V8 Overhaul Manual - land rover service factory manual RAVE
Contents
1. 15 Nm Coolant pump timing cover to cylinder block 22 Nm Lightly oil threads prior to assembly A Coatfirst three threads with Loctite 242 prior to assembly Coatthreads 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 lo gars hoped 4Nm MO star tese Ye Satan ER A MEUS teas 6 Nm M att hii eae hae iei ed e uera 18Nm O c de ANC tst 32 35 Nm M12 1 veis Exe kt dard Ee eon s 65 Nm Mirra T 80 Nm MO oo Rott Eten ete a ee deis 130 Nm UNC UNF MA o leia pta oaks 8 10 Nm ap 25 Nm 3 8 ear sce e a de SS 40 Nm PING A quara iba Each e oot 75 Nm rop DEDE 90 Nm JJ Een 135 Nm 2 TORQUE WRENCH SETTINGS ENGINE Pp 2000 This page is intentionally left blank DESCRIPTION AND OPERATION 1 ENGINE 12 0880 2 DESCRIPTION AND OPERATION CYLINDER BLOCK COMPONENTS 1 Cylinder block 2 Piston and gudgeon pin 3 Connecting rod 4 Core plugs 5 Camshaft 6 Dipstick 7 Camshaft key 8 Timing chain 9 Camshaft sprocket 10 Spacer 11 Distributor drive gear 12 Distributor 13 Oil pump gears 14 Timing cover and gasket 15 Timing cover oil seal 16 Crankshaft pulley 17 Crankshaft sprocket 18 Woodruff key 19 Crankshaft Engine numbers wi2. 12M0926 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 12M0927 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 OVERHAUL 21 ENGINE Pistons remove 6 LAT 12 014 5 LAT 12 013 9 12 0928 Clamp hexagon body of LRT 12 013 in vice 2 Screw large nut back until flush with end of 11 12 13 14 15 22 centre screw Push centre screw forward until nut contacts thrust race Locate piston adapter LRT 12 014 with its long spigot inside bore of hexagon body Fit parallel sleeve grooved end first onto centre screw and smear outside diameter with engine oil Locate piston and connecting rod assembly on centre screw and up to adapter LRT 12 014 Fit remover replacer bush of LRT 12 014 on centre screw with flanged end away from gudgeon pin Screw stop nut onto centre screw leaving clearance A between nut and remover replacer bush Clearance 3 mm Lock the stop nut securely with lockscrew Push connecting rod to right to locate end of gudgeon pin in adapter LRT 12 0
3. 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 ENGINE Bees Crankshaft spigot bearing renew 1 Carefully extract old spigot bearing 2 Clean bearing recess in crankshaft 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 OQ 12M0949 2 Fitupper 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 OVERHAUL 31 7 10 Clean seal location and running surface on 12 13 14 32 Apply EXP16A Marston Lubricants lubricant to threads of main bearing cap bolts Lubricate main bearing shells and fit numbers 1 to 4 bearing caps fit and lightly tighten bolts Fit side seals to rear main bearing cap CAUTION Seals must protrude approximately 1 5 mm above bearing cap
4. 0 1 mm Oil pressure relief valve inspection 1 2 Clean relief valve components and piston bore in timing cover Check piston and bore for scoring and that piston slides freely in bore with no perceptible side movement Check relief valve spring for damage distortion check spring free length Spring free length 60 0 mm ENGINE Pp 200o Oil pump refit 1 Lubricate rotors oil pump drive gear cover plate and housing with engine oil Assemble rotors in housing ensuring that reference marks are aligned Position cover plate to housing Apply Loctite 222 to threads of cover plate screws fit but do not fully tighten screws Position drive gear in oil pump tighten cover plate screws to correct torque Fit timing cover Oil pressure relief valve refit 1 2 Lubricate new O ring with engine oil and fit to relief valve plug Lubricate relief valve spring piston and piston bore with engine oil Assemble piston to relief valve spring insert piston and spring into piston bore Fit relief valve plug depress plug and fit circlip 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 4 Remove tappets and retain with their respective pushrods NOTE If tappets c
5. 3 5 3 9 amp 4 2 Liter VE motor Moteur de 3 5 3 9 amp 4 2L V8 Manuel de r vision 3 5 3 9 amp 4 21 VB motor Motore 3 5 3 9 amp 4 2 Litri V8 Manuale di revisione Motor 3 5 3 9 4 2 Litro V8 Manual de revisi n Motor do 3 5 3 9 4 4 21 Manval de revis o 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 How to use this Manual 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 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 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 oper
6. 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 SPECIFICATION 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 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 DATA Firing order Valve springs Free length Fitted length Load at fitted length Valves Valve stem diameter Inlet Exhaust Valve head diameter Inlet Exhaust Valve installed height maximum Valve stem to guide clearance Inlet Ex
