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Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
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ENGINE - V8 12-2-68 REPAIRS 8.Fit RH lower bolt to timing gear cover and position cover to cylinder head. NOTE: It is not possible to fit the RH lower bolt after fitting the LH upper timing gear cover. 9.Fit remaining 5 bolts and hand tighten 6 bolts securing timing cover. 10.Fit LRT-12-225/2 to LH camshaft cover. 11.Fit camshaft cover and tool, fit 4 bolts and tighten to 10 Nm (7 lbf.ft). 12.Tighten bolts securing timing gear cover to 15 Nm (11 lbf.ft). 13.Remove 4 bolts securing camshaft cover, remove camshaft cover and LRT-12-225/2. 14.Fit 2 new O rings to SAI pipe and position SAI pipe to engine. Fit and tighten 3 bolts securing SAI pipe to engine. 15.Fit bolt securing radiator lower coolant hose P clip to bracket and tighten. 16.Connect coolant hose to alternator and secure with clip. 17.Fit LH VCC solenoid valve. + Engine - V8, REPAIRS, Control solenoid - variable camshaft control (VCC) - LH.18.Fit LH camshaft cover. + Engine - V8, REPAIRS, Gasket - camshaft cover - LH. 19.Connect multiplug to alternator and secure alternator harness to 3 clips. 20.Secure fuel vapour pipe to bracket on timing gear cover. 21.Connect multiplug to CMP sensor. 22.Secure CMP sensor harness to clip and secure clip to timing gear cover. 23.Fit fan cowl. + COOLING SYSTEM - V8, REPAIRS, Coupling unit - viscous fan. 24.Fill cooling system. + COOLING SYSTEM - V8, ADJUSTMENTS, Coolant - drain, flush & refill. 25.Connect battery earth lead.
ENGINE - V8 REPAIRS 12-2-69 Cover - timing gear - lower $% 12.65.43 Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. + GENERAL INFORMATION, Electrical Precautions. Remove 1.Position vehicle on lift. 2.Disconnect battery earth lead. 3.Remove coolant pump. + COOLING SYSTEM - V8, REPAIRS, Gasket - coolant pump. 4.Remove LH upper timing gear cover. + Engine - V8, REPAIRS, Cover - timing gear - upper - LH. 5.Remove RH upper timing gear cover. + Engine - V8, REPAIRS, Cover - timing gear - upper - RH. 6.Remove crankshaft front oil seal. + Engine - V8, REPAIRS, Oil seal - crankshaft - front. 7.Remove 2 bolts securing ancillary drive belt tensioner to lower timing gear cover. 8.Remove dust cap from ancillary drive belt tensioner idler pulley and remove Torx bolt securing ancillary drive belt tensioner idler pulley. 9.Remove ancillary drive belt tensioner assembly.10.Remove nut and disconnect battery cable from alternator. 11.Release battery cable from lower timing gear cover. 12.Remove 6 alternator securing bolts and alternator harness securing clip. 13.Release and remove alternator from engine timing cover. 14.Discard alternator O ring.
ENGINE - V8 12-2-70 REPAIRS 15.Remove 2 Allen bolts and 1 nut securing PAS pump and move aside. 16.Remove 6 bolts securing lower timing gear cover to upper sump.17.Remove 15 bolts securing lower timing gear cover to cylinder block. lA = M8 X 75 mm lB = M6 X 40 mm lC = M6 X 85 mm lD = M6 X 80 mm lE = M8 X 90 mm lF = M6 X 60 mm NOTE: Note position of all securing bolts. 18.Remove lower timing gear cover. 19.Discard 3 lower timing gear cover gaskets. Refit 1.Clean timing gear cover and mating faces, clean dowels and dowel holes.
