Land Rover 4 0 4 6 V8 Engine Overhaul 3rd Edition Rover Manual

ENGINE
24
OVERHAUL 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.CAMSHAFT AND TAPPETS
Camshaft end-float - check
1.Remove rocker shaft assemblies.
2.Remove pushrods and store in their fitted...

ENGINE
OVERHAUL25
Camshaft and tappets - remove
1.Remove tappets and retain with their
respective pushrods.
2.When tappets prove difficult to remove due to
damaged camshaft contact area, proceed as
follows. 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 The tappets can then be withdrawn out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 and
camshaft are removed.
3.Remove 2...

ENGINE
26
OVERHAUL Camshaft and tappets - inspection
1.Thoroughly 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 (0.002
in)
4.Inspect thrust plate for wear, replace plate if
wear is evident.
5.Clean and inspect tappets. Check for an even,
circular wear pattern on the camshaft...

ENGINE
OVERHAUL27
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.Repeat above procedure for remaining pistons.
CAUTION: Big-end bearing shells must be
replaced whenever they are removed.Piston...

ENGINE
28
OVERHAUL Piston rings - inspection
1.Temporarily fit new compression rings to
piston.
NOTE: If replacement pistons are to be
fitted, ensure rings are correct for piston.
The 2nd compression ring marked TOP must be
fitted, with marking uppermost, into second
groove. The 1st compression ring fits into top
groove and can be fitted either way round.
2.Check compression ring to groove clearance:
1st compression ringA= 0.05 to 0.10 mm
(0.002 to 0.004 in).
2nd compression ringB= 0.05 to 0.10 mm
(0.002...

ENGINE
OVERHAUL29
Pistons - inspection
1.Clean carbon from pistons.
2.Inspect pistons for distortion, cracks and
burning.
3.Measure and record piston diameter at 90°to
gudgeon pin axis and 10 mm (0.4 in) from
bottom of skirt.
4.Check gudgeon pin bore in piston for signs of
wear and overheating.
NOTE: Pistons fitted on production are
graded A or B, the grade letter is
stamped on the piston crown.
Production piston diameter:
GradeA= 93.970 to 93.985 mm (3.700 to 3.7002 in)
GradeB= 93.986 to 94.00 mm...

ENGINE
30
OVERHAUL Cylinder liner bore - inspection
1.Measure cylinder liner bore wear and ovality in
two axis 40 to 50 mm (1.5 to 1.9 in) from top of
bore.
Cylinder liner bore:
Grade A piston fitted = 94.00 to 94.015 mm
(3.700 to 3.701 in)
Grade B piston fitted = 94.016 to 94.030 mm
(3.7014 to 3.702 in)
Maximum ovality = 0.013 mm (0.0005 in)
Cylinder liners having grade A pistons fitted
may be honed to accept grade B pistons
provided specified wear and ovality limits are
maintained.
CAUTION: The...

ENGINE
OVERHAUL31
Pistons - refit
CAUTION: Pistons have a 0.5 mm (0.02 in)
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.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.
2.Clamp hexagon body ofLRT-12-013in vice.
3.Slacken large nut and pull the centre...

ENGINE
32
OVERHAUL Piston to cylinder bore clearance - checking
1.Starting with number 1 piston, invert piston and
with arrow on piston crown pointing towards
REAR of cylinder block, insert piston in cylinder
liner.
2.Position piston with bottom of skirt 30 mm (1.2
in) from top of cylinder block.
3.Using feeler gauges, measure and record
clearance between piston and left hand side of
cylinder - viewed from front of cylinder block:
Piston to bore clearance = 0.02 to 0.045 mm
(0.001 to 0.002 in)
4.Repeat...

ENGINE
OVERHAUL33
9.Fit ring clamp to piston and compress piston
rings.
NOTE: Connecting rods shown in final
fitted positions.
10.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.
11.Fit big-end bearing caps and bearing shells.
12.Fit cylinder head(s).FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
1.Restrain crankshaft and remove 6 bolts...