7. Valves and springs refit 1 Lap each valve to its seat using fine grinding paste 2 Clean valve and seat 12 0903 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 12 0904 4 Check valve installed height if valve seats 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 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 12 09
8. float check Set up DTI to measure end float Move crankshaft forwards and zero gauge Move crankshaft rearwards record end float reading obtained Crankshaft end float 0 10 to 0 20mm 4 Remove DTI On NOTE Crankshaft end float is controlled ZN by thrust faces on upper half of centre main bearing shell 28 OVERHAUL Big end bearings remove 1 Remove sump Remove 2 bolts securing oil strainer Remove strainer remove and discard gasket Suitably identify bearing caps to their respective connecting rods 12 0945 5 Remove 2 nuts securing each bearing 6 Remove bearing cap and bearing shell CAUTION Keep bearing caps and shells N in their fitted order 7 Fita 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 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 12M0953 5 Lubrica
9. face Apply Hylomar SQ32M jointing compound to bearing cap rear mating face on cylinder block Lubricate bearing shell and side seals with clean engine oil carefully fit bearing cap assembly Fit bolts and lightly tighten crankshaft Engine numbers without suffix B Clean seal protector LRT 12 010 and lubricate with engine oil Engine numbers with suffix B Clean seal protector LRT 12 095 and lubricate with engine oil Lubricate oil seal lip with engine oil OVERHAUL A 15 16 17 ENGINE LRT 12 091 12M1255A NOTE Seal protector LRT 12 095 illustrated Position seal protector to crankshaft Engine numbers without suffix B Fit oil seal squarely using hand pressure only until fully seated in recess Engine numbers with suffix B Fit seal using tool LRT 12 091 Tighten main bearing cap bolts to correct torque Fit Woodruff key to crankshaft Check crankshaft end float Fit big end bearings Fit timing cover and gears Fit flywheel or drive plate and ring gear assembly SERVICE TOOLS ENGINE 9999 Land Rover Number LRT 12 010 18G 1014 LRT 12 013 18G 1150 LRT 12 014 18G 1150E LRT 12 034 18G 1519 LRT 12 037 RO 274401 LRT 12 038 RO 600959 LRT 12 055 LRT 12 089 LRT 12 090 LRT 12 091 LRT 12 095 LRT 12 501 MS76B LRT 12 503 MS150 8 5 LRT 12 504 MS76 621 LRT 12 515 RO 605774A Engine numbers without suffix B Engine numbers with su
10. fitted on side of cover nearest centre of engine 9 LH rocker shaft only Align dipstick tube to rocker cover fit and tighten screw OVERHAUL 3 ENGINE CYLINDER HEAD Cylinder head remove 1 Remove rocker shaft assembly 2 Mark heads LH and RH for reassembly Engine numbers without suffix B 12M1082 NOTE RH cylinder head illustrated 3 Using sequence shown remove 14 bolts securing cylinder head to cylinder block Engine numbers with suffix B NOTE RH cylinder head illustrated A 4 Using sequence shown remove and discard 10 bolts securing cylinder head to cylinder block NOTE No bolts are fitted in the four lower A holes in each cylinder head 4 OVERHAUL All engines 5 Release cylinder head from 2 dowels and remove cylinder head 6 Remove and discard cylinder head gasket Valves and springs remove 1 Remove spark plugs 7 LTR 12 034 K 12M0895 G2 2 Using valve spring compressor LRT 12 034 or a suitable alternative compress valve spring 3 Remove 2 collets 12M0896 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 A collets in fitted order 6 Remove and discard valve stem oil seals Valves valve springs and guides inspection 1 2 3 5 6 Clean cylinder head valve springs valves and valve guide bores Check existin
11. 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 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 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 NOTE Use an old broken piston ring with A a squared off end CAUTION Do not use a wire brush A ENGINE Bees 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
12. 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 A camshaft gear must be facing forwards 12M0915 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 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 A 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 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 ENGINE Pp 200o 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 fr