ENGINE - V8 REPAIRS 12-2-71 2.Apply sealant, Part No. STC 50550 to areas illustrated. 3.Fit 3 new lower timing gear cover gaskets. 4.Fit lower timing gear cover. 5.Fit 15 bolts securing lower timing gear cover to cylinder block and initially tighten to 5 Nm (4 lbf.ft). 6.Tighten 6 mm bolts securing lower timing gear cover to 10 Nm (7 lbf.ft) and 8 mm bolts securing lower timing gear cover to 22 Nm (16 lbf.ft). CAUTION: Check torque of all bolts once they have been tightened down. 7.Fit 6 bolts securing lower timing gear cover to upper oil sump and tighten to 12 Nm (9 lbf.ft). 8.Position PAS pump to mounting and fit Allen bolts and securing nut. Tighten Allen bolts to 10 Nm (7 lbf.ft) and securing nut to 25 Nm (18 lbf.ft). 9.Clean alternator and engine timing gear cover mating face. 10.Lubricate and fit new O ring to alternator. 11.Fit alternator and tighten securing bolts. 12.Secure battery cable to lower timing gear cover. 13.Connect battery lead to alternator and tighten nut securing battery lead to alternator to 13 Nm (10 lbf.ft). 14.Fit ancillary dive belt tensioner assembly, fit Torx bolt securing ancillary drive belt tensioner idler pulley and tighten Torx bolt. 15.Fit dust cap to ancillary drive belt tensioner idler pulley.16.Fit 2 bolts securing ancillary drive belt tensioner to timing gear cover but do not tighten at this stage. 17.Fit crankshaft front oil seal. + Engine - V8, REPAIRS, Oil seal - crankshaft - front. 18.Fit RH upper timing gear cover. + Engine - V8, REPAIRS, Cover - timing gear - upper - RH. 19.Fit LH upper timing gear cover. + Engine - V8, REPAIRS, Cover - timing gear - upper - LH. 20.Fit coolant pump. + COOLING SYSTEM - V8, REPAIRS, Gasket - coolant pump. 21.Connect battery earth lead.
ENGINE - V8 OVERHAUL 12-2-73 OVERHAUL Piston assemblies - engine set $% 12.17.03.01 Remove 1.Remove cylinder head gaskets. + Engine - V8, OVERHAUL, Gasket - cylinder head. 2.Remove connecting rod bearings. + Engine - V8, OVERHAUL, Bearings - connecting rods - engine set. 3.With a socket and bar fitted to crankshaft pulley bolt, rotate crankshaft for access to the lubrication jets. 4.Remove Allen screws securing lubrication jets and remove the jets. Disassembly 1.Mark connecting rod relative to its fitted position to aid reassembly.2.Mark piston relative to its fitted position to aid reassembly. 3.Fit guides LRT-12-176 to connecting rod to protect cylinder bore and crankshaft journals. 4.Remove ridge of carbon from top of cylinder bore. 5.Carefully push piston assembly from cylinder bore. 6.Remove guides LRT-12-176 from connecting rod. M12 7960LRT-12-176
ENGINE - V8 12-2-74 OVERHAUL 7.Hold connecting rods in a soft jawed vice. 8.Carefully remove and discard 2 retaining rings securing the gudgeon pin in the piston. 9.Push the gudgeon pin out of the piston and connecting rod, remove the piston. 10.Repeat for the 7 remaining pistons. Inspect 1.Clean cylinder bores, pistons, piston rings connecting rods and gudgeon pins. 2. Pistons and cylinder bores: check and record cylinder bore diameters at bottom, centre and top of bore ensuring that measurements are taken at the angle shown. 3.Repeat procedure at angle shown and from the 2 sets of measurements obtained, calculate cylinder bore ovality and taper. + GENERAL DATA, Engine - V8.4.Starting with No 1 piston, measure and record piston diameter at right angles to gudgeon pin holes, and 12 mm from bottom of piston skirt: 5.Compare piston diameter with cylinder bore size and determine piston to bore clearance. + GENERAL DATA, Engine - V8. 6.Using an expander, remove piston rings from piston. 7.Check new ring fitted gap 30 mm from top of bore. Ensure rings are fitted square to bore when checking gap. + GENERAL DATA, Engine - V8.
ENGINE - V8 OVERHAUL 12-2-75 8.Fit oil control ring rails and expander, ensuring ends butt and do not overlap. 9.Fit 2nd compression ring with TOP marking upwards. 10.Fit 1st compression ring with TOP marking upwards. 11.Check piston ring to groove clearance. + GENERAL DATA, Engine - V8. 12.Check fit of gudgeon pin in piston, pin must be a tight, sliding fit with no perceptible side play. 13.Check small-end bushes for wear, check that gudgeon pin is a sliding fit in the bush with no perceptible side play. Small end bushes cannot be replaced, a new connecting rod must be fitted.14.Check parallelism of connecting rods on both sides taking the measurement approximately 150 mm from the centre line of the connecting rod + GENERAL DATA, Engine - V8. 15.Check for distortion on both sides of connecting rod. Reassembly 1.Clean cylinder bores, pistons, piston rings and connecting rods. 2.Fit each piston to its connecting rod ensuring that the arrow on the piston which points to the front of the engine is relative to the mark made on the connecting rod during disassembly. 3.Lubricate gudgeon pins and bushes with engine oil, fit gudgeon pins and secure with new retaining rings ensuring that they are fully seated in their grooves. 4.Lubricate pistons, piston rings and cylinder bores with clean engine oil. 5.Check that piston rings are free to rotate, position ring gaps at 120° to each other and away from the thrust side - LH side of piston - viewed from front of piston.
