Land Rover Defender 90 110 Workshop Book 2 Rover

							V8 CYLINDER ENGINE 112 
Check crankshaft  bearings 
22. Locate the bearing upper shell into the connecting- 
rod. 
23.  Locate 
the connecting-rod  and  bearing on to the 
applicable  crankshaft  journal,  noting  that 
the 
domed shape boss on the connecting-rod must  face 
towards  the front  of the  engine  on  the  right
-hand 
bank  of cylinders  and towards  the  rear  on the 
left
-hand  bank. 
24. When  both  connecting-rods are fitted,  the  bosses 
will face inwards towards  each other. 
25.  Place 
a piece of Plastigauge across  the centre  of the 
lower  half 
of the crankshaft journal. 
26.  Locate the bearing lower  shell into the connecting
- 
rod cap. 
27. Locate  the cap and  shell on to  the connecting-rod. 
Note that  the 
rib on the edge  of the cap  must be the 
same side as the shape boss On the IR/IIORTANT: The connecting-rods, caps and bearing - - connecting-rod. 
28.  Secure  the  connecting
-rod cap,  and  tighten  to the shells must be retained  in sets, and in the  correct 
sequence, , 
correct  torque. 
.... 
29. Do not rotate  the crankshaft  or connecting-rod 
30. Remove  the connecting-rod cap and shell. 
31.  Using  the 
scalc printed  on the  Plastigauge  packet, 
measure 
the flattened  Plastigauge  at its  widest 
point. 
32.  The  graduation  that most  closely  corresponds to 
the  width 
of the  Plastigauge  indicates  the bearing 
clearance. 
33.  The  correct  bearing  clearance 
with new or 
overhauled  components  is 0,013  to 0,06 mm 
34. If a bearing  has been in service, it is advisable  to fit 
a new  bearing if the clearance  exceeds 0,08 mm 
(0.003 in). 
35. If a new  bearing  is  being  fitted,  use  selective 
assembly  to obtain the  correct clearance. 
36. Wipe off the Plastigauge with an  oily rag. DO NOT 
scrape it off. 
while 
the Plastigauge 
is in USC. 
(0.0006 !e 0.0022. in>. 
Assembling  pistons to connecting-rods 
37. If an hydraulic  press  and tool  605350  was used for 
dismantling,  refit cach piston  to its connccting-rod 
as follows: 
a.  Check  that the  base of tool  605350  and the  guide 
tube  are fitted  as follows:
- 
Place  the base  of tool 605350  on the bed of an 
hydraulic press  which has a capacity of 8 tons (8 
tonnes). 
Fit the  guide  tube into the  bore of the  base with 
its countersunk  face uppermost. 
b. Fit the long  mandrel  inside the guide  tube. 
c. 
Fit the  connccting-rod  into  the piston  with the 
markings  together 
if the original  pair arc being 
used, 
then place  the piston  and  connecting-rod 
assembly  over the long  mandrel  until the 
gudgeon  pin 
boss rests on thc guidc tube. 
d. Fit the gudgeon  pin into  the piston  up  to the 
connecting-rod,  and  the  spigot  end of the small 
diameter  mandrel into the gudgeon  pin. 
e. Press in the gudgeon  pin  until it abuts the 
shoulder 
of the  long  mandrel. 
continucd 
107  
						

