Land Rover 4 0 4 6 V8 Engine Overhaul 4th Edition Rover Manual
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ENGINE CONTENTS Page Pistons - remove 33.................................................. Pistons - inspection 34................................................ Gudgeon pins - inspection 35........................................... Cylinder liner bore - inspection 35........................................ Pistons - refit 36..................................................... Piston to cylinder bore clearance - checking 37............................. Pistons and connecting rods - refit 37..................................... FLYWHEEL AND STARTER RING GEAR 38............................... Flywheel - remove 38................................................. Flywheel and starter ring gear - inspection 39............................... Starter ring gear - renew 39............................................. Flywheel - refit 40.................................................... DRIVE PLATE AND RING GEAR ASSEMBLY 41........................... Drive plate and ring gear assembly - remove - Drive plates fitted with shimmed hub aligner 41....................................................... Drive plate and ring gear assembly - remove - Drive plates fitted with unshimmed hub aligner or modified’one-piece’starter ring gear 41.............. Drive plate and ring gear - inspection 42................................... Drive plate and ring gear assembly - refit - Drive plates fitted with shimmed hub aligner43 ........................................................... Drive plate and ring gear assembly - refit - Drive plates fitted with unshimmed hub aligner or modified’one-piece’starter ring gear 44....................... CRANKSHAFT, MAIN AND BIG-END BEARINGS 44........................ Big-end bearings - remove 44........................................... Big-end bearings - refit 45.............................................. Crankshaft - remove 46................................................ Knock sensor - remove 47............................................. Crankshaft position sensor - remove 48................................... Crankshaft - inspection 48.............................................. Crankshaft spigot bearing - renew 50..................................... Crankshaft - refit 50................................................... Crankshaft end - float - check 52......................................... Knock sensor - refit 53................................................ Crankshaft position sensor - refit 53......................................
ENGINE DESCRIPTION AND OPERATION1 This page is intentionally left blank
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.Oil pressure by-pass valve assembly 14.Oil pressure relief valve assembly - if fitted 15.Crankshaft sprocket 16.Oil filter 17.Timing cover oil seal 18.Woodruff keys 19.Crankshaft 20.Centre main bearing shell - upper21.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 cruciform seals 26.Rear main bearing shell 27.Big end bearing shell 28.Big end bearing cap 29.Big end bearing bolt 30.Oil pick-up pipe spacer, washers and nut 31.Sump drain plug washer 32.Sump drain plug 33.Centre and front main bearing caps 34.Main bearing cap bolt 35.Oil pick-up pipe 36.’O’ring 37.Sump 38.Crankshaft pulley 39.Washer 40.Crankshaft pulley bolt 41.Sump gasket - Later engines fitted with cast alloy sump * 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 shaft 9.Inlet valve seal, spring, cap and collets10.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 16.Secondary air injection adapters - if fitted 17.Spark plug
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 provided that the latest valve guides which are 5 mm (0.2 in) than those fitted to early engines are also fitted. 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.Oil pressure by-pass valve4.Oil pressure switch 5.Oil pressure relief valve - if fitted AOil to cooler - if fitted BOil from cooler - if fitted 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, oil pressure by-pass valve and oil pressure relief valve - if fitted. 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 - if fitted 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.Noting fitted positions of 2 longer screws or multi-hex bolts, remove and discard screws/bolts securing rocker cover to cylinder head. 3.Remove rocker cover. 4.Remove and discard gasket from rocker cover. CAUTION: Gaskets fitted to early engines were cork; these must be replaced with later type gaskets which incorporate compression limiters in the bolt holes.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.