Land Rover Lesson 2 Auto Trans Coolingine Rover Manual
Have a look at the manual Land Rover Lesson 2 Auto Trans Coolingine Rover Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 364 Land Rover manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
Cover13 Lifting eye14 Washer15 Bolt16 Bracket17 Bolt18 Seal19 Cap20 Inlet manifold cover assembly21 Washer22 Bolt23 Lifting eye24 Seal25 Camshaft bearing caps26 Bolts27 Gasket28 Camshaft bearing cap and seal housing29 Camshaft bearing cap and seal housing30 Inlet camshaft31 Exhaust camshaft32 LH cylinder head33 Cylinder head bolts34 Exhaust manifold studs35 LH cylinder head gasket36 Core plug37 Plug38 Seal39 Oil filler tube40 Oil filler cap41 Cover42 Injectors43 Bolts44 Bolt45 Vacuum pump46 Water outlet assembly47 Bolts48 (G421095) Technical Training102 Lesson 2 – PowertrainEngine
Cylinder Heads The aluminium gravity die cast cylinder heads are unique to each cylinder bank. Eight deep-seated bolts, to reduce distortion, secure each cylinder head to the cylinder block. The cylinder head bolts are located beneath the camshafts, four under the inlet camshaft and four under the exhaust camshaft. Two hollow dowels align each cylinder head with the cylinder block. NOTE: The cylinder head bolts are not accessible with the camshafts fitted. NOTE: The cylinder head cannot be reworked. EngineLesson 2 – Powertrain 103Technical Training (G421095)
The cylinder head has four ports machined at each cylinder location, two exhaust ports and two inlet ports. One of the inlet ports is helical and functions as a swirl port, the other is arranged laterally as a tangential port and functions as a charge port. The six fuel injection nozzles are centrally mounted; one above each cylinder and each is fixed to the cylinder head by means of a clamp and two M6 x 35 bolts. Harness connector1Glow plugs2 The glow plugs are arranged centrally on the inlet side of the cylinder head, between the two inlet ports of each cylinder. (G421095) Technical Training104 Lesson 2 – PowertrainEngine
Camshaft Position (CMP) sensor1 The CMP sensor locates through a hole in a flange on the front LH side of the LH cylinder head. The exhaust camshaft gear of the LH cylinder head incorporates a trigger wheel, which is used in conjunction with the sensor to measure engine position. The engine lifting eyes are bolted to the cylinder head, one at the front and two at the rear, one per cylinder head. Camshaft Covers Stud bolt M6 x 40, 6 of1Bolt M6 x 40, 7 of2 EngineLesson 2 – Powertrain 105Technical Training (G421095)
Oil filler aperture3RH camshaft cover assembly4 The camshaft covers are manufactured from vinyl ester composite. The RH bank camshaft cover incorporates an outlet for the full load engine breather and the engine oil filler cap. The LH bank camshaft cover incorporates an outlet for the part load engine breather. Silicon rubber in-groove gaskets seal the joints between the camshaft covers and the cylinder heads. Together with spacers and seals on the camshaft cover fasteners, they also isolate the covers from direct contact with the cylinder heads, to reduce noise. Cylinder Head Gasket The cylinder head gasket is a three-layer, laminated steel type and is available in five different thickness. The choice of gasket thickness is dependent on the maximum piston protrusion. Gasket thickness is identified by serrations cut into the front end of the gasket. Gasket Selection Table IdentificationGasket Thickness (mm)Piston Protrusion (mm) 11.120.541 - 0.590 21.170.591 - 0.640 31.220.641 - 0.690 41.270.691 - 0.740 51.320.741 - 0.790 To calculate the correct cylinder head gasket thickness, each piston must be measured at two points, with an average of the two measurements taken to determine the piston protrusion. The highest of the three measurements will determine the gasket required for that particular cylinder head. NOTE: The difference between the maximum and minimum protrusion measurement in any one bank should not be greater than 0.1mm. It is permissible to have a different grade of gaskets between the LH and RH banks. Camshafts The camshafts are of a hollow steel tube construction, with pressed on sintered lobes. Each camshaft is retained by aluminium alloy caps, five for the exhaust camshafts and four for the inlet camshafts. Location letters, A to I for the intake camshaft and R to Z for the exhaust camshaft, are marked on the outer faces of the caps for each cylinder head. The LH cylinder bank exhaust camshaft is machined to accept a rear camshaft gear. The rear camshaft gear provides drive for High Pressure (HP) fuel pump, located centrally at the rear of the vee, via a short-toothed belt and tensioner pulley. The RH cylinder head exhaust camshaft is machined at the rear end to provide a drive connection for the vacuum pump. NOTE: The camshaft drive sprockets also form the thrust faces for the camshaft endfloat. In production the endfloat is 0.065mm to 0.185mm. In service, if the endfloat is out of specification, the camshaft(s) or cylinder head(s) may have to be replaced. (G421095) Technical Training106 Lesson 2 – PowertrainEngine
