V8 Overhaul Manual - land rover service factory manual RAVE

V8 Overhaul Manual - land rover service factory manual RAVE
V8
ENGINE
OVERHAUL
MANUAL
This overhaul manual is applicable to 3.5,
3.9 and 4.2 Litre V8 engines with or without
suffix B added to the engine serial number.
Publication Part No. RCL
Published by Rover Technical Communication
 1996 Rover Group Limited
INTRODUCTION
INTRODUCTION
References
How to use this Manual
With the engine and gearbox assembly removed,
the crankshaft pulley end of the engine is referred to
as the front. References to RH and LH banks of
cylinders is taken viewing from the flywheel end of
the engine.
To assist in the use of this Manual the section title is
given at the top and the relevant sub-section is given
at the bottom of each page.
This manual contains procedures for overhaul of the
V8 engine on the bench with the gearbox, clutch,
inlet manifold, exhaust manifolds, coolant pump,
starter motor, alternator, and all other ancillary
equipment removed. For information regarding
General Information, Adjustments, removal of oil
seals, engine units and ancillary equipment, consult
the Repair Manual.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle is carried out particularly where safety
related items are concerned.
Dimensions
Each major section starts with a contents page,
listing the information contained in the relevant
sub-sections. To assist filing of revised information
each sub-section is numbered from page 1.
The dimensions quoted are to design engineering
specification with Service limits where applicable.
The individual overhaul items are to be followed in
the sequence in which they appear. Items numbers
in the illustrations are referred to in the text.
Overhaul operations include reference to Service
tool numbers and the associated illustration depicts
the tool. Where usage is not obvious the tool is
shown in use. Land Rover tool numbers are quoted,
for the equivalent Rover Cars tool number refer to
the Service Tool section. Operations also include
reference to wear limits, relevant data, and specialist
information and useful assembly details.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
INTRODUCTION
1
INTRODUCTION
REPAIRS AND REPLACEMENTS
SPECIFICATION
When replacement parts are required it is essential
that only Rover recommended parts are used.
Rover Group are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Torque wrench setting figures given in this Manual
must be used. Locking devices, where specified,
must be fitted. If the efficiency of a locking device is
impaired during removal it must be renewed.
The terms of the vehicle warranty may be
invalidated by the fitting of parts other than Rover
Group recommended parts. All Rover Group
recommended parts have the full backing of the
vehicle warranty.
Rover Group dealers are obliged to supply only
Rover Group recommended parts.
2
INTRODUCTION
This Manual does not constitute an offer for sale of
any particular component or vehicle. Rover Group
dealers are not agents of Rover Group and have no
authority to bind the manufacturer by any expressed
or implied undertaking or representation.
INFORMATION
DATA
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 8, 4, 3, 6, 5, 7, 2
Cylinders 1, 3, 5, 7 - LH side of engine
Cylinders 2, 4, 6, 8 - RH side of engine
Valve springs
Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.30 mm
Fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.40 mm
Load at fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . 339 ± 10 N
Valves
Valve stem diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve installed height - maximum . . . . . . . . . . . . . . .
Valve stem to guide clearance:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.664 to 8.679 mm
8.651 to 8.666 mm
39.75 to 40.00 mm
34.226 to 34.480 mm
47.63 mm
0.025 to 0.066 mm
0.038 to 0.078 mm
Valve guides
Valve guide installed height . . . . . . . . . . . . . . . . . . . . 24.13 mm
Valve seats
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460° 15’
Valve seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.0 mm
Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Oil pump
Gear to body minimum clearance . . . . . . . . . . . . . . . 0.05 mm
Oil pressure relief valve
Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.28 mm
Oil pump - Engine No’s with suffix B
Inner to outer rotor clearance - maximum . . . . . . . . . 0.25 mm
Rotors to cover plate clearance - maximum . . . . . . . 0.1 mm
Drive gear wear step depth - maximum . . . . . . . . . . . 0.15 mm
Oil pressure relief valve - Engine No’s with
suffix B
Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.0 mm
Camshaft
Maximum run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm
GENERAL DATA
1
INFORMATION
Piston rings
Ring to groove clearance:
Top compression . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd compression . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring fitted gap:
Top compression . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd compression . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil control rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil control ring width . . . . . . . . . . . . . . . . . . . . . . . . .
0.05 to 0.10 mm
0.05 to 0.10 mm
0.44 to 0.57 mm
0.44 to 0.57 mm
0.38 to 1.40 mm
3.00 mm, maximum
Pistons
Clearance in bore, measured at bottom of
skirt at right angles to bore . . . . . . . . . . . . . . . . . . . . 0.018 to 0.033 mm
Gudgeon pins
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.67 to 72.79 mm
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.215 to 22.220 mm
Clearance in piston . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 to 0.007 mm
Connecting rods
Length between centres . . . . . . . . . . . . . . . . . . . . . . 143.81 to 143.71 mm
Cylinder bore
Cylinder bore diameter:
3.5 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.90 mm
3.9 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.00 mm
4.2 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.00 mm
Crankshaft
Main journal diameter . . . . . . . . . . . . . . . . . . . . . . . .
Minimum regrind diameter . . . . . . . . . . . . . . . . . . . .
Maximum out of round . . . . . . . . . . . . . . . . . . . . . . .
Big-end journal diameter . . . . . . . . . . . . . . . . . . . . . .
Minimum regrind diameter . . . . . . . . . . . . . . . . . . . .
Maximum out of round . . . . . . . . . . . . . . . . . . . . . . .
End-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58.409 to 54.422 mm
57.393 to 57.406 mm
0.040 mm
50.800 to 50.812 mm
49.784 to 49.797 mm
0.040 mm
0.10 to 0.20 mm
Main bearings
Main bearing diametrical clearance . . . . . . . . . . . . . . 0.010 to 0.048 mm
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 mm, 0.508 mm
Big-end bearings
Big-end bearing diametrical clearance . . . . . . . . . . . 0.015 to 0.055 mm
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 mm, 0.508 mm
Endfloat on journal . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 to 0.36 mm
Flywheel
Flywheel minimum thickness . . . . . . . . . . . . . . . . . . . 39.93 mm
Drive plate
Drive plate setting height . . . . . . . . . . . . . . . . . . . . . . 8.08 to 8.20 mm
2
GENERAL DATA
INFORMATION
ENGINE
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . .
Timing cover to cylinder block bolts ** . . . . . . . . . . . .
Camshaft gear bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker shaft to cylinder head bolts . . . . . . . . . . . . . .
Cylinder head bolts: *
Outer row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centre row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head bolts - Engine No’s with suffix B: *
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting eye to cylinder head bolts . . . . . . . . . . . . . . . .
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing cap bolts *** . . . . . . . . . . . . . . . . . . . . .
Rear main bearing cap bolts *** . . . . . . . . . . . . . . . . .
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive plate and ring gear assembly bolts . . . . . . . . . .
Drive plate adapter bolts . . . . . . . . . . . . . . . . . . . . . .
Oil sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure relief plug . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump cover to timing cover . . . . . . . . . . . . . . . . .
Oil pump cover plate screws - Engine No’s with
suffix B **** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil strainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . .
Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant pump/timing cover to cylinder block . . . . . . .