							V8 CYLINDER ENGINE 
c 
37 
D 
A 
38. If tool 18G 1150 was  used for dismantling,  refit 
each  piston 
to its connecting-rod  as follows: 
a. Clamp  the hexagon  body  of 18G 1150 in a vice, 
with  the adaptor  18G 1150 E positioned as in 4d. 
b. Remove the  large nut of 18G 1150 and push  the 
centre  screw approximately 
50 mm (2 in) into 
the  body  until the shoulder 
is exposed. 
c.  Slide 
the parallel  guide sleeve, grooved  end last, 
onto the centre  screw and up  to the shoulder. 
I 1 
39. 
d. Lubricate the gudgeon  pin and  bores  of the 
connecting
-rod  and  piston  with graphited  oil 
(Acheson’s  Colloids  ‘Oildag’).  Also  lubricate 
the  ball  race  and centre  screw 
of 18G 1150. 
e. Fit the connecting-rod  and  the  piston together 
onto  the tool  with  the markings  together 
if the 
original  pair are being  used  and  with the 
connecting
-rod  around the sleeve  up  to the 
groove. 
f. Fit the  gudgeon  pin into the piston  bore up to 
the  connecting
-rod. 
g. 
Fit the removerheplacer bush  18G 115013 with 
its flanged  end towards  the gudgeon  pin. 
h. Screw the  stop-nut onto the centre  screw  and 
adjust  this nut to obtain 
a 1 mm (& in) end-float 
‘A’ on  the  whole  assembly,  and  lock the nut 
securely  with the screw. 
i.  Slide 
the assembly  back  into the hexagon  body 
and  screw on  the large 
nut up to the  thrust race. 
represents 
the minimum  load for an  acceptable 
interference 
fit of the  gudgeon  pin in the 
con  necti  ng
-rod. 
k. Using  the torque  wrench and socket 18G 587 on 
the large  nut, and  holding  the lock  screw,  pull 
the gudgeon  pin in until  the flange of the 
remover-rcplacer bush is 4 mm (0.160 in) ‘B’ 
from  the face  of the  piston.  Under no 
circumstances  must this  flange  be allowed to 
contact the piston. 
j. Set  the torque  wrench 18G 537 to 12 Ibf ft. This F~::, ,e:>; 
CAUTION: If the torque  wrench  has not broken 
throughout the pull,  the fit 
of the gudgeon pin to 
the  connecting
-rod is not  acceptable  and 
necessitates  the  renewal 
of components.  The 
large  nut  and  centre  screw 
of the tool  must  be 
kept well
-oiled. 
e, e. :-. “-” Remove  the tool  and check that the piston  moves 
freely 
on the  gudgeon  pin and  that no damage has 
occurred during  pressing. 
I’ 
I 
ST778M 
I08  
						

							V8 CYLINDER ENGINE 
/.2;:.2> prwrb> REMOVE AND OVERHAUL CRANKSHAFT *!,..,., .::.2 
1. Remove  the main  bearing  caps  and  lower bearing 
shells  and retain  in sequence. 
It is important  to 
keep  them  in pairs  and mark  them  with 
thc number 
of the respective journal until it is decided if thc 
bearing shells  are to be rcfitted. 
2. Lift  out the  crankshaft and rear oil seal. 
- ;,:::,., , .., ., . , . ... , .. .  . ... . .. a!: 
Inspect  and overhaul crankshaft 
3. Rest  the  crankshaft on vee-blocks at numbers  one 
and  five main  bearing journals. 
4. Using a dial  test  indicator,  check the run-out  at 
numbers  two, 
thrce and  four  main bearing 
journals.  The total  indicator  readings at each 
journal should  not exceed 
0,08 mm (0.003 in). 
5. While  checking the run-out  at  each  journal, note 
the  relation 
of maximum  eccentricity  on  each 
journal  to the  others.  The maximum  on 
all journals 
should  come at  very  near the  same  angular 
iocation. 
6. If the crankshaft  fails to meet  the foregoing checks 
it is bent  and is unsatisfactory  for service. 
7. Check  each  crankshaft  journal for ovality.  If 
ovality  exceeds 
0,040 mm (0.0015 in), a reground 
or  new  crankshaft should  be fitted. ,
						