ENGINE - V8 12-2-76 OVERHAUL 6.Using a piston ring clamp, compress piston rings. 7.Fit guides LRT-12-176 to connecting rod to protect cylinder bore and crankshaft journals. 8.Fit connecting rod and piston into cylinder bore. Ensure arrow on piston is facing towards the front of the cylinder block and dimples on connecting rods that share a journal face each other as shown. 9.Remove guides LRT-12-176 from connecting rod. Refit 1.Clean lubricating jet and mating face. 2.Fit lubrication jets and tighten Allen screws to 10 Nm (7 lbf.ft). 3.Fit connecting rod bearings. + Engine - V8, OVERHAUL, Bearings - connecting rods - engine set. 4.Fit cylinder head gaskets. + Engine - V8, OVERHAUL, Gasket - cylinder head. Bearings - connecting rods - engine set $% 12.17.16.01 Remove 1.Remove oil pump. + Engine - V8, OVERHAUL, Pump - engine oil. Disassembly 1.With a socket and bar fitted to crankshaft pulley bolt, rotate crankshaft in direction of rotation to gain access to connecting rod bearing cap bolts. 2.Mark connecting rod and bearing cap in relation to cylinder number. NOTE: Connecting rods and caps have reference marks which align for assembly. 3.Loosen and remove big-end bearing cap bolts, do not discard bolts at this stage. 4.Remove big-end bearing cap, remove and discard bearing shell. 5.Move connecting rod clear of crankshaft journal. M12 7995 LRT-12-176 M12 7858
ENGINE - V8 OVERHAUL 12-2-77 6.Remove bearing shell from connecting rod, discard the bearing shell. NOTE: Blue colour coded big-end bearing shells are fitted to the connecting rods and Red colour coded big end bearing shells are fitted to the bearing caps. 7.Repeat above procedure for remaining connecting rod bearings. Keep big-end bearing caps in fitted order. Inspect 1.Wipe big-end journals, new bearing shells, connecting rods and bearing caps. 2.Measure and record each crankshaft big-end journal diameter, taking 4 measurements at 90° intervals on each journal. + GENERAL DATA, Engine - V8. 3.Clean and lubricate the original big end bearing cap bolts. 4.Position crankshaft with journal at BDC. 5.Fit a new BLUE colour coded big-end bearing shell to the connecting rod. 6.Fit a new RED colour coded big-end bearing shell to the bearing cap. 7.Pull connecting rod onto big-end journal. 8.Place a strip of Plastigauge across the big-end journal. 9.Fit big-end bearing cap, ensure reference marks on connecting rod and the cap are aligned. CAUTION: Do not rotate the crankshaft when plastigauge is being used. 10.Fit the original big end bearing cap bolts and tighten to 5 Nm (3.7 lbf.ft), then tighten to 20 Nm (15 lbf.ft) and finally, using an angle gauge, tighten a further 80°. CAUTION: Do not rotate the crankshaft when plastigauge is being used.11.Remove bolts securing cap to connecting rod and remove the bearing cap. 12.Using the scale provided, measure the width of plastigauge on journal and compare with bearing clearance. 13.If correct bearing clearance cannot be obtained with the available bearing shells, the crankshaft must be replaced. + GENERAL DATA, Engine - V8. 14.Retain selected bearing shells with connecting rod and bearing cap. 15.Remove all traces of Plastigauge using clean engine oil and a cloth. 16.Repeat the above procedure for the remaining big-end bearings. 17.After completion of big-end bearing clearance checks, discard original bearing cap bolts. Reassembly 1.Lubricate crankshaft journals and selected bearing shells with clean engine oil. 2.Pull connecting rod onto its journal making sure the bearing shell is located correctly. 3.Fit big-end bearing cap, ensure reference marks on connecting rod and the cap are aligned. 4.Clean and lubricate new big-end bearing cap bolts. 5.Fit the new big end bearing cap bolts and tighten to 5 Nm (3.7 lbf.ft), then tighten to 20 Nm (15 lbf.ft) and finally, using and angle gauge, tighten a further 80°. Refit 1.Fit oil pump. + Engine - V8, OVERHAUL, Pump - engine oil. M12 7860 M12 7861 mm.025.038.051.076