*
**
***
****
270 Nm
22 Nm
50 Nm
8 Nm
38 Nm
60 Nm
90 Nm
90 Nm
20 Nm
Then 90°
Further 90°
25 Nm
50 Nm
70 Nm
90 Nm
80 Nm
40 Nm
80 Nm
40 Nm
23 Nm
45 Nm
12 Nm
4 Nm
10 Nm
20 Nm
15 Nm
22 Nm
Lightly oil threads prior to assembly.
Coat first three threads with Loctite 242 prior to assembly.
Coat threads with lubricant EXP16A (Marston Lubricants) prior to assembly.
Coat threads with Loctite 222 prior to assembly.
TORQUE WRENCH SETTINGS
1
INFORMATION
GENERAL
For bolts and nuts not otherwise specified:
METRIC
M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Nm
6 Nm
18 Nm
35 Nm
65 Nm
80 Nm
130 Nm
UNC / UNF
1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10 Nm
25 Nm
40 Nm
75 Nm
90 Nm
135 Nm
2
TORQUE WRENCH SETTINGS
ENGINE
This page is intentionally left blank
DESCRIPTION AND OPERATION
1
ENGINE
2
DESCRIPTION AND OPERATION
ENGINE
CYLINDER BLOCK COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Cylinder block
Piston and gudgeon pin
Connecting rod
Core plugs
Camshaft
Dipstick
Camshaft key
Timing chain
Camshaft sprocket
Spacer
Distributor drive gear
Distributor
Oil pump gears *
Timing cover and gasket *
Timing cover oil seal *
Crankshaft pulley
Crankshaft sprocket
Woodruff key
Crankshaft
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Centre main bearing shell - upper
Crankshaft rear oil seal
Rear main bearing cap and side seals
Connecting rod cap
Main bearing caps
Oil pump cover *
Oil pressure relief valve assembly *
Oil pressure switch *
Oil pump suction pipe and strainer
Sump
Drain plug
Timing cover **
Timing cover gasket **
Timing cover oil seal **
Oil filter **
Oil pressure switch **
Oil pressure relief valve assembly **
Camshaft thrust plate - if fitted
* Engine numbers without suffix B
** Engine numbers with suffix B
DESCRIPTION AND OPERATION
3
ENGINE
CYLINDER HEAD COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
4
Cylinder head
Rocker cover
PCV filter
Rocker shaft
Tappet
Pushrod
Rocker shaft bracket
Rocker arm
Rocker shaft spring
PCV air intake filter
DESCRIPTION AND OPERATION
11.
12.
13.
14.
15.
16.
17.
18.
Engine oil filler cap
Inlet valve seal, spring, cap, and collets
Exhaust valve seal, spring, cap and collets
Inlet valve and seat
Exhaust valve and seat
Inlet manifold gasket and seals
Cylinder head gasket
Valve guide
ENGINE
Operation
The V8 engine is an eight cylinder, water cooled unit
comprising of cast aluminium cylinder block and
cylinder heads.
The two banks of steel cylinder liners which are
pressed down to stops in the cylinder block, are set
at 900 to each other. The crankshaft is carried in five
main bearings, end-float being controlled by the
thrust faces of the upper centre main bearing shell.
The centrally located camshaft is driven by the
crankshaft via an inverted tooth chain. The valves
are operated by rockers, pushrods and hydraulic
tappets. Distributor drive is by skew gear from the
front of the camshaft.
The aluminium alloy, pistons have two compression
rings and an oil control ring and are secured to the
connecting rods by semi-floating gudgeon pins. On
later 4.2L engines the gudgeon pin is offset 0.5mm,
identified by an arrow mark on the piston crown,
which must always point to the front of the engine.
Plain, big-end bearing shells are fitted to each
connecting rod.
DESCRIPTION AND OPERATION
5
ENGINE
Lubrication - Engine numbers without suffix B
1.
2.
3.
4.
6
Oil strainer
Crankshaft main bearing oil feed
Oil pressure relief valve
Oil pump
DESCRIPTION AND OPERATION
5. Main gallery
A Oil to cooler
B Oil from cooler
ENGINE
Lubrication - Engine numbers with suffix B
1.
2.
3.
4.
Oil strainer
Oil pump
Pressure relief valve
Oil pressure switch
5. Main gallery
A Oil to cooler
B Oil from cooler
Engine numbers without suffix B
All engines
The full flow lubrication system uses an external
gear pump which is driven by the distributor drive
shaft. The oil pump gears are housed in the timing
cover and the oil pressure relief valve and warning
light switch are fitted to the oil pump cover.
Oil is drawn from the pressed steel sump through a
strainer and into the oil pump, excess pressure
being relieved by the pressure relief valve. The oil
pressure warning light switch is screwed into the oil
pump cover and registers the oil pressure in the
main oil gallery on the outflow side of the filter.
Pressurised oil passes through an oil cooler - if fitted
to the full flow oil filter and to internal drillings in the
crankshaft where it is directed to each main bearing
and to the big end bearings via Nos. 1, 3 and 5 main
bearings. An internal drilling in the cylinder block
directs oil to the camshaft where it passes through
further internal drillings to the hydraulic tappets,
camshaft journals and rocker shaft. Lubrication to
the thrust side of the cylinders is by oil grooves
machined in each connecting rod big end joint face,
which are timed to align with holes in the big end
journals on the power and exhaust strokes.
Engine numbers with suffix B
The full flow lubrication system uses a gear type oil
pump driven from the crankshaft. The assembly is
integral with the timing cover which also carries the
full flow oil filter, oil pressure switch and pressure
relief valve.
DESCRIPTION AND OPERATION
7
ENGINE
Distributor drive and timing chain lubrication
1.
2.
3.
4.
5.
6.
Bearing
Camshaft
Key
Camshaft timing chain sprocket
Spacer
Distributor drive gear
The distributor drive and timing chain are lubricated
from the camshaft front bearing. The feed to the
timing chain is channelled along the camshaft
sprocket, key and spacer.
Hydraulic tappets
1.
2.
3.
4.
5.
6.
7.
8.
Clip
Pushrod seat
Inner sleeve
Upper chamber
Non-return ball valve
Spring
Outer sleeve
Lower chamber - high pressure
The purpose of the hydraulic tappet is to provide
maintenance free and quiet operation of the inlet
and exhaust valves. It achieves this by utilising
engine oil pressure to eliminate the mechanical
clearance between the rockers and the valve stems.
During normal operation, engine oil pressure present
in the upper chamber passes through the non-return
ball valve and into the lower, high pressure,
chamber.
When the cam begins to lift the outer sleeve, the
resistance of the valve spring felt through the push
rod and seat causes the tappet inner sleeve to move
downwards inside the outer sleeve. This downward
movement of the inner sleeve closes the ball valve
and increases the pressure in the lower, high
pressure chamber, sufficiently to ensure that the
push rod opens the valve fully.
As the tappet moves off the peak of the cam the ball
valve opens to equalise the pressure in both
chambers which ensures the valve closes when the
tappet is on the back of the cam.
8
DESCRIPTION AND OPERATION
ENGINE
ROCKER SHAFTS
Rocker shaft - remove
1. LH rocker shaft only: Remove screw securing
dipstick tube to rocker cover.
6. Progressively slacken and remove 4 bolts
securing rocker shaft assembly to cylinder
head.
7. Remove rocker shaft assembly.
8. Remove pushrods and store in fitted order.
2. Remove 4 screws securing rocker cover to
cylinder head.
