Land Rover Range Rover Classic Workshop 1995 Rover Manual
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Tdi 3 SPECIFICATIONS, TORQUE Turbo charger oil drain adaptor to block 42.................................................... Oil drain pipe to turbocharger 25.................................................................... Turbocharger oil drain pipe to adaptor 38....................................................... Turbocharger oil feed pipe adaptor to block 25............................................... Turbocharger oil feed pipe to adaptor 25........................................................ Oil feed pipe to turbocharger 19..................................................................... Turbocharger to cylinder head (stud) 10......................................................... Turbocharger to cylinder head (nut) 45........................................................... Turbocharger to blanking plate 25.................................................................. Turbocharger to EGR valve 25....................................................................... EGR delivery tube to valve 25........................................................................ EGR delivery tube to mixing tube 25.............................................................. Fuel lift pump to filter (union) 15..................................................................... Fuel filter from lift pump (banjo bolt) 33........................................................... Fuel filter to fuel injection pump (banjo bolt) 33.............................................. Fuel injection pump from fuel filter (banjo bolt) 25.......................................... Injector pipes to injectors and fuel injection pump 29..................................... Spill rail to injectors (banjo bolt) 10................................................................. Spill rail to injection pump (banjo bolt) 25....................................................... Boost pipe injection pump (banjo bolt) 10....................................................... Plug, rear of injection pump 29....................................................................... PAS pump to mounting plate 25..................................................................... PAS pump mounting plate to auxiliaries mounting bracket 25........................ PAS pump pulley to hub 25............................................................................ Generator to auxiliaries mounting bracket 25................................................. Starter motor (bolt and nut) 45........................................................................ Tachometer electrical connection 4............................................................... Air conditioning compressor Compressor mounting bracket to front cover 45............................................. Compressor to mounting bracket (stud) 8...................................................... Compressor to mounting bracket (nut) 25...................................................... Belt tensioner pulley to tensioner arm 45........................................................ Belt tensioner assembly to front cover plate 25.............................................. Idler pulley to front cover plate 45................................................................... Compressor belt guard (nut) 25...................................................................... Sensors to water outlet elbow (air/con) 25...................................................... Blanking plug, water outlet elbow (air/con) 25................................................ Generator mounting bracket to front cover 45................................................ Generator to mounting bracket 85.................................................................. Generator pulley to hub 95............................................................................. Generator belt guard 25..................................................................................
12ENGINE 4 SPECIFICATIONS, TORQUEMETRIC Nm M5 6...................................................................................................... M6 9...................................................................................................... M8 25..................................................................................................... M10 45................................................................................................... M12 90................................................................................................... M14 105.................................................................................................. M16 180.................................................................................................. UNC / UNF 1/4 9...................................................................................................... 5/16 24................................................................................................... 3/8 39..................................................................................................... 7/16 78................................................................................................... 1/2 90..................................................................................................... 5/8 136.................................................................................................... NOTE: Torque values above are for all screws and bolts used except for those specified.
V8i 1 DESCRIPTION AND OPERATION DESCRIPTION The V8i engine has cast aluminium cylinder heads and cylinder block. The two banks of steel cylinder liners which are pressed down to stops in the block, are set at 90Ê to one another. The three ringed aluminium pistons transmit the power through the connecting rods to a cast iron five bearing crankshaft, which drives the centrally located camshaft via a duplex type chain. The electronic ignition distributor is driven by a gear off the front of the camshaft and the lubrication oil pump is driven by a gear off the front of the crankshaft. The overhead inlet and exhaust valves are operated by rocker shafts, pushrods and self adjusting hydraulic tappets. Multiport fuel injection ensures that engine performance, economy and exhaust emissions are automatically correct for the demands of highway and off road operation.
12ENGINE 2 DESCRIPTION AND OPERATION 1. Cylinder block 2. Pistons and gudgeon pins (8) 3. Connecting rods (8) 4. Core plugs 5. Camshaft 6. Dipstick 7. Camshaft key 8. Timing chain 9. Camshaft sprocket 10. Distance piece 11. Distributor drive gear 12. Distributor 13. Front cover 14. Front cover oil seal 15. Coolant pump 16. Crankshaft damper / pulley17. Crankshaft sprocket 18. Crankshaft sprocket key 19. Crankshaft 20. Centre main bearing shells (2) 21. Crankshaft rear oil seal 22. Spacer 23. Adaptor plate 24. Rear main bearing cap, shell and side seals 25. Connecting rod caps 26. Main bearing caps and shell bearings 27. Oil filter 28. Oil pump suction pipe/strainer 29. Oil sump 30. Oil sump drain plug 31. Oil pump drive key
