Land Rover Range Rover Classic Workshop 1995 Rover Manual
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![Page 95
12ENGINE
20
REPAIR CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery negative lead.
2.Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3.Drain coolant.
4.Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove injection pipes.
7.Disconnect spill rail from fuel injectors.
8.Remove fuel injectors and sealing washers.
Identify each injector to...](http://img.usermanuals.tech/thumb/2848/48615/w64_range-rover-classic-workshop-manual-1995-rover-94.png "Page 95
12ENGINE
20
REPAIR CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1.Disconnect battery negative lead.
2.Remove bonnet [Hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
3.Drain coolant.
4.Remove air cleaner assembly.
See FUEL
SYSTEM, Repair, Air Cleaner
5.Detach crankcase ventilation valve and side
breather hose from rocker cover and move to
one side.
6.Remove injection pipes.
7.Disconnect spill rail from fuel injectors.
8.Remove fuel injectors and sealing washers.
Identify each injector to...")
12ENGINE 16 REPAIR 8.Ensure housing seal is correctly seated in its groove in new housing and seal assembly. 9.Fit new assembly, with former/guide in-situ, over crankshaft flange, this action will eject former/guide. 10.Secure assembly to cylinder block with five bolts tightened to correct torque, removing slave studs individually and inserting bolts. 11.Refit flywheel. See Flywheel 12.Refit clutch.See CLUTCH, Repair, Clutch Assembly 13.Refit gearbox.See MANUAL GEARBOX, Repair, R380 Manual Gearbox 14.Reconnect battery negative lead.CRANKSHAFT BEARING BUSH Service repair no - 12.21.45 1.Disconnect battery negative lead. 2.Remove gearbox. See MANUAL GEARBOX, Repair, R380 Manual Gearbox 3.Remove clutch.See CLUTCH, Repair, Clutch Assembly 4.Remove flywheel.See Flywheel 5.Remove bearing bush. NOTE: The bearing bush can be removed by using one of the following methods. Method 1. Obtain a short length of steel rod of a diameter having a good slide fit in the bore of the bush. Pack the bore with grease and insert the steel rod into the end of the bore, give a sharp blow with a hammer and the grease should drive out the bush. It is recommended that the bush and rod be covered by a suitable cloth or rag to prevent grease from splashing.
Tdi 17 REPAIR Method 2. Thread the bore of the existing bush and using a suitable bolt extract the bush. Thoroughly clean bush location ensuring all swarf is removed. Fitting 6.Fit new bush using a suitable shouldered drift, inserting bush flush with end of crankshaft. 7.Refit flywheel. See Flywheel 8.Refit clutch.See CLUTCH, Repair, Clutch Assembly 9.Refit gearbox.See MANUAL GEARBOX, Repair, R380 Manual Gearbox 10.Reconnect battery negative lead.FLYWHEEL HOUSING Service repair no - 12.53.01 Remove 1.Disconnect battery negative lead. 2.Remove gearbox. See MANUAL GEARBOX, Repair, R380 Manual Gearbox 3.Remove clutch.See CLUTCH, Repair, Clutch Assembly 4.Remove flywheel.See Flywheel 5.Remove starter motor. 6.Remove two bolts from top of flywheel housing. 7.Remove four bolts from bottom of flywheel housing. 8.Remove six inner bolts and lift off flywheel housing. Refit 9.Clean rear face of housing and mating face on block, ensuring all old sealant is removed.
12ENGINE 18 REPAIR 10.Apply sealant to flywheel housing mating face on cylinder block (Fig. J5944). 11.Fit housing to cylinder block and secure with bolts as removed. Tighten to 45 Nm. 12.Remove surplus sealant from block. 13.Refit starter motor. 14.Refit flywheel. See Flywheel 15.Refit clutch.See CLUTCH, Repair, Clutch Assembly 16.Refit gearbox.See MANUAL GEARBOX, Repair, R380 Manual Gearbox 17.Reconnect battery negative lead.OIL FILTER Service repair no - 12.60.01 Remove 1.Place drain tray under filter. 2.Unscrew filter anti-clockwise, using a strap or spanner. Refit 3.Smear clean engine oil on seal of new filter. 4.Screw on filter until sealing ring touches machined face, then tighten a further half turn by hand only. Do not over tighten.
Tdi 19 REPAIR OIL TEMPERATURE CONTROL VALVE Service repair no - 12.60.69 Remove 1.Disconnect oil cooler pipes. 2.Remove two bolts and carefully withdraw thermostat extension housing (1) complete with O ring seal (2), thermostat (3), two washers (4) and spring (5). 3.Clean adaptor housing. 4.Inspect all parts and renew as necessary. Refit 5.Fit thermostat to extension housing ensuring pin locates in hole. 6.Fit two washers and spring to thermostat. 7.Fit a new O ring to extension housing. 8.Insert spring into adaptor and secure extension housing to adaptor with bolts. Tighten to 9 Nm. OIL FILTER HEAD GASKET Service repair no - 12.60.03 Renew 1.Disconnect oil cooler pipes. 2.Disconnect pressure switch lead. 3.Remove securing bolts and withdraw head complete with gasket. 4.Clean mating faces. 5.Refit head with new gasket. 6.Secure with bolts Tighten to 45 Nm. 7.Refit pipes and reconnect pressure switch.