Camshaft Timing PositionValve 8.5° BTDCInlet valve opens 35.5° ABDCInlet valve closes 64° BBDCExhaust valve opens 12° ATDCExhaust valve closes Inlet and Exhaust Valves Valve spring collets1 Valve spring retainer2 Valve spring3 Valve stem seal4 Inlet valve5 Exhaust valve6 Each cylinder head incorporates two overhead camshafts operating four valves per cylinder via steel roller rockers with hydraulic lash adjusters. Roller rocker1 Hydraulic lash adjuster2 The lightweight valve gear provides good economy and noise levels. Valve head diameters are 31mm (1.220 in) for the exhaust and 35mm (1.378 in) for the intake. All valves have 5mm (0.197 in) diameter stems supported in sintered metal seats and guide inserts. Collets, valve EngineLesson 2 – Powertrain 107Technical Training (G421095)
collars and spring seats locate single valve springs on both intake and exhaust valves. Valve stem seals are integrated into the spring seats. Vacuum Pump Location dowels1 Bracket2 Vacuum pump3 Bolt4 Bolts5 Nut6 Bracket (transmission breather hose)7 Stud8 The vacuum pump is located at the rear of the RH side cylinder head and is driven from the exhaust camshaft. (G421095) Technical Training108 Lesson 2 – PowertrainEngine
Fuel InjectorsBolt, 2 per injector1 Clamp2 Injectors3 The fuel injectors inject the quantity of fuel required for all the engine operating conditions into the combustion chambers. The quantity of fuel injected during each working cycle is composed of a noise-reducing pilot injection phase and a main injection phase. The six, side fed, piezo electrically controlled fuel injectors are installed in the fuel rails. The start of fuel injection and the quantity of fuel injected is controlled directly by the ECM. Two O-rings seal each injector to the manifold interface. EngineLesson 2 – Powertrain 109Technical Training (G421095)
Water Outlet Assembly Bolt, 4 of1 Water outlet assembly2 Seals3 Water outlet housing assembly, EGR outletA Water outlet housing assembly, radiator outletB Water outlet housing assembly, bleed valveC The water outlet assembly connects the cooling channels of the cylinder block to the cooling channels of the LH and RH cylinder heads and provides the coolant outlet for the EGR and coolant return. LUBRICATION SYSTEM General Oil is drawn from the reservoir in the oil pan and pressurised by the oil pump. The output from the oil pump is then filtered and distributed through internal oil passageways. All moving parts are lubricated by pressure or splash oil. Pressurised oil is also provided for operation of the hydraulic adjusters and the timing gear chain tensioners. The engine is lubricated by a force-feed oil circulation system with a full flow oil filter. The oil cooler forms a unit with the oil filter and fuel cooler, which is mounted centrally in the middle of the cylinder block between the two banks of cylinders. The engine oil is cooled using the engine cooling system. The eliminates the need for an additional engine oil cooler remotely mounted. The fuel cooler, which forms part of the oil filter body, is also cooled by engine coolant. In addition there is a further fuel cooler in the return line to the fuel tank. (G421095) Technical Training110 Lesson 2 – PowertrainEngine
The oil returns to the oil pan under gravity. Large drain holes through the cylinder heads and cylinder block ensure the quick return of the oil, reducing the volume of oil required and enabling an accurate check of the contents soon after the engine stops. System replenishment is through the oil filler cap on the RH camshaft cover. With the exception of the pump and level gauge, all oil system components are installed on the sump. Oil Pick-up The moulded composite oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump during all normal vehicle attitudes. The castellated inlet allows the supply to be maintained even if the sump pan is deformed (e.g. by grounding). A mesh screen in the inlet prevents debris from entering the oil system. Oil Pump Oil pump1 Bolt2 The oil pump is a gear type pump and is bolted and dowelled to the front of the engine block. It is sealed by means of a rubber gasket, which is recessed into the oil pump housing. The pump inlet and outlet ports align with oil passages in the ladder frame. The pumping element is an eccentric rotor, which is directly driven by flats on the crankshaft. An integral pressure relief valve regulates pump outlet pressure at 4.5 Bar (65.25 Psi). The front crankshaft oil seal is housed in the oil pump casing and is fitted such that its front face is 1mm underflush with the machined front face of the oil pump. NOTE: The seal is not to be pushed all the way into the bore as this will block the seal drains. EngineLesson 2 – Powertrain 111Technical Training (G421095)