13. switch are fitted to the oil pump cover 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 ENGINE 5 Main gallery A Oil to cooler B Oil from cooler All engines 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 DESCRIPTION AND OPERATION 7 ENGINE Distributor drive and timing chain lubrication 12M1086 1 Bearing 2 Camshaft 3 Key 4 Cam
14. 05 3 Fit cylinder head gasket with the word uppermost NOTE Gasket must be fitted dry CAUTION Engines without suffix B have a N 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 numbers without suffix B 12M 0861 NOTE RH cylinder head illustrated A 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 Engine numbers with suffix B 10 12M 1248 NOTE RH cylinder head illustrated A 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 A lower holes in each cylinder head ENGINE 9999 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 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 12M0908A Scribe an alignme
15. 14 Ensure remover replacer is located in gudgeon pin bore of piston Screw large nut up to thrust race Hold lockscrew and turn large nut until gudgeon pin is withdrawn from piston Dismantle tool and remove piston connecting rod and gudgeon pin Repeat above operation for remaining pistons OVERHAUL Pistons inspection 1 Clean carbon from pistons 2 Inspect pistons for distortion and cracks 12M0929 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 Pp 200o 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 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 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 necessa
16. ATION ENGINE Crankshaft pulley bolt 270 Nm Timing cover to cylinder block bolts 22 Nm Camshaft gear bolt 50 Nm Rocker cover bolts 8 Nm Rocker shaft to cylinder head bolts 38 Nm Cylinder head bolts QULERTOW ORs 60 Nm Centre vow ris eta alee Tl ae Bele tae a wae 90 Nm Inner FOW 90 Nm Cylinder head bolts Engine No s with suffix B SIage T a od ed 20 Nm Stage PDT D EE Then 90 NIC ro CC EPI Further 90 Lifting eye to cylinder head bolts 25 Nm Connecting rod bolts 50 Nm Main bearing cap bolts 70 Nm Rear main bearing cap bolts 90 Nm Flywheel bolts 80 Nm Drive plate and ring gear assembly bolts 40 Nm Drive plate adapter bolts 80 Nm Oil sump drain plug 40 Nm Oil sump bolts 23 Nm Oil pressure relief plug 45 Nm Oil pump cover to timing cover 12Nm Oil pump cover plate screws Engine No s with 4 Nm cR ee ER ae eee Oil strainer 10 Nm Distributor clamp 20 Nm Spark plug
17. aft OVERHAUL Crankshaft inspection 1 Clean crankshaft and blow out oil passages 12 0946 2 Support crankshaft front and rear bearings 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 Crankshaft dimensions 12 0947 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
18. annot 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 6 Withdraw camshaft taking care not to damage bearings in cylinder block Camshaft and tappets inspection 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 Camshaft and tappets refit 1 Lubricate camshaft journals with clean engine oil and carefully insert camshaft into cylinder block 2
19. ary 3 Inspect ring gear for worn chipped and broken teeth 4 Renew ring gear assembly if necessary ENGINE Pp 200o Drive plate and ring gear assembly refit CAUTION To prevent distortion to flexible AN drive plate when bolted to torque converter drive plate setting height must be checked as follows 2 12M0940 Fit existing shim and crankshaft adapter plate 2 Fit socket head screws and lightly tighten 3 Fitring 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 OVERHAUL 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 CRANKSHAFT MAIN AND BIG END BEARINGS Crankshaft end
20. ations 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 References 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 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 The dimensions quoted are to design engineering specification with Service limits where applicable INTRODUCTION 1 INTRODUCTION REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Rover recommended parts are used
21. dgeon pins Length s nz sse Ie E est ERES 72 67 to 72 79 mm Diameter ge 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 88 90 3 9 engine Va ak Pas oa 94 00 mm 4 2 94 00 Crankshaft Main journal diameter 58 409 to 54 422 mm Minimum regrind 57 393 to 57 406 mm Maximum out of round 0 040 mm Big end journal diameter 50 800 to 50 812 mm Minimum regrind 49 784 49 797 Maximum out of round 0 040 mm End float 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 0 15 to 0 36 mm Flywheel Flywheel minimum thickness 39 93 mm Drive plate Drive plate setting 8 08 to 8 20 mm 2 GENERAL DATA INFORM