NOTE: Mark position of 2 longer screws.
3. Remove rocker cover.
4. Remove and discard gasket from rocker cover.
5. Mark each rocker shaft in relation to original
cylinder head.
CAUTION: Incorrect fitment of rocker
shafts will lead to an oil feed restriction.
OVERHAUL
1
ENGINE
Dismantle
1. Remove split pin from one end of rocker shaft.
2. Remove plain washer, wave washer, rocker
arms, brackets and springs.
Inspect
1. Thoroughly clean components.
2. Inspect each component for wear, in particular
rocker arms and shafts. Discard weak or
broken springs.
3. Inspect pushrod seats in rocker arms.
4. Check pushrods for straightness and inspect
ball ends for damage, replace as necessary.
Assembly
2. Fit new split pin to one end of rocker shaft.
3. Fit plain washer and wave washer.
4. Lubricate rocker arm bushes with clean engine
oil.
5. Early type rocker arms are angled, and must
be fitted with the valve end of the rocker arms
angled away from each other as illustrated.
6. On later type rocker arms the valve end is
offset and must be fitted as illustrated.
NOTE: Early and late rocker arms are
interchangeable provided the complete set
is changed.
7. Assemble rocker arms, brackets and springs to
rocker shaft.
8. Compress springs, fit wave washer, plain
washer and secure with new split pin.
1. Assemble rocker shafts with identification
groove at one o’clock position with push rod
end of rocker arm to the right.
CAUTION: If rocker shafts are incorrectly
assembled and fitted to engine, oil supply
to rocker arms will be restricted.
2
OVERHAUL
ENGINE
Rocker shaft - refit
1. Lubricate pushrods with engine oil.
2. Fit pushrods in removed order.
6. Apply a thin coating of Bostik 1775 or
equivalent impact adhesive to mating surfaces
of rocker cover and gasket.
7. Allow adhesive to cure, then fit gasket to rocker
cover.
CAUTION: Gasket fits one way round only,
it must be fitted accurately as subsequent
movement will destroy bonding.
8. Fit rocker cover to cylinder head, fit screws and
tighten to correct torque.
CAUTION: The 2 short screws must be
fitted on side of cover nearest centre of
engine.
9. LH rocker shaft only: Align dipstick tube to
rocker cover, fit and tighten screw.
3. Fit each rocker shaft assembly, ensuring
identification groove is uppermost and towards
front of engine on RH side and towards rear of
engine on LH side.
CAUTION: Incorrect fitment will result in
an oil feed restriction.
4. Fit bolts and tighten to correct torque.
5. Clean gasket surface in rocker cover using
Bostik cleaner 6001 or equivalent, and allow to
dry.
OVERHAUL
3
ENGINE
CYLINDER HEAD
Cylinder head - remove
1. Remove rocker shaft assembly.
2. Mark heads LH and RH for reassembly.
All engines
5. Release cylinder head from 2 dowels and
remove cylinder head.
6. Remove and discard cylinder head gasket.
Valves and springs - remove
Engine numbers without suffix B
1. Remove spark plugs.
NOTE: RH cylinder head illustrated
3. Using sequence shown, remove 14 bolts
securing cylinder head to cylinder block.
2. Using valve spring compressor LRT-12-034 or
a suitable alternative, compress valve spring.
3. Remove 2 collets.
Engine numbers with suffix B
NOTE: RH cylinder head illustrated
4. Using sequence shown, remove and discard
10 bolts securing cylinder head to cylinder
block.
NOTE: No bolts are fitted in the four lower
holes in each cylinder head.
4
OVERHAUL
4. Release spring compressor and remove valve,
valve spring cap and valve spring.
5. Repeat above operations for remaining valves.
CAUTION: Keep valves, springs, caps and
collets in fitted order.
6. Remove and discard valve stem oil seals.
ENGINE
Valves, valve springs and guides - inspection
1. Clean cylinder head, valve springs, valves and
valve guide bores.
2. Check existing valve stem and head diameters.
3. Check valve stem to guide clearance using
new valves.
7. Check valve stem to guide clearance.
Valve stem to guide clearance D:
Inlet = 0.25 to 0.66 mm
Exhaust = 0.38 to 0.78 mm
8. Check condition of valve springs:
Free length = 48.30 mm
Fitted length = 40.40 mm
Load at fitted length = 339 ± 10N
Load at valve open length = 736 ± 22N
CAUTION: Valve springs must be replaced
as a complete set.
Valve guide - renew
1. Using valve guide remover, LRT-12-037 press
valve guide out from combustion chamber side
of cylinder head.
NOTE: Service valve guides are 0.025mm
oversize on outside diameter to ensure
interference fit.
2. Lubricate new valve guide with engine oil and
place in position.
4. Renew valves and guides as necessary.
Valve head diameter A:
Inlet = 39.75 to 40.00 mm
Exhaust = 34.226 to 34.48 mm
Valve stem diameter B:
Inlet = 8.664 to 8.679 mm
Exhaust = 8.651 to 8.666 mm
5. Check installed height of each valve.
Valve installed height C= 47.63 mm
6. Renew valve/valve seat insert as necessary.
OVERHAUL
5
ENGINE
Valve seat insert - renew
NOTE: Service valve seat inserts are
available 0.25 mm oversize on outside
diameter to ensure interference fit.
3. Using LRT-12-038 partially press guide into
cylinder head, remove tool.
4. Fit LRT-12-515 over valve guide and continue
to press guide into cylinder head until tool
contacts spring seat. Remove tool.
Valve guide installed height A = 24.13 mm
1. Grind a crescent in seat insert, until thin
enough to break using a cold chisel.
Valve seat insert - inspection
CAUTION: Do not damage counterbore.
1. Check valve seat inserts for pitting, burning
and wear. Replace inserts as necessary.
2. Heat cylinder head evenly to approximately
65°C.
3. Using a suitable mandrel, press new insert fully
into counterbore.
4. Allow cylinder head to air cool.
6
OVERHAUL
ENGINE
Valve seats - renew
1. Check condition of valve seats and valves that
are to be reused.
2. Remove carbon from valves and valve seats.
3. Reface valves as necessary. If a valve has to
be ground to a knife-edge to obtain a true seat,
fit a new valve.
Valve seating face angle A = 45°
5. Ensure cutter blades are correctly fitted to
cutter head with angled end of blade
downwards, facing work, as illustrated. Check
that cutter blades are adjusted so that middle
of blade contacts area of material to be cut.
Use light pressure and remove only minimum
of material necessary.
4. Cut valve seats using LRT-12-501 with
LRT-12-503 and LRT-12-504.
Valve seat:
Width A: Inlet = 37.03 mm
Exhaust = 31.50 mm
Width B = 1.5 - 2.00 mm
Angle C = 70°
Angle D = 46° ± 15’
Angle E = 20°
OVERHAUL
7
ENGINE
Valves and springs - refit
1. Lap each valve to its seat using fine grinding
paste.
2. Clean valve and seat.
Cylinder head - refit
1. Clean cylinder block faces using a suitable
release agent and plastic scraper; ensure that
bolt holes in cylinder block are clean and dry.
CAUTION: Do not use metal scraper or
machined surfaces may be damaged.
2. Engine numbers without suffix B: Thoroughly
clean threads of cylinder head bolts.