							112 I V8 CYLINDER ENGINE 
8. Bearings for the crankshaft  main journals  and the 
connecting
-rod  journals  are available in the 
following  undersizes: 
03 mm (0.010 in) 
0,50 mm (0.020 in) 
9. The centre  main bearing  shell, which  controls 
crankshaft  thrust, has the thrust  faces increased 
in 
thickness  when more than 0,25 mm (0.010 in) 
undersize, as  shown 
on thc following chart. 
10 14 
-  
RR1793E 13 
Crankshaft  dimensions - millimetres 
Crankshaft 
Diameter Width Diameter Grade 
12 13 14 
Standard s8,4oo-s8,413 26,97s-27,020 wwo-sn.812 0,254 u/s 58,146-58,158 26,97527,026 50,546-50,559 0,508 U/S 57,892-57,904 27,22927,280 50,292-.50,305 
Crankshaft dimensions - inches 
Crankshaft  Diameter 
Width Diamctcr 
Grade 12 13 14 
10. When a crankshaft  is to  be  reground,  the thrust Standard 2.2992-2.2997 I .062-1 .Oh4 2.0000-2.0005 faces  on either side of the centre  main journal  must 0.010 u/s 2.2892-2.2897 1.062- I .Oh4 1.9900- 1.9905 be machined in accordance  with the dimensions  on 0.020 u/s 2.2792-2.2797 I .072- I .074 1.9800- 1 .I805 
the following  charts. 
Main bearing  journal  size  Thrust face width 
Standard  Standard 
0.25 mm 0.010 in) undersize  Standard 0,50 mm t0.020 in) undersize 0,25 mm (0.010 in) ovcrsize Check main bearing clearance 
11. For example: If a 0,50 mm (0.020 in) Undersize 
bcaring  is to  be  fitted,  then 0,12 mm (0.005 in) 
must  be machined 
off each  thrust face of thc centre 
journal,  maintaining  the correct  radius. 
16. Remove the oil seals from the cylinder block and 
the rear  main bearing  cap. 
17. Locate the upper main bearing shells into the 
cylinder  block. These must be the  shells  with the oil 
drilling  and oil grooves. 
18. Locate the flanged  upper main bcaring shell in the 
centre  position. 
19. Place the crankshaft in position  on the  bearings. 
Crankshaft  dimensions 
12. The radius for  all journals  except the  rear  main 
bearing  is 
1,90 to 2,28 mm (0.075 to 0.090 in). 
13. The radius  for  the  rear main bearing  journal  is 
14. Main bearing  journal  diameter, sec the following 
15.  Thrust  face width,  and connecting
-rod journal 
2 (\/I -- (0 130 ; >,-I 11,111 (W. I&W %a&). 
charts. 
diameter,  see 
the following charts. 
continued 
110  
						

							V8 CYLINDER ENGINE 112 
20. Place  a piece  of Plastigauge  across the centre of the 
crankshaft  main bearing  journals. 
21.  Locate  the bearing  lower shell into 
the main 
bearing  cap. 
22. 
Fit numbers  one to four main  bearing  caps and 
shells.  Torque: 
7,O to 7,6  kgf m (50 to 55 Ibf ft). 
23.  Fit the  rear  main  bearing  cap and  shell.  Torque: 
9,0 to 9,6 kgf  m (65  to 70  Ibf  ft). Do not  allow  the 
crankshaft 
to be  rotated  while the Plastigauge is in 
use. 
24.  Remove  the main  bearing  caps and shells. 
25.  Using  the scale  printed  on 
the Plastigauge  packet, 
measure  the flattened  Plastigauge  at its  widest 
point. 
26.  The  graduation  that most  closely  corresponds  to 
the width of the  Plastigauge  indicates the bearing 
clearance. 
27. The  correct  bearing  clearance  with new or 
overhauled  components  is 0,023  to 0,065 mm 
(0.0009 to 0.0025  in). 
28.  If the  correct  clearance  is not  obtained  initially, use 
selective  bearing assembly. 
29. Wipe off the Plastigauge  with an oily rag. Do NOT 
scrape it off. 
30.  Maintain  the bearing  shells and caps 
in sets  and in 
the correct  sequence. 
Renew spigot bearing 
31. Carefully  remove the old  bearing. 
32.  Fit the  spigot  bearing  flush with, 
or to a maximum 
of 1,6 mm (0.063  in) below  the end  face of the 
crankshaft. 
33.  Ream  the spigot  bearing 
to 19,177 + 0,025 mm 
(0.7504 + 0.001 in) inside  diameter.  Ensure all 
swarf  is removed. 
ASSEMBLING ENGINE 
FIT  CRANKSHAFT  AND MAIN BEARINGS 
1. Locate  the upper  main bearing  shells into thc 
cylinder  block; these must be the  shells  with the oil 
drilling  and oil grooves. 
2. Locate  the flanged  upper main bearing  shell in the 
centre  position. 
3.  Lubricate  the crankshaft  main bearing  journals  and 
bearing  shells with clean  engine  oil and  lower  the 
crankshaft  into position. 
Ill  
						