22. elly 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 2D 12 1258 4 Make suitable alignment marks inner outer rotors remove rotors OVERHAUL 17 ENGINE Oil pressure relief valve remove 12M1263 Remove circlip Remove relief valve plug remove and discard O ring 3 Remove relief valve spring and piston No 18 OVERHAUL 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 12M1259 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 Place a straight edge across housing Using feeler gauges check clearance between straight edge and rotors Maximum clearance
23. ffix 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 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 SERVICE TOOLS 1
24. ft remove 1 LH rocker shaft only Remove screw securing dipstick tube to rocker cover 12M0891 2 Remove 4 screws securing rocker cover to cylinder head i 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 A shafts will lead to an oil feed restriction ENGINE 12M0892 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 OVERHAUL 1 ENGINE Dismantle 12M0886 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 12M0887 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 Fit new split pin to one end of rocker shaft Fit plain washer a
25. g is to enable engine to be started When engine is refitted ignition timing must be set using electronic equipment ENGINE 9999 OIL COOLER ADAPTER ENGINE NUMBERS WITHOUT SUFFIX B Oil cooler adapter remove 1 Remove oil filter element 12M0920 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 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 16 1 Remove sump 2 Remove distributor 3 4 Remove oil cooler adapter if fitted Remove timing cover Remove oil pressure relief valve plug discard sealing washer Withdraw pressure relief valve spring and valve Remove oil pressure switch discard sealing washer Remove bolts securing oil pump cover Remove cover remove and discard gasket Withdraw oil pump gears OVERHAUL Oil pump inspection 1 NO Throughly clean oil pump gear housing cover and gears 2 Clean oil pressure relief valve bore in housing 3 4 Inspect pump gears for wear and scoring Clea
26. g valve stem and head diameters Check valve stem to guide clearance using new valves 12 0897 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 Check installed height of each valve Valve installed height C 47 63 mm Renew valve valve seat insert as necessary ENGINE 9999 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 N as a complete set Valve guide renew 12M0898 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 OVERHAUL 5 ENGINE LTR 12 038 T c N P ZO 2 LACHES LTR 12 515 SS 12 0899 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
27. haust Valve guides Valve guide installed height Valve seats Valve seat angle Valve seat width Valve face angle Oil pump Gear to body minimum clearance Oil pressure relief valve Spring free length Oil pump Engine No s with suffix B Inner to outer rotor clearance maximum Rotors to cover plate clearance maximum Drive gear wear step depth maximum Oil pressure relief valve Engine No s with suffix B Spring free length Camshaft Maximum run out INFORMATION 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 40 40 mm 339 10N 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 24 13 mm 460 15 1 5 to 2 0 mm 45 GENERAL DATA 1 INFORMATION Piston rings Ring to groove clearance Top compression 0 05 to 0 10 mm 2nd compression 0 05 to 0 10 mm Ring fitted gap Top compression 0 44 to 0 57 mm 2nd compression 0 44 to 0 57 mm Oil control rails 0 38 to 1 40 mm Oil control ring width 3 00 mm maximum Pistons Clearance in bore measured at bottom of skirt at right angles to 0 018 to 0 033 mm Gu
28. hown 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 Distributor refit 2 12M0917 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 12M0919 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 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 MN A A 12 1250 10 Fit distributor clamp nut ensuring that counterbored portion is towards clamp tighten nut 11 Fit rotor arm CAUTION This distributor settin
29. mm Valve seat insert inspection 1 Check valve seat inserts for pitting burning and wear Replace inserts as necessary 6 OVERHAUL Valve seat insert renew NOTE Service valve seat inserts are available 0 25 mm oversize on outside diameter to ensure interference fit 1 Grind a crescent in seat insert until thin enough to break using a cold chisel CAUTION Do not damage counterbore 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 ENGINE Pp 2000 Valve seats renew 1 Check condition of valve seats and valves that are to be reused 2 Remove carbon from valves and valve seats A 12 0901 42M0902 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 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 12 0918 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