CAUTION: Cylinder head bolts - Cylinder
head bolts fitted to engines without suffix
B added to serial number are not
interchangeable with those fitted to engines with
suffix B added to serial number.
3. Coat valve seat with a small quantity of
engineers blue, insert valve and press it into
position several times without rotating. Remove
valve and check for even and central seating.
Seating position shown by engineers blue
should be in centre of valve face.
3. Fit cylinder head gasket with the word ’TOP’
uppermost.
NOTE: Gasket must be fitted dry.
4. Check valve installed height if valve seats have
been recut or new valves or valve seat inserts
have been fitted.
Valve installed height A = 47.63 mm
5. Thoroughly clean cylinder head, blow out
oilways and coolant passages.
6. Fit new valve stem oil seals, lubricate valve
stems, fit valves, valve springs and caps,
compress valve springs using LRT-12-034 and
fit collets.
7. Using a wooden dowel and mallet, lightly tap
each valve stem two or three times to seat
valve cap and collets.
8
OVERHAUL
CAUTION: Engines without suffix B have a
steel gasket whilst engines with suffix B
have a composite gasket. The two types of
gasket are not interchangeable and it is essential
to ensure that the correct type of gasket is fitted.
4. Carefully fit cylinder head and locate on
dowels.
5. Lightly oil threads of cylinder head bolts.
ENGINE
Engine numbers without suffix B
9. Using sequence shown, tighten cylinder head
bolts to:
Stage 1 - Correct torque
Stage 2 - 90°
Stage 3 - Further 90°
All engines
10. Fit rocker shaft assembly.
TIMING CHAIN AND GEARS
NOTE: RH cylinder head illustrated
6. Fit cylinder head bolts:
Long bolts: 1, 3 and 5.
Medium bolts: 2, 4, 6, 7, 8, 9, and 10.
Short bolts: 11, 12, 13 and 14.
7. Using sequence shown, progressively tighten
cylinder head bolts to correct torque.
Distributor - remove
1. Remove distributor cap.
2. Rotate crankshaft until centre line of rotor arm
is aligned with No. 1 spark plug segment in
distributor cap and No. 1 piston is at TDC.
Engine numbers with suffix B
3. Scribe an alignment mark between distributor
body and clamp.
4. Remove nut securing distributor clamp.
5. Remove distributor.
6. Remove clamp.
7. Remove and discard ’O’ ring from distributor.
NOTE: RH cylinder head illustrated
8. Fit new cylinder head bolts:
Long bolts: 1, 3 and 5
Short bolts: 2, 4, 6,7, 8, 9 and 10
NOTE: There are no bolts fitted in the four
lower holes in each cylinder head.
OVERHAUL
9
ENGINE
Sump - remove
Timing cover - remove - Engine numbers without
suffix B
1. Remove crankshaft pulley bolt and collect
spacer washer.
2. Remove crankshaft pulley.
1. Remove dipstick.
2. Remove screw securing dipstick tube to LH
rocker cover.
3. Remove bolts and nut securing timing cover to
cylinder block.
4. Release and remove timing cover.
5. Remove and discard gasket.
6. Remove and discard oil seal from timing cover.
3. Remove 16 bolts securing sump to cylinder
block.
NOTE: Engine numbers with suffix B, 17
bolts are used to secure sump to cylinder
block.
4. Carefully release sump from cylinder block.
CAUTION: Take care not to damage
sealing faces of cylinder block and sump.
5. Remove sump.
10
OVERHAUL
ENGINE
Timing cover - remove - Engine numbers with
suffix B
Timing gears - remove
NOTE: Timing cover, oil pump and oil
pressure relief valve are only supplied as
an assembly.
1. Using assistance, restrain flywheel and remove
crankshaft pulley bolt; collect spacer washer.
2. Remove crankshaft pulley.
1. Restrain camshaft gear and remove bolt
securing gear, collect washer.
2. Remove distributor drive gear and spacer.
3. Noting their fitted position, remove bolts
securing timing cover to cylinder block; remove
cover.
NOTE: Dowel located.
3. Remove timing chain and gears as an
assembly.
4. Collect Woodruff keys from camshaft and
crankshaft.
Timing gears - inspection
4. Remove oil pump drive gear.
5. Remove and discard gasket.
6. Remove and discard oil seal from timing cover.
1.
2.
3.
4.
Thoroughly clean all components.
Inspect distributor drive gear for wear.
Inspect timing chain links and pins for wear.
Inspect timing chain sprockets for wear. Renew
parts as necessary.
OVERHAUL
11
ENGINE
Timing gears - refit
1. Clean gear locations on camshaft and
crankshaft, fit Woodruff keys.
2. Check camshaft Woodruff key is fully engaged
in keyway.
CAUTION: Space between Woodruff key
and keyway acts as an oil feed. It is
therefore most important that key is
properly seated and parallel to axis of camshaft.
Overall dimension ’A’ must not exceed 30.15
mm.
3. Temporarily fit crankshaft gear, and if
necessary turn crankshaft to bring timing mark
on gear to the twelve o’clock position, remove
gear.
4. Temporarily fit camshaft gear with marking ’F’
facing forwards.
5. Turn camshaft until mark on camshaft sprocket
is at the six o’clock position, remove gear
without moving camshaft.
12
OVERHAUL
6. Position timing gears on work surface with
timing marks upwards and aligned.
7. Fit timing chain around gears, keeping timing
marks aligned.
8. Fit gear and chain assembly.
NOTE: Timing marks and ’F’ mark on
camshaft gear must be facing forwards.
9. Fit spacer to camshaft with flange facing
forwards.
10. Fit distributor drive gear to camshaft with
grooved face towards camshaft gear.
11. Fit camshaft gear bolt and washer, restrain
camshaft gear and tighten bolt to correct
torque.
ENGINE
Timing cover - refit - Engine numbers without
suffix B
1. Clean sealant from threads of cover bolts.
2. Clean all traces of old gasket material from
timing cover and mating face of cylinder block.
CAUTION: Use a plastic scraper.
3. Use a lint free cloth and thoroughly clean oil
seal location in timing cover.
4. Lubricate new oil seal sealing surfaces with
engine oil.
Timing cover - refit - Engine numbers with suffix
B
NOTE: Timing cover, oil pump and oil
pressure relief valve are only supplied as
an assembly.
1. Clean sealant from threads of timing cover
bolts.
2. Clean all traces of gasket material from mating
faces of timing cover and cylinder block.
CAUTION: Use a plastic scraper.
3. Clean oil seal location in timing cover.
4. Lubricate oil pump gears and oil seal recesss
in timing cover with engine oil.
5. Apply Hylosil jointing compound to new timing
cover gasket, position gasket to cylinder block.
6. Position oil pump drive gear in timing cover
with groove towards front of timing cover.
5. Locate seal to timing cover and press seal in
squarely until flush with front face of timing
cover.
6. Position new gasket to cylinder block.
7. Coat threads of timing cover bolts with Loctite
242 sealant.
8. Fit timing cover, fit bolts and nut and tighten to
correct torque.
9. Fit crankshaft pulley.
10. Fit spacer washer to pulley bolt, fit bolt and
tighten to correct torque.
7. Locate tool LRT-12-090 on timing cover and oil
pump drive gear.
8. Position timing cover to cylinder block and at
the same time, rotate tool LRT-12-090 until
drive gear keyway is aligned with Woodruff
key.