							El V8 CYLINDER ENGINE 
4. Lubricate  the lower  main bearing  shells and fit 
numbers  one to four main  bearing  caps and shells 
only,  leaving  the fixing  bolts finger  tight at this 
stage. 
5. Fit  the  cruciform  side seals  to the  grooves  each side 
of the rear  main  bearing  cap. Do not cut the  side 
seals  to length,  they must  protrude 
1,5 mm 
(0.062  in) approximately  above the bearing  cap 
parting  face. 
6. Apply Hylomar PL32M jointing  compound to thc 
rearmost  half of the rear  main  bearing cap parting 
face  or, 
if preferred,  to the  equivalent arca on the 
cylinder  block as illustrated. 
7. Lubricate  the bearing  half and bearing  cap side 
seals  with clean  engine  oil. 
8. Fit the bearing  cap assembly to the engine. Do not 
tighten 
the fixings  at this  stage  but ensure  that the 
cap  is fully  home  and squarely  seated 
on the 
cylinder  block. 
9. -Tension  the cap  bolts  equally  by one-quarter  turn 
approximately, 
then back  off one  complete  turn on 
each fixing  bolt. 
NOTE:  The lubricant  coating must cover  the seal 
guide  outer surface  completely  to ensure  that the 
oil 
seal lip is not turned  back during  assembly. 
Position  the oil seal,  lipped  side towards  the engine, 
onto  the seal  guide.  The seal outside  diameter  must 
be  clean  and dry. 
12. Push  home  the oil seal fully  and squarely  by hand 
into  the recess  formed 
in the cap  and  block  until it 
abuts against the machined  step in the recess. 
Withdraw  the seal  guide. 
13.  Tighten  the main  bearing  cap bolts  to the  corrcct 
torque  noting that the bolts  for numbers 
one to 
four  bearings  have 
a different  torque to number 
five  bearing  cap bolts. 
14.  Using 
a feeler  gauge  or a dial  indicator  check the 
crankshaft  end
-float, 0,lO to 0,20 mm (0.004 to 
0.008 in). 
 ST831M  
CAUTION: Do not handle  the seal lip, visually  check 
that  it 
is not damaged  and ensure  that the outside 
diameter  remains clean and dry. 
10. Position  the seal  guide RO 1014  on the  crankshaft 
flange. 
11.  Ensure  that the oil seal  guide  and the crankshaft 
journal  are scrupulously  clean, then coat the seal 
guide  and 
oil seal journal  with clean  engine  oil. 
CAUTION:  DO not exceed 1,000 engine rev/min when c-* 
first  starting  the engine,  otherwise  the crankshaft  rear . ,/ 
oil seal will be damaged. 
112  
						

							V8 CYLINDER ENGINE 112 
,.” -- a- .. ... . FIT CONNECTING-RODS AND PISTONS 7. Using a piston  ring compressor,  locate the piston 
into  the cylinder  bore, until 
the piston  crown is just 
below 
the cylinder  block top face. 
., c 
1. Locate the applicable crankshaft journal  at B.D.C. 
2. Place the bearing  upper shell in the connecting- - rod. 
3. Retain  the  upper shell by screwing  the guide  bolts 
605351 onto the connecting-rods. 
4. insert  the connecting-rod  and  piston  assembly  into 
its  respective  bore, noting  that 
the domed  shape 
boss  on  the connecting
-rod  must  face  towards the 
front of the  engine  on the right-hand  bank  of 
cylinders  and  towards 
the rear on the  left-hand 
bank.  When  both connecting
-rods are fitted,  the 
bosses  will face  inwards towards  each other. 
5. Position  the oil control  piston  rings so that the ring 
gaps  are all at one  side,  between 
the gudgeon  pin 
and  piston  thrust  face. 
Spacc thc gaps in the  ring 
rails  approximately 
25 mm (1 in)  each  side of thc 
expander  ring joint. 
6. Position  the compression  rings so that their  gaps 
are  on  opposite  sides 
of the  piston  between  the 
gudgeon  pin and  piston thrust  face. 
8. Pull the connecting  rods on to the crankpins  using 
the guide 
rods. 
- - - .. . . 9. Place  the bearing  lower  shell in thc connecting-rod 
cap. 
10. Locate  the cap  and  shell onto the connecting-rod, 
noting  that  the  rib on the  edge 
of the  cap  must be 
towards  the front  of 
the engine on the right-hand 
bank  of cylinders  and towards  the  rear on the 
left
-hand  bank. 
11. Check  that the connecting-rods  move  freely 
sideways  on 
the crankshaft.  Tightness indicates 
insufficient  bearing clearance 
or a misaligned 
connecting
-rod. 
6 5 
.. . . ., $. ’.. . ST835M 
continued 
I13  
						