12ENGINE 20 REPAIR CYLINDER HEAD GASKET Service repair no - 12.29.02 Remove 1.Disconnect battery negative lead. 2.Remove bonnet [Hood]. See CHASSIS AND BODY, Repair, Bonnet [Hood] 3.Drain coolant. 4.Remove air cleaner assembly. See FUEL SYSTEM, Repair, Air Cleaner 5.Detach crankcase ventilation valve and side breather hose from rocker cover and move to one side. 6.Remove injection pipes. 7.Disconnect spill rail from fuel injectors. 8.Remove fuel injectors and sealing washers. Identify each injector to the location from which it is removed. See FUEL SYSTEM, Repair, Injectors 9.Remove inter-connecting harness from glow plugs. 10.Remove glow plugs. See FUEL SYSTEM, Repair, Glow Plugs 11.Remove top hose, radiator to thermostat. 12.Disconnect by-pass hose from thermostat. 13.Disconnect hose, thermostat to water pump. 14.Disconnect water temperature sensor lead. 15.Remove hose inter-cooler to induction manifold. 16.Remove induction manifold. See MANIFOLD AND EXHAUST SYSTEM, Repair, Exhaust Manifold - Tdi 17.Remove exhaust manifold and turbocharger assembly. See MANIFOLD AND EXHAUST SYSTEM, Repair, Exhaust Manifold - Tdi 18.Disconnect heater hose from water pump and move heater rail aside. 19.Disconnect heater hose from rear of cylinder head. 20.Remove bolt securing air cleaner mounting bracket to support strut. 21.Remove bolt securing harness bracket to cylinder head. 22.Remove rear lifting bracket, this will also release clips securing transmission and engine breather pipes and multiplug. Note loose spacer under clip securing engine breather pipe and multiplug.
Tdi 21 REPAIR 23.Remove rocker cover. 24.Remove nuts and bolts and withdraw rocker shaft assembly. 25.Remove push rods, store as an identified set to allow refitment to same location. 26.Remove valve stem caps. 27.Evenly slacken, then remove, bolts retaining cylinder head to block. Two of the bolts also secure the air cleaner mounting bracket. 28.Lift off cylinder head and remove gasket. Refit 29.Ensure face of cylinder block is thoroughly clean. 30.Select new gasket of correct thickness. CAUTION: Three thicknesses of gasket are available, different thicknesses are identified by the number of small holes punched in the right hand side of the gasket. One hole identifies the thinnest gasket and three holes the thickest. When renewing gaskets the gasket being fitted must be of the same thickness as the one removed. Therefore if the removed gasket had two holes punched in the side the replacement gasket must also have two holes punched in the side. 31.Place gasket on cylinder block with identification holes positioned towards rear on right hand side and side marked TOP uppermost. 32.Clean mating face of cylinder head. 33.Lower cylinder head onto block ensuring correct location with dowels.
12ENGINE 22 REPAIR NOTE: Cylinder head retaining bolts can be used up to a maximum of five times. 34.Lubricate threads of bolts with light oil and fit to positions illustrated. Bolt sizes: M10 x 117mm locations 3, 5, 12, and 13. M12 x 140mm locations 1, 2, 7, 8, 9, 10, 15, 16, 17, and 18. M12 x 100mm locations 4, 6, 11, 14. 35.Tighten bolts so that underside of heads just make contact with cylinder head. 36.Following the sequence illustrated tighten all bolts to 40 Nm. 37.Attach degree disc special tool LRT-12-007 to a power bar. 38.Make a suitable pointer from welding rod and attach to a bolt screwed into a rocker shaft securing bolt hole. 39.Tighten all bolts through 60°strictly in sequence illustrated. 40.Repeat 60°tightening procedure, again strictly in sequence illustrated. 41.Tighten the ten longer bolts (M12 x 140mm) a further 20°, again following the sequence illustrated. NOTE: Repositioning of the pointer will be necessary to reach all bolts, the pointer can be fitted to the rocker shaft securing studs using two nuts. CAUTION: The double tightening procedure must be carried out, on no account should the total angles of tightening be performed in one operation, otherwise damage to the cylinder head may occur. 42.Fit valve stem caps. 43.Fit push rods to locations from which they were removed. 44.Fit rocker shaft assembly evenly tightening securing nuts and bolts to correct torque. 45.Fit rocker cover ensuring oil seal is satisfactory for continued use. NOTE: Rocker cover seals can be re-used up to a maximum of five times. 46.Secure rocker cover with special seal washers and nuts tightened to correct torque. 47.Refit remainder of items by reversing operations 1 to 22 tightening securing bolts to correct torque where applicable.