9. Fit timing cover to cylinder block.
10. Smear threads of timing cover bolts with
Loctite 242 sealant, fit bolts and tighten
progressively to the correct torque.
NOTE: Do not fit coolant pump bolts at
this stage.
11. Remove tool LRT-12-090.
OVERHAUL
13
ENGINE
Distributor - refit
12. Lubricate new timing cover oil seal with engine
oil.
13. Fit timing cover oil seal using tool LRT-12-089.
14. Fit crankshaft pulley, fit bolt and spacer
washer; tighten bolt to correct torque.
Sump - refit
1. Remove all traces of old sealant from mating
faces of cylinder block and sump.
2. Clean mating faces with suitable solvent and
apply a 2 mm bead of Hylosil white silicone
sealant to sump joint face as shown.
3. Fit sump, taking care not to damage sealant
bead.
4. Fit sump bolts and working from the centre
outwards, tighten progressively to correct
torque.
5. Fit and tighten screw securing dipstick tube to
LH rocker cover.
6. Fit dipstick.
14
OVERHAUL
1. Ensure timing pointer is aligned with 30 mark
on crankshaft pulley and No.1 piston is on the
compression stroke.
2. Engine numbers without suffix B: Position
oil pump drive shaft tongue at the ten to four
position.
3. Lubricate a new ’O’ ring with engine oil and fit
to distributor.
4. Turn distributor drive until rotor arm is
approximately 30° anti-clockwise from No.1
spark plug segment in distributor cap.
5. Insert distributor into timing cover, engage
drive gear and push distributor down until ’O’
ring enters bore; position distributor clamp on
stud.
ENGINE
6. Engine numbers without suffix B: Locate
slotted adaptor to oil pump drive shaft tongue.
7. Check that centre line of rotor arm is aligned
with No.1 spark plug segment in distributor cap
and reference marks on distributor body and
clamp are aligned; reposition distributor if
necessary.
8. Remove rotor arm.
9. Rotate distributor to position pick-up opposite
nearest reluctor tooth.
OIL COOLER ADAPTER - ENGINE NUMBERS
WITHOUT SUFFIX B
Oil cooler adapter - remove
1. Remove oil filter element.
2. Mark position of adapter in relation to oil pump
cover.
3. Remove centre screw and withdraw adapter.
4. Remove and discard sealing ring.
Oil cooler adapter - refit
10. Fit distributor clamp nut ensuring that
counterbored portion is towards clamp; tighten
nut.
11. Fit rotor arm.
CAUTION: This distributor setting is to
enable engine to be started. When engine
is refitted, ignition timing must be set
using electronic equipment.
1. Thoroughly clean adapter.
2. Position new sealing ring, fit adapter, ensuring
marks previously made line up, fit and tighten
centre screw.
3. Lubricate sealing ring of oil filter with engine oil.
4. Screw filter on to filter head until it seats then
tighten a further half-turn.
OVERHAUL
15
ENGINE
OIL PUMP - ENGINE NUMBERS WITHOUT
SUFFIX B
Oil pump - remove
1.
2.
3.
4.
Remove sump.
Remove distributor.
Remove timing cover.
Remove oil cooler adapter - if fitted.
5. Remove oil pressure relief valve plug, discard
sealing washer.
6. Withdraw pressure relief valve spring and
valve.
7. Remove oil pressure switch, discard sealing
washer.
8. Remove bolts securing oil pump cover.
9. Remove cover, remove and discard gasket.
10. Withdraw oil pump gears.
16
OVERHAUL
Oil pump - inspection
1. Throughly clean oil pump gear housing, cover
and gears.
2. Clean oil pressure relief valve bore in housing.
3. Clean relief valve filter screen.
4. Inspect pump gears for wear and scoring.
5. Fit pump gears into housing.
6. Place straight edge across gears.
7. Check clearance between straight edge and
housing face.
Gear to housing minimum clearance =
0.05mm.
If clearance is below minimum specified check
gear recess in housing for wear. Renew
housing if necessary.
8. Remove oil pump gears from housing.
9. Clean oil pressure relief valve and spring.
10. Inspect relief valve for wear and scoring.
11. Inspect relief valve spring for wear or signs of
collapse.
Relief valve free length = 81.28 mm.
12. Check relief valve slides freely in its bore with
no perceptible side movement.
ENGINE
Oil pump - refit
1. Lubricate relief valve, spring, and bore in
housing with clean engine oil.
2. Fit relief valve and valve spring.
3. Fit new sealing washer to plug, fit plug and
tighten to correct torque.
4. Pack oil pump housing with Petroleum Jelly.
CAUTION: Use only Petroleum Jelly, no
other grease is suitable.
OIL PUMP - ENGINE NUMBERS WITH SUFFIX B
CAUTION: Overhaul procedures for the oil
pump and oil pressure relief valve are
limited to carrying out dimensional
checks. In the event of wear or damage being
found, a replacement timing cover assembly
must be fitted.
Oil pump - remove
1. Remove timing cover.
5. Fit oil pump gears ensuring that Petroleum
Jelly is forced into every cavity between teeth
of gears.
CAUTION: Unless pump is fully packed
with Petroleum Jelly it may not prime itself
when the engine is started.
6. Fit new pump cover gasket.
7. Position cover, fit bolts and tighten
progressively to correct torque.
8. Fit oil cooler adapter.
9. Fit timing cover.
10. Fit distributor.
11. Fit sump.
2. Remove oil pump drive gear.
3. Remove 9 screws securing cover plate,
remove plate.
4. Make suitable alignment marks on inner and
outer rotors, remove rotors.
OVERHAUL
17
ENGINE
Oil pressure relief valve - remove
Oil pump - inspection
1. Thoroughly clean oil pump drive gear, cover
plate, rotors and housing. Remove all traces of
Loctite from cover plate securing screws;
ensure tapped holes in timing cover are clean
and free from oil.
2. Check mating surfaces of cover plate, rotors
and housing for scoring.
3. Assemble rotors and oil pump drive gear in
housing ensuring that reference marks are
aligned.
1. Remove circlip.
2. Remove relief valve plug, remove and discard
’O’ ring.
3. Remove relief valve spring and piston.
4. Using feeler gauges, check clearance between
teeth of inner and outer rotors:
Maximum clearance = 0.25 mm
5. Remove oil pump drive gear, check depth of
any wear steps on gear teeth:
Wear step maximum depth = 0.15 mm
18
OVERHAUL
ENGINE
Oil pump - refit
1. Lubricate rotors, oil pump drive gear, cover
plate and housing with engine oil.
2. Assemble rotors in housing ensuring that
reference marks are aligned.
3. Position cover plate to housing.
4. Apply Loctite 222 to threads of cover plate
screws, fit but do not fully tighten screws.
5. Position drive gear in oil pump, tighten cover
plate screws to correct torque.
6. Fit timing cover.
6. Place a straight edge across housing.
7. Using feeler gauges, check clearance between
straight edge and rotors:
Maximum clearance = 0.1 mm
Oil pressure relief valve - inspection
1. Clean relief valve components and piston bore
in timing cover.
2. Check piston and bore for scoring and that
piston slides freely in bore with no perceptible
side movement.
3. Check relief valve spring for damage and
distortion; check spring free length:
Spring free length = 60.0 mm
Oil pressure relief valve - refit
1. Lubricate new ’O’ ring with engine oil and fit to
relief valve plug.
