TVR Cerbera Workshop Service Manual - Engine
Contents
1. Finally the anti roll bar cover can be replaced torqueing the M10x15 bolts with washers to 30 ft Ib Run engine and check for leaks Remembering to check oil level after switching the engine off Wait 2 mins before checking Service Workshop Manual Oil Filter Hosted and optimised by www TheTVRSite com a ome Cerbera p geen and h r sge CEE EK bartai Service Workshop Manual Air Filter Hosted and optimised by www The TVR Site com Access to the air filter is gained through the air filter box which is situated at the front of the engine bay Firstly remove the air flow sensor plug which is situated on the N S of the car 2 Remove the air pipes from the air filter box by loosening the Jubilee clips P 3 Next remove the split pins on the two securing clips on the front of the box 4 Service Workshop Manilal Air Filter Hosted and optimised by www The TVR Site com CERBERA SERVICE WORKSHOP MANUAL X The filter box should now come free A o 8 Oe Service Workshop Manual Air Filter Once the filter box is free the air filter can be removed and replaced with the course side down i 6 Then refit filter to cut out in bodywork and refit filter box back onto car a o AS Service Workshop Manual a Age Peper Sere re rre eee treet ere eee creer eer iter rete tee terete tre rete eter teeter rete ee errr teeter rere ttre ere Finally replace split pins on securing c2. Hosted and optimised by www TheTVRSite com To obtain access to the spark plugs the top engine cover needs to be removed first Next remove the air boxes and air pipes The spark plugs are situated under the coolant rail and run down each side of the engine It is advisable to remove any dirt from around the plug recesses with a dry brush or air line before removing the plug to prevent any dirt dropping into the cylinders lt lt e A Service Workshop Manual S park Pl ugs Hosted and optimised by www The TVR Site com CERBERA SERVICE WORKSHOP MANUAL Remove the plug leads and label Once this has been done the spark plug can be unscrewed using a spark plug spanner suitable box spanner or a deep socket and extension bar Remembering to keep the socket aligned with the spark plug otherwise the ceramic insulator maybe broken Once the spark plug has been removed they should be checked Service Workshop Manual Spark Plugs Hosted and optimised by www TheTVRSIte com 9 10 BC 2 429 Gee AR Service Workshop Manual Spark Plugs 12 Ten N LES Service Workshop Manual Spark Plugs Replace with a new pre set plug or with the old checked plug Excharge every 6 000 miles Replace the plug leads onto the correct plug ensuring they click on Reseal air boxes with 1 4 inch sticky foam before fitting if required and then refit air pipes j Finally replac
3. Section G Engine Hosted and optimised by www TheTVRSite com contents Oil Pressure Switch Hosted and optimised by www TheTVRSite com me Cerbera pepe S En 2 Service Workshop Manual Engine Setup Lap Top Instructions Hosted and optimised by www TheTVRSite com Remove the 2 x M4 allen bolts that hold the top trim panel in place Remove both air intake pipes Remove all 5 M6 x 15 allen bolts on the throttle assembly that releases the air boxes Remembering to remove the Air pressure sensor pipe on the N S air box when removing Helo Tis Service Workshop Manual Engine Setup Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL Remove the throttle linkage rod retaining clips and remove the rod Adjust base idle screw to allow the throttle butterflies to be fully closed Ensure computer is fully charged or connected to the mains Then connect 9 pin connection lead as shown Service Workshop Manual Engine Setup Next remove ECU from footwell and remove cover Then connect the cable from the computer as shown N B Do not touch any wiring inside ECU Service Workshop Manual Engine Setup Hosted and optimised by www TheTVRSite com Turn on computer with ON OFF switch as shown You should now see a TVR diagnostics page as shown opposite A communication error will shown at the bottom of the page if the ig
4. Pressure Switch Hosted and optimised by www TheTVRSIte com i CERBERA SERVICE WORKSHOP MANUAL Notes Hosted and optimised by www TheTVRSite com
5. inlet cam follower is exactly 1 5mm lower than the exhaust check with cam timing piece DO NOT TURN THE ENGINE BACKWARDS DURING THIS OPERATION 9 Now scribe the camshaft and camshaft sprocket with a horizontal line exactly level with the top of the cylinder head These parts are very hard so a carbide tipped scribe is required 10 Next remove the remaining cam sprocket retaining bolts Ml Then fit the cam sprocket retaining tool 12 Service Workshop Manual Tappets Hosted and optimised by www TheTVRSIte com CERBERA SERVICE WORKSHOP MANUAL And tighten in place with the bolts provided Now turn the crankshaft anti clockwise until the camshaft has moved 1 1 2 teeth if working on the odd bank i e 1 3 5 7 If working on the even bank turn the crankshaft clockwise until the camshaft has rotated 1 1 2 teeth This puts the engine in a safe position so that the valves are not bent when removing adjusting or replacing the camshaft Slacken the timing chain tensioner but do not remove it completely Then slide the cam sprocket off the cam and onto the retaining tool Tappets Service Workshop Manual Hosted and optimised by www TheTVRSite com Now slacken all the cam caps evenly remove K lock nuts and caps Remove camshaft Remove any cam followers which need adjustment f Remove Top ha shim 6 20 2 SR teen eee e eee nent earn meen se