Tdi 23 REPAIR VACUUM PUMP Service repair no - 70.50.19 Remove NOTE: To ease pump removal set engine to T.D.C. on No.1 cylinder. 1.Disconnect battery negative lead. 2.Detach servo hose from vacuum pump. 3.Remove six bolts securing vacuum pump. 4.Detach pump complete with harness bracket. Note location of bracket for refitting. Refit 5.Clean mating faces of pump and block. 6.Loosely assemble pump to block with a new gasket and with harness bracket located under head of bolt noted during removal. 7.Evenly tighten bolts, to depress pump plunger, finally tightening to 25 Nm. 8.Connect vacuum hose and secure with clip. 9.Reconnect battery negative lead.GENERATOR Service repair no - 86.10.02 Remove 1.Disconnect battery negative lead. 2.Remove drive belt. See Drive Belt Renew 3.Disconnect electrical leads from rear of generator. 4.Remove securing bolt from bottom of generator. 5.Remove long through bolt from top fixing and withdraw generator. Refit 6.Reverse removal procedure.
Tdi 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Engine block Bearing cap 133............................................................................................... Blanking plug, oil gallery, rear 37.................................................................... Oil squirt jet assembly 17................................................................................ Drain plug, cylinder block 25........................................................................... Oil squirt jet, vacuum pump cam 7................................................................. Connecting rod to cap 59................................................................................ Oil pick up assembly to bearing cap 9........................................................... Oil pick up assembly to front cover 25............................................................ Camshaft thrust plate 9.................................................................................. Oil drain pipe to block (internal) 25................................................................. Oil drain pipe to block (external) 25................................................................ Sump to cylinder block and front cover 25...................................................... Drain plug, oil sump 35................................................................................... Tappet guide 14.............................................................................................. Breather side cover assembly 25.................................................................... Baffle plate to breather side cover 4.............................................................. Vacuum pump 25............................................................................................ Fuel lift pump 25............................................................................................. Flywheel housing 45....................................................................................... Flywheel housing clutch cover stud 10........................................................... Plug, flywheel housing 12............................................................................... Rear oil seal assembly 25............................................................................... Oil filter adaptor 45.......................................................................................... Waxstat adaptor to oil filter adaptor 9............................................................ Oil pressure switch 17..................................................................................... Oil filter, spin on 13......................................................................................... Oil cooler unions to filter adaptor 45............................................................... Oil level tube 25.............................................................................................. Engine mounting foot to cylinder block 85...................................................... Engine mounting foot to flywheel housing 45................................................. Engine mounting foot rubber to mounting foot (bolt and nut) 85..................... Flywheel to crankshaft 146.............................................................................. Clutch cover plate to flywheel 34.................................................................... Flex drive plate to crankshaft (auto) 146.......................................................... Flex drive plate to ring gear (auto) 25............................................................. Flex drive plate to torque converter (auto) 45.................................................
12ENGINE 2 SPECIFICATIONS, TORQUECylinder head Cylinder head to cylinder block See repair section...................................................... Stub pipe heater feed 22................................................................................. Water temperature sensor 14......................................................................... Blanking plug cylinder head 14....................................................................... Engine lifting brackets 25................................................................................ Electrical harness clip bracket 25................................................................... Exhaust manifold stud 10................................................................................ Exhaust manifold nut 45................................................................................. Inlet manifold stud 8....................................................................................... Inlet manifold nut and bolt 25.......................................................................... Air temperature sensor, inlet manifold 14....................................................... Blanking plug, inlet manifold 14...................................................................... Heatshield to inlet manifold 6......................................................................... Glow plug 20................................................................................................... Glow plug terminal nut 2................................................................................ Injector clamp (stud) 8................................................................................... Injector clamp (nut) 25.................................................................................... Thermostat housing 25................................................................................... Water outlet elbow to thermostat housing 25.................................................. Water temperature switch, thermostat housing 11.......................................... Plug thermostat housing 6............................................................................. Rocker shaft pedestal bolt 5 + 50° ..................................................................... Rocker cover (stud) 8..................................................................................... Rocker cover (fixing nut) 10............................................................................ Breather cyclone to rocker cover 9................................................................ Tappet adjusting nut 16.................................................................................. Front cover to cylinder block 25...................................................................... Front cover plate to front cover 25.................................................................. Static idler - timing belt (stud) 10..................................................................... Static idler - timing belt (nut) 45...................................................................... Tensioner (timing belt) 45............................................................................... Camshaft hub bolt 80...................................................................................... Timing pulley to camshaft hub 25................................................................... Fuel injection pump (stud) 8........................................................................... Fuel injection pump (nut) 25........................................................................... Abutment bracket to injection pump 25........................................................... Support bracket injection pump to cylinder block 25....................................... Fuel injection pump access plte to front cover plate 25.................................. Timing pulley to injection pump hub 25........................................................... TV Damper pulley bolt to crankshaft 80 + 90° ..................................................... Fan pulley to hub 25....................................................................................... Fan and viscous coupling to hub 45............................................................... Auto tensioner, auxiliary drive (stud) 14.......................................................... Auto tensioner, auxiliary drive (nut) 45........................................................... Auxiliary mounting bracket to cylinder block (stud) 8..................................... Auxiliary mounting bracket to cylinder block (bolt and nut) 25........................ Water pump to block and mounting plate 25.................................................. Water pump pulley to hub 25..........................................................................