2. Lubricate relief valve spring, piston and piston
bore with engine oil.
3. Assemble piston to relief valve spring, insert
piston and spring into piston bore.
4. Fit relief valve plug, depress plug and fit circlip.
5. Ensure circlip is fully seated in groove.
OVERHAUL
19
ENGINE
CAMSHAFT AND TAPPETS
Camshaft and tappets - remove
1. Remove rocker shaft assemblies.
2. Remove pushrods and store in fitted order.
3. Remove timing chain and gears.
6. Withdraw camshaft, taking care not to damage
bearings in cylinder block.
4. Remove tappets and retain with their
respective pushrods.
NOTE: If tappets cannot be removed due
to damaged camshaft contact area,
proceed as follows:
5. Lift tappets in pairs to the point where
damaged face is about to enter tappet bore
and fit rubber bands to retain tappets. Repeat
until all tappets are retained clear of camshaft
lobes. The tappets can then be withdrawn out
the bottom of their bores when the sump is
removed.
20
OVERHAUL
Camshaft and tappets - inspection
1. Throughly clean all components.
2. Inspect camshaft bearing journals and lobes
for signs of wear, pitting, scoring and
overheating.
3. Support camshaft front and rear bearings on
vee blocks, and using a DTI, measure
camshaft run-out on centre bearing.
Maximum permitted run-out = 0.05 mm.
4. Clean and inspect tappets. Check for an even,
circular wear pattern on the camshaft contact
area. If contact area is pitted or a square wear
pattern has developed, tappet must be
renewed.
5. Inspect tappet body for excessive wear or
scoring. Replace tappet if scoring or deep wear
patterns extend up to oil feed area. Clean and
inspect tappet bores in engine block.
6. Ensure that tappets rotate freely in their
respective bores.
7. Inspect pushrod contact area of tappet, replace
tappet if surface is rough or pitted.
ENGINE
Camshaft and tappets - refit
1. Lubricate camshaft journals with clean engine
oil and carefully insert camshaft into cylinder
block.
2. Immerse tappets in clean engine oil. Before
fitting, pump the inner sleeve of tappet several
times using a pushrod, to prime tappet and
reduce tappet noise when engine is first
started.
3. Lubricate tappet bores with clean engine oil
and fit tappets in removed order.
Piston rings - inspection
1. Temporarily fit new compression rings to
piston.
NOTE: The ring marked ’TOP’ must be
fitted, with marking uppermost, into
second groove. The chrome ring fits into
top groove and can be fitted either way round.
NOTE: Some tappet noise may be evident
on initial start-up. If necessary, run the
engine at 2500 rev/min for a few minutes
until noise ceases.
4. Fit timing chain and gears.
5. Fit rocker shaft assemblies.
PISTONS, CONNECTING RODS, PISTON RINGS
AND CYLINDER BORES
2. Check compression ring to groove clearance:
Top compression ring A = 0.05 to 0.10 mm.
2nd compression ring B = 0.05 to 0.10 mm.
Pistons and connecting rods - remove
1. Remove cylinder head(s).
2. Remove big-end bearings.
3. Remove carbon ridge from top of each cylinder
bore.
4. Suitably identify each piston to its respective
cylinder bore.
5. Push connecting rod and piston assembly to
top of cylinder bore and withdraw assembly.
6. Remove plastic tubing from connecting rod
bolts.
7. Repeat above procedure for remaining pistons.
Piston rings - remove
1. Using a suitable piston ring expander, remove
piston rings.
2. Remove carbon from piston ring grooves.
3. Insert new piston ring into relevant cylinder,
held square to bore with piston, and check ring
gaps.
Top compression ring = 0.44 to 0.57 mm.
2nd compression ring = 0.44 to 0.57 mm.
Oil control ring rails = 0.38 to 1.40 mm.
4. Use a fine-cut flat file to increase gap if
required. Select a new piston ring if gap
exceeds limit.
NOTE: Use an old broken piston ring with
a squared off end.
CAUTION: Do not use a wire brush.
OVERHAUL
21
ENGINE
Pistons - remove
Pistons - inspection
1. Clean carbon from pistons
2. Inspect pistons for distortion and cracks.
1. Clamp hexagon body of LRT-12-013 in vice.
2. Screw large nut back until flush with end of
centre screw.
3. Push centre screw forward until nut contacts
thrust race.
4. Locate piston adapter LRT-12-014 with its long
spigot inside bore of hexagon body.
5. Fit parallel sleeve, grooved end first, onto
centre screw and smear outside diameter with
engine oil.
6. Locate piston and connecting rod assembly on
centre screw and up to adapter LRT-12-014.
7. Fit remover/replacer bush of LRT-12-014 on
centre screw with flanged end away from
gudgeon pin.
8. Screw stop nut onto centre screw leaving
clearance A, between nut and
remover/replacer bush.
Clearance A = 3 mm.
9. Lock the stop nut securely with lockscrew.
10. Push connecting rod to right to locate end of
gudgeon pin in adapter LRT-12-014.
11. Ensure remover/replacer is located in gudgeon
pin bore of piston.
12. Screw large nut up to thrust race.
13. Hold lockscrew and turn large nut until
gudgeon pin is withdrawn from piston.
14. Dismantle tool and remove piston, connecting
rod and gudgeon pin.
15. Repeat above operation for remaining pistons.
22
OVERHAUL
3. Measure piston diameter at 90° to gudgeon pin
axis and 8 mm from bottom of skirt. The piston
must be 0.018 mm to 0.033 mm smaller than
cylinder bore.
ENGINE
Cylinder bore - inspection
Pistons - refit
CAUTION: On later 4.2L engines the piston
has a 0.5 mm offset gudgeon pin which
can be identified by an arrow mark on the
piston crown. This arrow MUST always point to
the front of the engine.
1. Measure cylinder bore wear in two axis 40 to
50 mm from top of bore.
Piston to cylinder bore clearance = 0.018 to
0.033 mm.
NOTE: Pistons are available in service
standard size and 0.508 mm oversize.
Service standard size pistons are supplied
0.0254 mm oversize. When fitting new service
standard size pistons, check for correct piston to
bore clearance, hone bore if necessary.
1. 4.2L engine only: Assemble pistons to
connecting rods with arrow on piston pointing
towards domed shaped boss on connecting
rod for RH bank of cylinders, and arrow
pointing away from dome shaped boss for LH
bank of cylinders.
CAUTION: The temperature of piston and
cylinder block must be the same to ensure
accurate measurement. When reboring
cylinder block, the crankshaft main bearing caps
must be fitted and bolts tighten to correct
torque.
2. If only new piston rings are to be fitted, break
cylinder bore glazing using a fine grit, to
produce a 60° cross-hatch finish.
CAUTION: Ensure all traces of grit are
removed after above operation.
Connecting rod - inspection
1. Check alignment of connecting rod.
2. Clamp hexagon body of LRT-12-013 in vice.
3. Remove large nut and pull the centre screw 50
mm out of hexagon body.
4. Locate piston adapter LRT-12-014 with its long
spigot inside bore of hexagon body.
5. Fit parallel sleeve, grooved end last, up to
shoulder on centre screw.
6. Lubricate gudgeon pin and bores of connecting
rod and piston with graphited oil.
7. Locate connecting rod and piston to centre
screw with connecting rod entered on sleeve
up to groove.