6. e the 12 M8 caphead bolts holding the inlet manifold to the cylinder head DO NOT remove the fuel rail or throttle linkage Remove the inlet trumpets as a complete assembly and place on one side Note the spacers between the inlet manifold and cam covers Ensure that these 2 DO NOT fall into the inlet ports when the inlet Remove the cam cover retaining bolts and then the cam cover of the bank to be checked Only work on one bank at a time or the cam timing may be lost Service Workshop Manual Tappets And check cam clearances with a feeler gauge as shown Ensuring measurement is done at the back of the cam i e Directly opposite the cam lobe If adjustment is required note down clearance for reference later Service Workshop Manual Tappets Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL If adjustment is required proceed as followers turn the front pulley until the front two cam followers are on the overlap period inlet just opening exhaust just closing i e cam followers approx leave or push the car in 5th gear if a front pulley is not fitted Remove the uppermost cam sprocket retaining bolts Turn the front pulley clockwise or push the car forwards in 5th gear until Service Workshop Manual Tappets Hosted and optimised by www TheTVRSite com The back two cam followers are level Then carefully turn the crank clockwise slightly more until the
7. e the top engine cover Hosted and optimised by www TheTVRSIte com CERBERA SERVICE WORKSHOP MANUAL Notes Hosted and optimised by www TheTVRSite com s w Cerbera p gt oa F z Service Workshop Manual Oil Filter Hosted and optimised by www TheTVRSite com To obtain access to the oil filter the car must first be raised on a ramp or driven over a pit The oil filter is situated to the N S of the car The engine oil has to be drained first by removing the two sump plug bolts M10x15 and filler cap There are two sump plugs as shown because the sump is divided into two canals Once all the engine oil has been drained then the sump plate bolts M10x15 have to be removed to release the anti roll bar cover to create better access to the oil filter Service Workshop Manual Oil Filter Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL Once this has been done the oil filter is ready to be removed using a strap wrench N B This picture shows the anti roll bar cover still fitted Before replacing the new oil filter it must be filled with new oil and refitted as quickly as possible so as the oil doesn t drain from the pump When the sump bolts are replaced they should be torqued to 25 ft 1b When this has been done the engine can be filled with new oil and the filler cap refitted Service Workshop Manual Oil Filter
8. en ee scer ete nen ea een en sero n setae ne ee then rarsemebenee eee eeeer eee eeecenseeeeen ene se sene x Service Workshop Manual Tappets Hosted and optimised by www TheTVRSIte com CERBERA SERVICE WORKSHOP MANUAL And measure shim with a micrometer 21 Replace with a new shim which gives a clearance of 0 010 inch on the exhaust valve or 0 008 on an inlet valve ae Gi 22 Service Workshop Monal z Tappets 42 2 22 2 2 2 24 2 2 Replace the camshaft but do not connect the cam sprocket 23 Lubricate cam caps with nulon or suitable engine build lubricant F 24 am oo RENE uated A EOE E E a amague nus iep EENE Service Workshop Manual Tappets Hosted ana optimised by www TheTVRSite com 6 Replace caps and tighten progressively toward the back of the engine note cam position whilst fitting caps Apply engine oil to camshaft and cam followers J The camshaft may be rotated whilst the engine is in the safe position in order to check the valve clearances DO NOT rotate the crankshaft or valve damage will occur Repeat steps 17 to 25 until clearances are correct When adjustment is completed torque caps to 17 lb ft Hosted and optimised by www The TVR Site com CERBERA SERVICE WORKSHOP MANUAL Turn cam until scribe marks line up with cylinderhead and Service Workshop Manual Tappets Slide cam sproc
9. ent to the other adjust the link rod by slackening the two locknuts from the ball socket and rotating the link rod Note one of the ends of the link rod has a LH thread Hosted and optimised by www The TVR Site com CERBERA SERVICE WORKSHOP MANUAL Adjust idler screw to set engine to speed Re adjust if necessary The two adaptive valves should be between 0 and 10 If it is not adjust throttle pot slightly Increase throttle by turning the throttle pot This will decrease the adaptive valve for that bank and visa versa Only small adjustments should be necessary at this stage Adaptive valves are greater than 15 indicate a fault elsewhere Mee ee eel Service Workshop Manual Engine Setup Once this has been done disconnect computer Unclamped the purge pipe and refit the airboxes Remembering to re connect the pressure sensor and crankcase breather pipe Service Workshop Manual Engine Setup Hosted and optimised by www TheTVRSite com Refit the Air pipes And finally refit top engine cover remembering to connect the washer pipes Service Workshop Manual Engine Setup Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL Notes Hosted and optimised by www TheTVRSite com Service Workshop Manual Crank Sensor Hosted and optimised by www TheTVRSite com To gain access to the crank sensor the car has to be raised on a ramp or dri
