENGINE - Tie Rod 2,6 Litre Petrol
ENGINE - Mountings and Rubbers 2.6 Litre Petrol
NT605061L
NH605041L
7015L
SHE06081L (4
509885
272498 y &)
SH606121L(4
©
WD110061L(4)
NH605041L(2)
HM600051L (2),
.. .
WM600061L oS 5988534) €)
>
3933. DO
NRC2029 @ D(D NH606041
2851. DO) A 2513224) [email protected]
oe 850641 M DO NY110041L(4) [email protected]
504607
WM6000611 (4) D @
WL110001L (4) DO)
NT605061L
NH406041L (4)
D110061L(2 NRC2054(2)D D
"ini y 200 leo
WC110061L(2) DB) NRC2053(2
BSF Fixings
Metric Fixings
3) Front Mounting
(4) Rear Mounting
© 1 Топ
ID an ROVER 10 15 CI чо ROVER
2RE 38 10 15
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