Land Rover Lesson 2 Auto Trans Coolingine Rover Manual
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compact and very stiff bottom end of the engine. The cylinder heads are cast aluminium with a moulded plastic camshaft cover. The single-piece oil sump is formed from stamped steel. The cast iron exhaust manifolds are unique for each cylinder bank and a moulded plastic acoustic cover is fitted over the upper engine to reduce engine-generated noise. TECHNICAL FEATURES The technical features include: •60 degree vee 6 cylinder engine with a CGI cylinder block •Plastic cylinder head cover •Two light, high strength, aluminium cylinder heads •4-valve technology with centrally arranged fuel injectors •Steel roller rockers with hydraulic lash adjusters •Twin plenum intake system integrated with the camshaft cover •Variable Geometry Turbocharger •Common rail direct fuel injection system •High pressure fuel pump •Gallery cooled pistons with a central crown bowl •Two electronically controlled Exhaust Gas Recirculation (EGR) valves •Two EGR coolers •Exhaust re-treatment by means of a diesel specific oxidation catalytic converter and primary catalytic converter •Cooling fan with electro-viscous clutch drive. ENGINE DATA The technical data is detailed below: TYPEDESCRIPTION 60 degree V6Configuration 147 kW at 4000 rpmMaximum power 440 Nm at 1900 rpmMaximum torque 2720ccDisplacement 81mm/88mmStroke/bore 17.3:1Compression ratio 1 4 2 5 3 6Firing order 6.55 litres (initial fill) 5.45 litres (service fill, includes oil filter) Oil capacity 235kg (Automatic) 260kg (Manual, inc. clutch plate and cover) Engine weight (with oil) (G421095) Technical Training82 Lesson 2 – PowertrainEngine
CYLINDER BLOCK COMPONENTS Oil filter cap1 Oil filter element2 Scavenge pipe3 Diaphragm4 Spring5 Scavenge pipe6 Crankcase ventilation oil separator assembly7 Turbocharger feed filter8 Bolt9 Crankcase ventilation drain reservoir assembly10 Bolt11 Crankcase ventilation oil return tube12 Bracket13 Bolt14 EngineLesson 2 – Powertrain 83Technical Training (G421095)
Crankcase ventilation oil return assembly15 Bolt16 Bolt17 Oil level gauge18 Bolt19 Crankcase ventilation return hose20 Cylinder head locating dowels21 Core plug22 Seal23 Transmission locating dowel24 Bolt, 2 of25 Water inlet connector assembly26 O ring27 Bolt28 Crankshaft position (CKP) sensor29 Cylinder block aperture cover30 Bolt31 Blanking plug32 O ring33 Crankshaft timing plug34 Bolt35 Bolt, 3 of36 Piston cooling jets37 O ring38 Water pump39 Bolt, 3 of40 Bolt, 3 of41 Water pump pulley42 Core plug43 Stud bolts, 3 of44 Coolant drain plug45 Cylinder head locating dowels46 Lower oil filter and cooler assembly47 Seal48 Upper oil filter and cooler assembly49 Bolt, 8 of50 Fuel cooler51 Cylinder Block The cylinders and crankcase are contained in the cylinder block, which is of single cast CGI construction with a hollow beam structure. With this type of construction less material is required than for a conventional cast iron block, therefore, reducing engine weight and length. (G421095) Technical Training84 Lesson 2 – PowertrainEngine
Piston Cooling Jets Bolt1 Piston cooling jet2 Jets located in the cylinder block provide piston and gudgeon pin lubrication and cooling. These jets spray oil on to the inside of the piston, the oil then flows through two internal wave shaped channels to help cool each piston crown. Lubrication oil is distributed through the cylinder block, via the main oil gallery and channels bored in the block, to all critical moving parts. These channels divert oil to the main and big-end bearings via holes machined into the crankshaft. A tapping at the rear RH side of the cylinder block, below the RH cylinder head, connects a pipe to the turbocharger by means of a banjo connection. Oil is supplied, under pressure, via this tapping, from the oil pump to provide lubrication for the turbocharger bearings. Cylinder cooling is achieved by coolant circulating through chambers in the cylinder block casting. Two hollow metal dowels are used to locate the cylinder heads to the cylinder block, one on each side at the rear of the unit. A port is included at the rear LH side of the ladder frame, below the turbocharger, to connect the turbocharger oil return pipe to the sump. A plug sealing the lubrication cross-drilling gallery is located at the front RH side of the cylinder block. Plugs for the main lubrication gallery are included at the front and rear of the cylinder block. Engine Data Locations Engine data locations1 Engine data is marked at two locations at the back of the cylinder block. Component diameters are represented by alphabetical and numerical codes; keys to the codes are in the Service Repair Procedures (SRP) Manual. EngineLesson 2 – Powertrain 85Technical Training (G421095)