30. n relief valve filter screen Fit pump gears into housing Place straight edge across gears 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 Remove oil pump gears from housing Clean oil pressure relief valve and spring Inspect relief valve for wear and scoring Inspect relief valve spring for wear or signs of collapse Relief valve free length 81 28 mm Check relief valve slides freely in its bore with no perceptible side movement ENGINE 9999 OIL PUMP ENGINE NUMBERS WITH SUFFIX B Oil pump refit 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 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 l l must be fitted 4 Pack oil pump housing with Petroleum Jelly CAUTION Use only Petroleum Jelly no Oil pump remove A other grease is suitable 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 J
31. nd wave washer Lubricate rocker arm bushes with clean engine oil 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 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 Assemble rocker arms brackets and springs to rocker shaft Compress springs fit wave washer plain washer and secure with new split pin Rocker shaft refit 1 Lubricate pushrods with engine oil 2 Fit pushrods in removed order 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 A 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 ENGINE Pp 2000 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
32. nt mark between distributor body and clamp Remove nut securing distributor clamp Remove distributor Remove clamp Remove and discard O ring from distributor Noo fb OVERHAUL 9 ENGINE Sump remove 12M1251 1 Remove dipstick 2 Remove screw securing dipstick tube to LH rocker cover 12M0909A 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 N sealing faces of cylinder block and sump 5 Remove sump 10 OVERHAUL Timing cover remove Engine numbers without suffix B 1 Remove crankshaft pulley bolt and collect spacer washer 2 Remove crankshaft pulley 6 Lars d omer 3 Remove bolts and nut securing timing cover to cylinder block Release and remove timing cover Remove and discard gasket Remove and discard oil seal from timing cover oca Timing cover remove Engine numbers with suffix B 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 12M1252 3 Noting their fitted position remove bolts securing timing cover to cylinder block remove cover NOTE Dowel located A 0 ee 4 12M1262 4 Rem
33. om 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 Clean oil seal location in timing cover Lubricate oil pump gears and oil seal recesss in timing cover with engine oil 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 A al LRT 12 090 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 12M1254 LRT 12 089 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 12 0864 2 Clean mating faces with suitable solvent and apply a 2 mm bead of Hylosil white silicone sealant to sump joint face as s
34. ontrolled by the thrust faces of the upper centre main bearing shell Ud SR OS Be 2 a 5 E ES pees 4 ENGINE F CZAR AG Y p f A 12M1087 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 12M0983A 1 Oil strainer 5 Main gallery 2 Crankshaft main bearing oil feed A Oil to cooler 3 Oil pressure relief valve B Oil from cooler 4 Oil pump 6 DESCRIPTION AND OPERATION Lubrication Engine numbers with suffix B 12M 1256 Oil strainer Oil pump Pressure relief valve Oil pressure switch khOND Engine numbers without suffix B 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
35. ove oil pump drive gear 5 Remove and discard gasket 6 Remove and discard oil seal from timing cover ENGINE Pp 200o Timing gears remove 12M0911 1 Restrain camshaft gear and remove bolt securing gear collect washer 2 Remove distributor drive gear and spacer 12M0912A 3 Remove timing chain and gears as an assembly 4 Collect Woodruff keys from camshaft and crankshaft Timing gears inspection 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 Co NE CS 2 Check camshaft Woodruff key is fully engaged 12 0913 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 12M0914 6 Position timing
36. ry LRT 12 014 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 LRT 12 013 12M0973 removed after above operation 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 CAUTION Ensure all traces of grit are Connecting rod inspection spigot inside bore of hexagon body I MM 5 Fit parallel sleeve grooved end last up to 1 Check alignment of connecting rod 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 9 10 11 12 13 Set torque wrench to 16 Nm and using socket Fit gudgeon pin onto centre screw and into piston bore up to connecting rod Fit remover replacer bush with flanged end towards gudgeon pin Screw the stop nut onto centre screw and position piston against face of adaptor LRT 12 014 Lubricate centre screw threads and thrust race with graphited oil fit and