OVERHAUL
23
ENGINE
8. Fit gudgeon pin onto centre screw and into
piston bore up to connecting rod.
9. Fit remover/replacer bush with flanged end
towards gudgeon pin.
10. Screw the stop nut onto centre screw and
position piston against face of adaptor
LRT-12-014.
11. Lubricate centre screw threads and thrust race
with graphited oil, fit, and screw large nut up to
thrust race.
12. Adjust stop nut leaving clearance B, between
nut and remover/replacer bush.
Clearance B = 0.8 mm.
13. Lock the stop nut securely with lockscrew.
14. Set torque wrench to 16 Nm, and using socket
on large nut, pull gudgeon pin in until flange of
remover/replacer bush is distance C from face
of piston.
Distance C = 4 mm.
CAUTION: Flange of remover/replacer
must not be allowed to contact piston. If
torque figure is not achieved during above
operation, fit of gudgeon pin to connecting rod is
not acceptable and necessitates renewal of
components. The centre screw and thrust race
must be kept well lubricated throughout
operation.
Pistons and connecting rods - refit
1. Fit oil control ring rails and expander, ensuring
ends butt and not overlap.
2. Fit ring marked ’TOP’ with marking uppermost
into second groove.
3. Fit top compression ring into groove either way
round.
15. Dismantle tool, remove piston, check no
damage has occurred during pressing and
piston moves freely on gudgeon pin.
16. Repeat above operation for remaining pistons.
4. Position oil control expander ring joint and ring
rail gaps all at one side, between gudgeon pin
and piston thrust face. Space gaps in ring rails
approximately 25 mm each side of expander
ring joint.
5. Position compression rings with ring gaps on
opposite sides of piston between gudgeon pin
and piston thrust face.
6. Fit big-end bearing shell to connecting rod.
7. Lubricate big-end bearing shell, piston rings
and gudgeon pin with engine oil.
8. Lubricate cylinder bores and crankshaft
big-end journals with engine oil.
24
OVERHAUL
ENGINE
FLYWHEEL
Flywheel- remove
9. Fit ring clamp to piston and compress piston
rings.
10. Fit plastic tubing to connecting rod bolts.
1. Restrain crankshaft and remove 6 bolts
securing flywheel.
2. Remove flywheel.
Inspect
11. Insert connecting rod and piston assembly into
respective cylinder bore ensuring domed
shaped boss on connecting rod faces towards
front of engine on RH bank of cylinders, and
towards rear on LH bank of cylinders.
NOTE: When both connecting rods are
fitted to each journal, bosses will face
towards each other.
12. Pull connecting rod on to crankshaft journal.
CAUTION: Take care not to scratch
crankshaft journals.
1. Inspect flywheel face for cracks, scores and
overheating. The flywheel can be refaced
providing thickness does not go below
minimum.
Flywheel minimum thickness A = 39.93 mm
2. Inspect ring gear for worn, chipped and broken
teeth.
3. Renew ring gear if necessary.
13. Fit big-end bearing caps and bearing shells.
14. Fit cylinder head(s).
OVERHAUL
25
ENGINE
Flywheel ring gear - renew
5. Heat new ring gear uniformly to between
170°and 175° C.
1. Drill a 10 mm diameter hole axially at base of
tooth and inner diameter of starter ring,
sufficiently deep enough to weaken ring gear.
CAUTION: Do not allow drill to enter
flywheel.
2. Secure flywheel in soft jawed vice.
3. Split ring gear using a cold chisel.
WARNING: Wear safety goggles and take
precautions against flying fragments when
splitting ring gear.
4. Remove flywheel from vice, remove old ring
gear, and place flywheel, clutch side down, on
a flat surface.
CAUTION: Do not exceed this
temperature.
6. Locate ring gear on flywheel with chamfered
inner diameter towards flywheel flange.
NOTE: If ring gear is chamfered on both
sides, it can be fitted either way round.
7. Press ring gear onto flywheel until it butts
against flywheel flange.
8. Allow flywheel to air cool.
Flywheel - refit
1. Fit flywheel and locate on 2 dowels.
2. Fit flywheel bolts.
3. With assistance, restrain crankshaft and
tighten flywheel bolts to correct torque.
26
OVERHAUL
ENGINE
DRIVE PLATE AND RING GEAR ASSEMBLY
Drive plate and ring gear assembly - remove
1. Mark each component to enable reassembly in
original position.
Drive plate and ring gear assembly - refit
CAUTION: To prevent distortion to flexible
drive plate when bolted to torque
converter, drive plate setting height must
be checked as follows:
2. Remove 4 bolts securing drive plate.
3. Remove clamp ring, flexible drive plate, hub
aligner and ring gear assembly.
4. Remove 6 socket head screws securing
crankshaft adapter plate, remove adapter plate
and selective shim.
Inspect
1. Inspect flexible drive plate for cracks and
distortion.
2. Renew drive plate if necessary.
3. Inspect ring gear for worn, chipped and broken
teeth.
4. Renew ring gear assembly if necessary.
1. Fit existing shim and crankshaft adapter plate.
2. Fit socket head screws and lightly tighten.
3. Fit ring gear assembly, hub aligner, drive plate
and clamping ring, fit bolts and lightly tighten.
4. Check the setting height.
Drive plate setting height A = 8.08 to 8.20 mm.
5. Remove bolts, remove clamp ring, flexible
drive plate, hub aligner and ring gear
assembly.
6. Remove socket head screws, remove
crankshaft adapter and shim.
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27
ENGINE
7. Measure existing shim and, if necessary, select
appropriate shim to maintain setting height.
Shims available:
1.20 - 1.25mm
1.30 - 1.35mm
1.40 - 1.45mm
1.50 - 1.55mm
1.60 - 1.65mm
1.70 - 1.75mm
1.80 - 1.85mm
1.90 - 1.95mm
2.00 - 2.05mm
2.10 - 2.15mm
8. Fit shim selected, position adapter, ensuring
marks previously made line up, fit socket head
bolts and tighten to correct torque.
9. Fit ring gear assembly, hub aligner, flexible
drive plate and clamp ring. ensuring marks
previously made line up.
10. Apply Loctite 242 to threads of bolts, fit bolts
and tighten to correct torque.
Big-end bearings - remove
1. Remove sump.
2. Remove 2 bolts securing oil strainer.
3. Remove strainer, remove and discard gasket.
4. Suitably identify bearing caps to their
respective connecting rods.
CRANKSHAFT, MAIN AND BIG-END BEARINGS
Crankshaft end - float - check
5. Remove 2 nuts securing each bearing cap.
6. Remove bearing cap and bearing shell.
CAUTION: Keep bearing caps and shells
in their fitted order.
1. Set-up DTI to measure end float.
2. Move crankshaft forwards and zero gauge.
3. Move crankshaft rearwards, record end-float
reading obtained.
Crankshaft end-float = 0.10 to 0.20mm.
4. Remove DTI.
NOTE: Crankshaft end-float is controlled
by thrust faces on upper half of centre
main bearing shell.
28
OVERHAUL
7. Fit a length of plastic tubing over each
connecting rod bolt.
8. Push each piston up its respective bore and
remove shells from connecting rods.
CAUTION: Keep bearing shells in their
fitted order.
ENGINE
Big-end bearings - Inspection
1. Check big-end bearing shells for wear and
damage.
