Land Rover 4 0 4 6 V8 Engine Overhaul 4th Edition Rover Manual
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Page 61
ENGINE 32 OVERHAUL 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...
Page 62
ENGINE OVERHAUL33 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...
Page 63
ENGINE 34 OVERHAUL 13.Dismantle toolLRT-12-013and remove piston, connecting rod and gudgeon pin. NOTE: Keep each piston and gudgeon pin with their respective connecting rod. 14.Repeat above operations for remaining pistons.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:...
Page 64
ENGINE OVERHAUL35 Gudgeon pins - inspection NOTE: Gudgeon pins are only supplied as an assembly with replacement pistons. 1.Check gudgeon pins for signs of wear and overheating. 2.Check clearance of gudgeon pin in piston. Gudgeon pin to piston clearance = 0.006 to 0.015 mm (0.0002 to 0.0006 in). 3.Check overall dimensions of gudgeon pin. Overall length = 60.00 to 60.50 mm (2.35 to 2.4 in). Diameter - measured at each end and centre of pin = 23.995 to 24.00 mm (0.94 to 0.95 in).Cylinder liner bore -...
Page 65
ENGINE 36 OVERHAUL 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 bosses on connecting rod for RH bank of cylinders, and arrow pointing away from dome shaped bosses for LH bank of cylinders. 2.Clamp hexagon body ofLRT-12-013in vice. 3.Screw large nut back until flush with...
Page 66
ENGINE OVERHAUL37 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 = 0.015 to 0.045 mm (0.001 to 0.002 in) 4.Repeat...
Page 67
ENGINE 38 OVERHAUL 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 flywheel and remove 6 bolts...
Page 68
ENGINE OVERHAUL39 Flywheel and starter ring gear - inspection 1.Inspect flywheel face for cracks, scores and overheating. The flywheel can be refaced on the clutch face providing thickness does not go below minimum. Flywheel minimum thicknessA= 40.45 mm (1.6 in) 2.Inspect starter ring gear for worn, chipped and broken teeth. CAUTION: Do not attempt to remove reluctor ring. 3.Renew starter ring gear if necessary.Starter ring gear - renew 1.Drill a 6 mm (0.250 in) diameter hole at root of 2 teeth. CAUTION:...
Page 69
ENGINE 40 OVERHAUL 5.Heat new ring gear uniformly to between 170° and 175°C (340°and 350°F). CAUTION: Do not exceed this temperature. WARNING: Take care when handling hot ring gear. 6.Locate ring gear on flywheel with chamfered inner diameter towards flywheel flange. NOTE: If ring gear is chamfered on both sides, it can be fitted either way round. 7.Press ring gear on to flywheel until it butts against flywheel flange. 8.Allow flywheel to air cool.Flywheel - refit 1.Ensure bolt holes are clean and dry....
Page 70
ENGINE OVERHAUL41 DRIVE PLATE AND RING GEAR ASSEMBLY Drive plate and ring gear assembly - remove - Drive plates fitted with shimmed hub aligner 1.Suitably identify each component to its fitted position. NOTE: 4.0 litre drive plate illustrated. 2.Remove 4 bolts securing drive plate assembly. 3.Remove clamp ring and drive plate assembly. NOTE: Drive plate assembly is dowel located. 4.Remove 6 socket head Allen bolts securing hub aligner to crankshaft, remove hub aligner and selective shim; retain shim....