37. screw large nut up to thrust race Adjust stop nut leaving clearance B between nut and remover replacer bush Clearance B 0 8 mm Lock the stop nut securely with lockscrew on large nut pull gudgeon pin in until flange of remover replacer bush is distance C from face of piston Distance C 4mm 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 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 24 OVERHAUL Pistons and connecting rods refit 1 Fit oil control ring rails and expander ensuring ends butt and not overlap 12 0931 2 Fit ring marked with marking uppermost into second groove 3 Fit top compression ring into groove either way round 12M0932 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 Position compression rings with ring gaps on opposite sides of piston between gudgeon pin and piston thrust face Fit big end bearing shell
38. shaft timing chain sprocket 5 Spacer 6 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 8 DESCRIPTION AND OPERATION Hydraulic tappets 12M0884 Clip Pushrod seat Inner sleeve Upper chamber Non return ball valve Spring Outer sleeve Lower chamber high pressure ADORA The purpose of the hydraulic tappet is to provide maintenance free and quiet operation of the inlet and exhaust valves lt 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 ROCKER SHAFTS Rocker sha
39. te 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 crankshaft Tightness indicates insufficient bearing clearance or misaligned connecting rod 11 12 ENGINE Pp 200o Check clearance between connecting rods on each crankshaft journal Connecting rod clearance 0 15 to 0 37 mm Clean oil strainer Clean gasket mating faces on strainer and cylinder block Fit gasket to strainer position strainer fit bolts and tighten to correct torque Fit sump OVERHAUL 29 ENGINE Crankshaft remove 1 Remove flywheel or drive plate and ring gear assembly 2 Remove timing cover 3 4 Remove timing gears Remove big end bearings 10 30 Starting at centre main bearing and working outwards progressively slacken then remove 10 main bearing cap bolts Remove 5 main bearing caps and bearing shells retain bearings with their caps Lift out crankshaft and rear oil seal Remove and discard oil seal Remove 5 bearing shells from cylinder block and retain in their fitted order Remove and discard side seals from rear main bearing cap Remove Woodruff key from cranksh
40. thout suffix B Engine numbers with suffix B ENGINE 9999 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 DESCRIPTION AND OPERATION 3 ENGINE CYLINDER HEAD COMPONENTS 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 12M0881 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 NYO 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 c
41. to connecting rod Lubricate big end bearing shell piston rings and gudgeon pin with engine oil Lubricate cylinder bores and crankshaft big end journals with engine oil 9 Fit ring clamp to piston and compress piston rings 10 Fit plastic tubing to connecting rod bolts 12M0934 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 A crankshaft journals 13 Fit big end bearing caps and bearing shells 14 Fit cylinder head s ENGINE Besos FLYWHEEL Flywheel remove 12M0935 1 Restrain crankshaft and remove 6 bolts securing flywheel 2 Remove flywheel Inspect A pl BS 12M0936 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 OVERHAUL 25 ENGINE Flywheel ring gear renew lle PA ZTA o 12M0937 1 Drill a 10 mm diameter hole axially at base of tooth and inner diameter of starter ring sufficiently deep eno
42. ugh to weaken ring gear CAUTION Do not allow drill to enter A 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 26 OVERHAUL 12M0938 5 Heat new ring gear uniformly to between 170 and 175 C CAUTION Do not exceed this N temperature 6 Locate ring gear on flywheel with chamfered inner diameter towards flywheel flange NOTE If ring gear is chamfered on both AN 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 Fit flywheel and locate on 2 dowels 2 Fit flywheel bolts 3 With assistance restrain crankshaft and tighten flywheel bolts to correct torque DRIVE PLATE AND RING GEAR ASSEMBLY Drive plate and ring gear assembly remove 1 Mark each component to enable reassembly in original position 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 necess
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