Connecting Rods and PistonsThe connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The bearing caps are produced by fracturing the opposing sides of the connecting rod at the bearing horizontal centre-line. As well as being easier to manufacture, when reassembled the fractured surfaces interlock to form a strong seamless joint. The cylinder position is etched on adjoining sides of the joint to identify matching connecting rods and bearing caps. The selective connecting rod bearings are aluminium/tin split plain bearings. The connecting rod bearing is sputter coated, which is a manufacturing process that layers the bearing material to produce a higher load capacity for improved durability. NOTE: The connecting rods are not selective. (G421095) Technical Training86 Lesson 2 – PowertrainEngine
Connecting Rod Installation Piston and connecting rod assembly, cylinders 4-6 1 Piston and connecting rod assembly, cylinders 1-3 2 Bolts3 Connecting rod bearing cap4 Connecting rod lower bearing5 When installing a connecting rod, ensure the back of the connecting rod faces the centre of the vee. The pistons are made from aluminium alloy and are fitted with three rings. The piston crown incorporates a pronounced bowl; this forms the combustion chamber, which promotes swirl and turbulence necessary for good combustion and improved emissions. In addition, the piston skirt has a molybdenum-coated surface, which counteracts scoring of the cylinder bore and piston. The piston also incorporates a double wave gallery within the piston crown to enhance piston cooling. The pistons are supplied oil by means of spray jets located in the cylinder block oil gallery. These jets ensure optimum piston cooling to counteract the high temperatures generated by the combustion process. Each piston is installed on a wrist pin located in a aluminium/tin bushing in the connecting rod. EngineLesson 2 – Powertrain 87Technical Training (G421095)
Piston Installation When installing pistons ensure the arrows on the piston crowns all point to the front of the engine and the pistons are located in the correct cylinder banks, i.e. cylinders 1, 2, 3 or cylinders 4, 5, 6. NOTE: All pistons are common single grade/single part number for all engines. The piston top ring is a taper type and is fitted with the taper to the top of the piston. All rings marked top are assembled with top uppermost. All rings must be spaced evenly around the piston before installing. The circumference gap of the double bevelled oil control ring must be opposite the spiral control joint. Crankshaft Position Sensor The Crankshaft Position (CKP) sensor is located at the rear of the crankshaft, behind the flywheel in the LH side of the rear oil seal retainer. The sensor provides an input of engine crankshaft speed and position. The sensor works on the principle of the Hall effect and scans a trigger wheel (magnetic disc) on the crankshaft. An air gap of 0.4 to 1.5mm, between the trigger wheel and the CKP sensor, is achieved by the positional mounting of the sensor. Starter Motor The engine starter motor is installed at the rear RH side of the ladder frame, at the cylinder block to ladder frame split line. Coolant Drain Plug Two coolant drain plugs are installed in the cylinder block, one is fitted in the rear RH side, and the other is fitted in the middle of the cylinder block on the LH side. Cylinder Block Heater On vehicles destined for cold climates, a cylinder block heater replaces a core plug in the middle of the cylinder block on the LH side. (G421095) Technical Training88 Lesson 2 – PowertrainEngine
Coolant Pump Bolts1 Water pump2 O ring seal3 The coolant pump is installed on the LH side of the cylinder block front face and is secured and sealed via three bolts and an O ring. The coolant pump is driven by a poly-vee belt via the crankshaft. EngineLesson 2 – Powertrain 89Technical Training (G421095)
High-Pressure Fuel Pump Fuel pipe1 Diverter rail assembly2 Rear cover3 Belt4 Fuel pump pulley5 Front cover6 Nut7 Bolt8 Bolt9 Tensioner10 LH exhaust camshaft pulley11 High pressure fuel pump12 Bolt13 Stud bolts14 (G421095) Technical Training90 Lesson 2 – PowertrainEngine
The high-pressure fuel pump supplies the common rail with fuel and is fixed to the rear of the cylinder block in the centre of the vee. The pump is a 3 radial piston type controlled by the EMS and belt driven from the exhaust camshaft of the LH cylinder head. EngineLesson 2 – Powertrain 91Technical Training (G421095)