10. ket on to camshaft Now turn the crankshaft until the scribe lines match exactly on the cam and sprocket now remove the sprocket retaining tool Degrease cam sprocket retaining bolts with solvent apply loctite thread locking compound and refit bolts torqueing to 20 lb ft Loctite cam chain tensioner bolt Tighten and secure with lockwire Service Workshop Manual Tappets Hosted and optimised by www TheTVRSite com Turn crankshaft 1 revolution clockwise and refit remaining cam sprocket retaining bolts torqueing to 20 lb ft Place a bead of silicone over the joint between the cylinder and the front cover j Apply a thin bead of silicone all around the cam cover ensuring silicone is applied all around the bolt holes Refit the cam cover torque M5 bolts to 10 lb ft and M8 bolts to 15 lb ft a O E E A TT ETE ETET i Service Workshop Manual Tappets Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL Refit the manifolds remembering to refit the spacers between the manifolds and cam covers The spacers must be an exact fit in their respectively caps or cracking will occur around the cam cover bosses fit shims if necessary Refit the airboxes and air inlet pipes reconnect the battery and refit top engine cover Service Workshop Manual Tappets Hosted and optimised by www TheTVRSIte com c10 Service Workshop Manual Spark Plugs
11. lips and then refit the air pipes and reconnect the air flow sensor 8 j OECS ET cescsnscesssesccnsusssccsnsuessoussesssesccsssdeccusversessnneseseessesetentenstinisersnsesteesess Hosted and optimised by www TheTVRSite com Service Workshop Manual Oil Pressure Switch Hosted and optimised by www TheTVRSite com To gain access to the oil pressure switch firstly remove the top engine cover by the two M4 allen bolts then disconnect the battery and remove washer pipes as shown The switch is located under the rear coil which is held on by 4 x M5 allen bolts These have to be removed using a ball end socket Service Workshop Manual Oil Pressure Switch Once all four bolts have been removed it can then be pushed to one side to reveal the switch Remove the oil pressure switch wire wt ri te Service Workshop Manual Oil Pressure Switch Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL Using a deep 1 inch scocket with an extension carefully undo and remove the switch Replace with new switch and washer Note Apply a small amount of grease glue on the washer to ensure it does not fall into the engine bay when fitting Replace the oil pressure switch wire Refit and tighten bolts on coil and make sure plugs leads are all o k and no other wires have been disturbed Hosted and optimised by www TheTVRSite com Service Workshop Manual Oil
12. nition is not on or the computer not connected correctly Turn the immobiliser off and then the ignition on you should here the fuel pump run for a few seconds The computer should now show all the inputs and outputs of the system Press page down to show current and logged faults 12 Service Workshop Manual Engine Setup Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL Press page down again to show throttle pot settings only this allows computer screen to be seen clearly from a distance whilst setting throttle pots Next ensure the throttle butterflies are shut Adjust throttle petiometers to between 14 8 and 15 2 Then fit the throttle linkage arm back in position by rotating the bar to make it longer shorter until it fits perfectly without moving either throttle arm Tighten the lock nuts ensuring that the linkage rod can still rotate slightly to prevent binding pan J J Service Workshop Manual Engine Setup Hosted and optimised by www TheTVRSite com Then fit retaining clips Unscrew the idler screw until the throttle pots read 19 Block off the purge line with a pipe clamp as shown Then start the engine and allow it to warm up to normal operating temperature The engine should run between 900 and 950 rpm Measure the air flow with the air synchrometer This should read between 4 and 5 on the scale on all cylinders If one bank is differ
13. ven over a pit N B Only use a four post ramp Service Workshop Manual Crank Sensor The crank sensor is situated on the O S of the car on the engine bellhousing adjacent to the dip stick tube Firstly the crank sensor connector wire has to be removed Press the spring C Cup in to release the plug Next the M8 allen bolt is to be removed using a M6 alan key this is because of the size of the allen head CHR bisa k Sensor Service Workshop Manua Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL Once this has be done the sensor will slide out freely If it does not it is acceptable to bend the dipstick tube very slightly to aid removal 5 Clean the sensor ensuring the hole at the end is free of dirt etc 6 Apply loctite to the sensor bolt and washer X 7 Replace the sensor with its bolt and washer 8 Service Workshop Manual Crark Sensor Hosted and optimised by www TheTVRSite com B 2 Tighten with an M6 allen key Service Workshop Manual Reconnect the sensor wire mee OW Service Workshop Manual Crank Sensor Hosted and optimised by www TheTVRSite com CERBERA SERVICE WORKSHOP MANUAL Notes Hosted and optimised by www TheTVRSite com EES Service Workshop Manual Tappets Hosted and optimised by www TheTVRSite com Remove Air inlet pipes and Air boxes Disconnect the Battery Remov
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