Land Rover 4 0 4 6 V8 Engine Overhaul 3rd Edition Rover Manual
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ENGINE DESCRIPTION AND OPERATION3 CYLINDER BLOCK COMPONENTS 1.Cylinder block 2.Connecting rod 3.Piston and gudgeon pin 4.Core plugs 5.Camshaft 6.Dipstick 7.Camshaft Woodruff key 8.Timing chain 9.Camshaft sprocket 10.Thrust plate 11.Timing cover and oil pump assembly * 12.Oil pressure switch 13.Timing cover oil seal 14.Oil pressure relief valve assembly 15.Crankshaft sprocket 16.Oil filter 17.Timing cover gasket 18.Woodruff keys19.Crankshaft 20.Centre main bearing shell - upper 21.Crankshaft rear oil seal 22.Main bearing socket head cap bolt 23.Main bearing hexagonal head bolt 24.Crankshaft knock sensor 25.Rear main bearing cap and side seals 26.Rear main bearing shell 27.Big end bearing cap 28.Big end bearing shell 29.Big end bearing bolt 30.Centre and front main bearing caps 31.Main bearing cap bolt 32.Oil pick-up pipe 33.Sump 34.Crankshaft pulley 35.Oil pick-up pipe spacer, washers and nut * New Range Rover timing cover illustrated
ENGINE DESCRIPTION AND OPERATION5 CYLINDER HEAD COMPONENTS 1.Cylinder head 2.Rocker cover 3.Rocker shaft spring 4.Rocker arm 5.Rocker shaft bracket 6.Pushrod 7.Tappet 8.Rocker shaft9.Inlet valve seal, spring, cap and collets 10.Exhaust valve seal, spring, cap and collets 11.Exhaust valve and seat 12.Inlet manifold gasket and seals 13.Inlet valve and seat 14.Cylinder head gasket 15.Valve guide
ENGINE 6 DESCRIPTION AND OPERATION OPERATION The V8 engine is an eight cylinder, water cooled unit comprising cast aluminium cylinder block and cylinder heads. The cast iron cylinder liners are shrink fitted and located on stops in the cylinder block. The banks of cylinders are at 90°to each other. The crankshaft is carried in five main bearings, end-float being controlled by the thrust faces of the upper centre main bearing shell.The centrally located camshaft is driven by the crankshaft via a chain. The valves are operated by rockers, pushrods and hydraulic tappets. Exhaust valves used on later engines are of the carbon break type which incorporate a machined undercut at the combustion chamber end of the valve. The design prevents carbon build-up on the valve stem which could lead to valves sticking. These valves are interchangeable with valves fitted to early engines. Each of the aluminium alloy pistons has two compression rings and an oil control ring. The pistons are secured to the connecting rods by semi-floating gudgeon pins. The gudgeon pin is offset 0.5 mm (0.02 in), 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.
ENGINE DESCRIPTION AND OPERATION7 1.Oil strainer 2.Oil pump 3.Pressure relief valve4.Oil pressure switch AOil to cooler BOil from cooler Lubrication 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. 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 timing 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 mounted in front of the radiator to the full flow oil filter. The oil then passes through internal drillings to the crankshaft where it is directed to each main bearing and to the big end bearings via numbers 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 either by oil grooves machined in each connecting rod big end joint face or by splash.
ENGINE 8 DESCRIPTION AND OPERATION Hydraulic tappets 1.Clip 2.Pushrod seat 3.Inner sleeve 4.Upper chamber 5.Non-return ball valve 6.Spring 7.Outer sleeve 8.Lower chamber The purpose of the hydraulic tappet is to provide maintenance free and quiet operation of valves. It achieves this by utilising engine oil pressure to eliminate the mechanical clearance between the rockers and the valve stems.During normal operation, engine oil pressure, present in the upper chamber, passes through the non-return ball valve and into the lower 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 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.
ENGINE OVERHAUL1 ROCKER SHAFTS Rocker shafts - remove 1.LH rocker shaft only:Remove screw securing dipstick tube to rocker cover. 2.Remove 4 bolts securing rocker cover to cylinder head. NOTE: Mark position of 2 longer bolts. 3.Remove rocker cover. 4.Remove and discard gasket from rocker cover.5.Mark each rocker shaft in relation to original cylinder head. CAUTION: Incorrect fitment of rocker shafts will lead to an oil feed restriction. 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.
ENGINE 2 OVERHAUL Rocker shafts - dismantling 1.Remove and discard split pin from one end of rocker shaft. 2.Remove plain washer, wave washer, rocker arms, brackets and springs.Inspecting components 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.
ENGINE OVERHAUL3 Rocker shafts - assembling 1.Assemble rocker shafts with identification groove at one oclock position with push rod end of rocker arm to the right. CAUTION: Incorrect assembly of rocker shafts will lead to an oil feed restriction. 2.Fit new split pin to one end of rocker shaft. 3.Fit plain washer and wave washer. 4.Lubricate rocker arm bushes with engine oil. 5.Fit rocker arms with offsets as illustrated. 6.Assemble rocker arms, brackets and springs to rocker shaft. 7.Compress springs, fit wave washer, plain washer and secure with new split pin.Rocker shafts - 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 of rocker shafts will lead to an oil feed restriction. 4.Fit bolts and starting at centre brackets, tighten to 38 Nm (28 lbf.ft).