2. Renew big-end bearing shells as necessary.
NOTE: Big-end bearings are available in
0.254 mm and 0.508 mm undersizes.
Big-end bearings - refit
1. Fit bearing shells to each connecting rod.
2. Lubricate bearing shells and crankshaft
journals with clean engine oil.
3. Pull connecting rods onto crankshaft journals
and remove plastic tubing.
4. Fit bearing shells to each big-end bearing cap.
8. Check clearance between connecting rods on
each crankshaft journal.
Connecting rod clearance = 0.15 to 0.37 mm.
9. Clean oil strainer.
10. Clean gasket mating faces on strainer and
cylinder block.
11. Fit gasket to strainer, position strainer, fit bolts
and tighten to correct torque.
12. Fit sump.
5. Lubricate bearing shells and fit bearing caps
ensuring reference marks on connecting rods
and bearing caps are aligned.
NOTE: Rib on edge of bearing cap must
face towards front of engine on RH bank
of cylinders and towards rear on LH bank
of cylinders.
6. Fit bearing cap nuts and tighten to correct
torque.
7. Check connecting rods move freely sideways
on crankshaft. Tightness indicates insufficient
bearing clearance or misaligned connecting
rod.
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29
ENGINE
Crankshaft - remove
1. Remove flywheel or drive plate and ring gear
assembly.
2. Remove timing cover.
3. Remove timing gears.
4. Remove big-end bearings.
5. Starting at centre main bearing and working
outwards, progressively slacken then remove
10 main bearing cap bolts.
6. Remove 5 main bearing caps and bearing
shells, retain bearings with their caps.
7. Lift out crankshaft and rear oil seal. Remove
and discard oil seal.
8. Remove 5 bearing shells from cylinder block
and retain in their fitted order.
9. Remove and discard side seals from rear main
bearing cap.
10. Remove Woodruff key from crankshaft.
30
OVERHAUL
Crankshaft - inspection
1. Clean crankshaft and blow out oil passages.
2. Support crankshaft front and rear bearings on
vee blocks, and using a DTI, measure run-out
on centre main bearing.
Maximum permitted run-out = 0.08 mm.
If run-out exceeds permitted maximum,
crankshaft is unsuitable for regrinding and
should be renewed.
3. Measure each journal for overall wear and
ovality.
Main bearing journal diameter = 58.409 to
58.422 mm
Maximum out of round = 0.040 mm.
Big-end bearing journal diameter = 50.800 to
50.812 mm
Maximum out of round = 0.040 mm.
If measurements exceed permitted maximum,
regrind or fit new crankshaft.
NOTE: Ovality checks should be made at
120° intervals around each journal.
Crankshaft main bearings are available in
0.254 mm and 0.508 mm undersizes. When fitting
0.508 mm undersize bearings, centre main
bearing, which controls crankshaft end-float, has
thrust faces increased in thickness by 0.254 mm.
Therefore if 0.508 mm undersize bearings are
fitted, 0.127 mm must be machined off each
thrust face of centre main bearing journal to
maintain correct radius.
ENGINE
Crankshaft dimensions:
Crankshaft spigot bearing - renew
1. Carefully extract old spigot bearing.
2. Clean bearing recess in crankshaft.
Bearing journal radius - all journals except rear main
journal A = 1.90 to 2.28 mm.
Rear main bearing journal radius B = 3.04 mm.
Bearing journal diameter C :
Standard = 58.400 to 58.413mm.
0.254 mm undersize = 58.146 to 58.158 mm.
0.508 mm undersize = 57.892 to 57.904 mm.
Bearing journal width D :
Standard = 26.975 to 27.026 mm.
0.254 mm undersize = 26.975 to 27.026 mm.
0.508 mm undersize = 27.229 to 27.280 mm.
Bearing journal diameter E :
Standard = 50.800 to 50.812 mm.
0.254 mm undersize = 50.546 to 50.559 mm.
0.508 mm undersize = 50.292 to 50.305 mm.
3. Fit new bearing flush with, or to a maximum of
1.6 mm below end face of crankshaft.
4. Ream bearing to correct inside diameter.
Spigot bearing inside diameter = 19.177 +
0.025 mm.
5. Remove all traces of swarfe.
Crankshaft - refit
1. Clean main bearing caps, bearing shell
recesses and mating surfaces of cylinder
block.
2. Fit upper main bearing shells, with oil holes
and grooves, in cylinder block, ensuring
flanged shell is fitted in centre position.
3. Lubricate bearing shells with clean engine oil
and position crankshaft in cylinder block.
4. Fit main bearing shells to bearing caps.
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31
ENGINE
5. Apply EXP16A (Marston Lubricants) lubricant
to threads of main bearing cap bolts.
6. Lubricate main bearing shells and fit numbers
1 to 4 bearing caps, fit and lightly tighten bolts.
7. Fit side seals to rear main bearing cap.
CAUTION: Seals must protrude
approximately 1.5 mm above bearing cap
face.
8. Apply Hylomar SQ32M jointing compound to
bearing cap rear mating face on cylinder block.
9. Lubricate bearing shell and side seals with
clean engine oil, carefully fit bearing cap
assembly.
10. Fit bolts and lightly tighten.
11. Clean seal location and running surface on
crankshaft.
12. Engine numbers without suffix B: Clean seal
protector LRT-12-010 and lubricate with engine
oil.
13. Engine numbers with suffix B: Clean seal
protector LRT-12-095 and lubricate with engine
oil.
14. Lubricate oil seal lip with engine oil.
32
OVERHAUL
NOTE: Seal protector LRT-12-095
illustrated.
15. Position seal protector to crankshaft.
16. Engine numbers without suffix B: Fit oil seal
squarely using hand pressure only until fully
seated in recess.
17. Engine numbers with suffix B: Fit seal using
tool LRT-12-091.
18. Tighten main bearing cap bolts to correct
torque.
19. Fit Woodruff key to crankshaft.
20. Check crankshaft end-float.
21. Fit big-end bearings.
22. Fit timing cover and gears.
23. Fit flywheel or drive plate and ring gear
assembly.
ENGINE
SERVICE TOOLS
Land Rover Number
Rover Number
Description
LRT-12-010*
LRT-12-013
LRT-12-014
LRT-12-034
LRT-12-037
LRT-12-038
LRT-12-055
LRT-12-089**
LRT-12-090**
LRT-12-091**
LRT-12-095**
LRT-12-501
LRT-12-503
LRT-12-504
LRT-12-515
18G 1014*
18G 1150
18G 1150E
18G 1519
RO.274401
RO.600959
Protection sleeve - crankshaft rear oil seal
Remover/replacer gudgeon pin
Adaptor remover/replacer gudgeon pin
Valve spring compressor
Drift remover - valve guide
Drift replacer - valve guide
Distance piece - valve guide
Replacer - timing cover oil seal
Retainer - oil pump gears
Replace - crankshaft rear oil seal
Protection sleeve - crankshaft rear oil seal
Basic handle set - valve seat cutters
Adjustable valve seat pilot
Adjustable valve seat cutter
Distance piece - valve guide
MS76B
MS150-8.5
MS76-621
RO.605774A
* Engine numbers without suffix B ** Engine
numbers with suffix B
Service tools must be obtained direct from the
manufacturers:
V.L. Churchill,
P.O. Box No 3,
London Road,
Daventry,
Northants, NN11 4NF.
England.
SERVICE TOOLS
1
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