							1121 V8 CYLINDER ENGINE 
3. Temporarily  fit the  camshaft  chain wheel  with the 
marking  ‘FRONT’ or ‘F’ outwards. 
4.  Turn  the camshaft  until the mark 
on the camshaft 
chain  wheel 
is at the  six o’clock  position,  then 
remove  the chain  wheel  without  disturbing 
thc 
camshaft. 
5. Encircle  the chain  wheels  with the chain  keeping 
the  timing  marks aligned. 
-. ‘5 12. Check  the end-float  between  the connecting-rods 
on  each  crankshaft  journal. Clearance  limits: 
0,15 
to 0,37 mm (0.006 to 0.014 in). 
13. Tighten thc connecting-rod nuts  to the  correct 
torque.  Fit the 
oil straincr and joint washer. 
FIT CAMSHAFT  TIMING GEARS AND CHAIN RR 1800E 
1. Lubricate  the camshaft  journals and carefully 
insert  the camshaft  into the cylinder  block. 
2. Turn the crankshaft  to bring  number  one piston  to 
T.D.C. 
6. Engage  the chain  wheel  asscmbly  on the  camshaft 
and  crankshaft  key locations  and check  that the 
camshaft 
key is parallel  to the  shaft  axis to ensure 
adequate  lubrication 
of the distributor  drive gear. 
114  
						

							V8 CYLINDER ENGINE El 
m ,‘. 4 &$;.A 45k4 ._ _. CAUTION: The space  between the  key and keyway acts 
as an oilway for lubrication of the  drive  gear.  Ensure 
that the  key 
is seated to the full  depth of the keyway.  The 
overall  dimension 
of shaft  and  key  must  not  exceed 
30,15 mm (1.187 in). Dimension A below.  FIT 
THE  FLYWHEEL 
1. Locate  the flywheel in position  on  the crankshaft 
spigot,  with the ring  gear  towards the engine. 
2. Align  the flywheel  fixing bolt holes which arc 
off-set to prevent incorrect  assembly. 
3. Fit the flywheel  fixing  bolts  and  before finally 
tightening,  take  up  any  clearance by rotating 
the 
flywheel  against the direction of engine  rotation. 
Tighten  the bolts evenly 
to the correct  torque. 
- ST841 M -. -I. . 
7. Check  that  the timing  marks  line-up and fit the 
spacer  with the flange  to the  front. 
8. Fit the  distributor  drive gear ensuring  that the 
annular  grooved side is fitted  to the rear, that  is 
towards  the spacer. 
9. Secure the drive gear and camshaft  chain  wheel 
assembly 
with the bolt and  washer  and  tighten  to 
the  correct  torque. 
FIT CYLINDER HEADS 
1. Fit new cylinder  head gaskets with the word ‘TOP’ 
uppermost. Do NOT use sealant. 
continucd 
RR 1799E I I 
115  
						

							El V8 CYLINDER ENGINE 
2. Locate the cylinder  heads on the block dowel  pins. 
3. Clean  the threads of the cylinder  head bolts then 
coat them with Thrcad Lubricant-Sealant  Loctite 
572. 
4. Locate the cylinder  head bolts in position  as 
illustrated  and 
fit dipstick tube. 
Long  bolts 
- 1,3 and 5. 
Medium bolts-2,4,6, 7,8, 9 and 10 
Short  bolts 
- 11,12, 13 and 14. 
5. Tighten the cylinder  head bolts a little  at a time in 
the scqucnce shown to the following  figures: 
FIT  TAPPETS, PUSH RODS AND ROCKER 
ASSEMBLIES 
Fit tappets  and push  rods 
1. Fit the tappets  and push  rods to their  original 
locations.  Ensure that the tappets  move freely 
in 
their respective  bores. Before  fitting the tappets 
immerse  them 
in clean engine oil to reduce  tappet 
noise  when  the engine  is first  started  after the 
overhaul. 
Bolts 
1 to  10  65  to 70  Ibf ft (88 to 95  Nm). 
Bolts 
11 to  1440  to 45 Ibf ft (54  to61  Nm). Fit the rocker assemblies 
2. The  rocker  shafts are handed  and must  be fitted 
correctly 
to align  the oilways. 
3. Each  rocker  shaft is notched at one  end  and on one 
side  only. 
The notch  must be uppermost  and 
towards  the front 
of the engine on the right-hand 
side,  and towards  the rear 
on the left-hand  side. 
6. When  all bolts  have been  tightened,  re-check the 
torque  settings. 
p. 5 .- > 
Note: Left-hand cylinder head illustrated. 
Arrow points 
to front  of vehicle. 
continued 
116