V8i 3 DESCRIPTION AND OPERATION 1. Cylinder heads (2) 2. Rocker covers (2) 3. PCV filter 4. Rocker shafts (2) 5. Hydraulic tappets (8) 6. Pushrods (8) 7. Rocker brackets (8) 8. Rocker arms (4) left and (4) right 9. Rocker shaft springs (6) 10. Inlet manifold 11. Plenum chamber lower 12. Ram pipes (8)13. Plenum chamber upper 14. PCV air intake filter 15. Oil filler 16. Thermostat 17. Thermostat cover 18. Inlet valve seal, spring, cap and collets (8) 19. Exhaust valve seal, spring, cap and collets (8) 20. Inlet valve and seat (8) 21. Exhaust valve and seat (8) 22. Inlet manifold gasket and seals 23. Cylinder head gaskets (2) 24. Valve guides (16)
12ENGINE 4 DESCRIPTION AND OPERATION Lubrication system The V8i full flow lubrication system uses a gear type oil pump which is driven from the front of the crankshaft. The oil pump gears are housed in the front cover and the pressure relief valve, warning light switch and filter are also fitted to the front cover. Oil drawn through the centrally located steel gauze strainer in the sump, is pumped under pressure through oil cooler located in the lower half of the main coolant radiator. The cooled oil then passes through the filter, before being distributed from the main gallery via drillings, to the various components in the engine. Lubrication to the thrust side of the cylinders is by oil grooves machined in each connecting rod big end joint face, which are timed to align with holes in the big end journals on the power and exhaust strokes. Lubrication system 1. Oil to cooler 2. Oil from cooler
V8i 5 DESCRIPTION AND OPERATION Distributor and timing chain lubrication The distributor and timing chain are lubricated from the camshaft front bearing. The feed to the timing chain is channelled along the camshaft sprocket, key and spacer where it sprays onto the chain. 1. Bearing 2. Camshaft 3. Key 4. Camshaft timing chain sprocket 5. Spacer 6. Distributor drive gearHydraulic 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 - high pressure The purpose of the hydraulic tappet is to provide maintenance free and quiet operation of the inlet and exhaust valves. It achieves its designed purpose by utilizing 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 4, passes through the non-return ball valve 5 and into the lower (high pressure) chamber 8. When the cam begins to lift the outer sleeve 7, the resistance of the cylinder valve spring felt through the pushrod seat 2, causes the inner sleeve 3, to move downwards inside the outer. This slight downward movement of the inner sleeve closes the ball valve 5 and increases the hydraulic pressure in the high pressure chamber, sufficient to ensure that the push rod opens the valve fully. As the tappet assembly moves off the peak of the cam the ball valve 5 opens to equalize the pressure in both chambers which ensures that the valve fully closes when the tappet is on the back of the cam.
V8i 1 FAULT DIAGNOSIS ENGINE OIL PRESSURE TEST Service tools: LRT-12-052: Pressure test equipment WARNING: Use suitable exhaust extraction equipment, if test is being carried out in workshop. WARNING: If vehicle has been running, engine oil will be hot, care must be taken when fitting equipment to prevent personal injury due to scalding. Test 1.Check lubricant is to correct level. 2.Place vehicle on a ramp [hoist]. 3.Disconnect battery negative lead. Remove oil pressure switch. 4.Fit the test gauge. 5.Reconnect battery negative lead. 6.Start and run engine to normal operating temperature. 7.At a steady engine speed of 2500 rev/min - engine oil pressure reading should be - 2.75 bar (40 lbf/in 2). 8.If the pressure is low - Remove and overhaul oil pump CYLINDER COMPRESSION - TEST Equipment: Compression pressure gauge Test 1.Start and run engine until normal engine operating temperature is achieved (thermostat open). 2.Remove all spark plugs. 3.Disconnect both coil negative (WB) leads 4.Insert compression gauge, crank engine until reading stabilises. 5.Expected readings, throttle fully open, battery fully charged: 8.31:1 = 10.2-10.9 bar, 150-160lbf/in 2 9.35:1 = 11.5-12.2 bar, 170-180lbf/in2
12ENGINE 2 FAULT DIAGNOSIS ENGINE NOISES Excessive or obtrusive noise from the engine compartment originates from three main sources: A. The exhaust system, which makes an unmistakable and easy to diagnose noise. B. External components emit the greatest variety of noises, but are also easy to diagnose by simply removing the drive belt. C. Engine internal mechanical noises which can vary in volume and pitch and may be a combination of, tapping - knocking or rumbling, are the most difficult to diagnose. The following is therefore a guide to diagnosis of engine internal mechanical noises only. Engine internal mechanical noises. Single or multiple, light tapping noise, particularly when engine is cold. See Description and operation, Description 1.Is engine oil level correct? NO - Top up to correct level. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended Lubricants and Fluids YES - Continue. 2.Is the lubricating pressure correct? NO - See Engine Oil Pressure Test YES - Suspect valve operating mechanism. 3.To confirm diagnosis, remove the rocker covers and with the engine idling, insert a feeler gauge of 0,015mm between each rocker and valve stem. A faulty valve operating mechanism will emit a different noise when the feeler gauge is inserted. See Repair, Rocker Shaft Renew Heavy knocking noise (particularly on load and when engine is hot). See Description and operation, Description 1.Is engine oil level correct? NO - Top up to correct level. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended Lubricants and Fluids YES - Continue. 2.Is the lubricating pressure correct? NO - See Engine Oil Pressure Test YES - Drain engine oil and filter, and examine for metallic contamination. 3.Is the oil contaminated with metal particles? YES - Suspect faulty big end bearings. To confirm diagnosis, short out the ignition to each spark plug in turn. The noise will disappear or be reduced when the cylinder with the faulty big end is shorted out. 4.If noise is not conclusively diagnosed, check the security of the flywheel and crankshaft front pulley. Temporarily release the drive belt to reduce general noise level and use a stethoscope to locate source of noise. Heavy rumbling noise (particularly during hard acceleration). See Description and operation, Description 1.Is engine oil level correct? NO - Top up to correct level. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended Lubricants and Fluids YES - Continue. 2.Is the lubricating pressure correct? NO - See Engine Oil Pressure Test YES - Drain engine oil and filter, and examine for metallic contamination. 3.Is the oil contaminated with metal particles? YES - Suspect faulty main bearings. If noise is not conclusively diagnosed, check the security of the flywheel and crankshaft front pulley. Temporarily release the drive belt to reduce general noise level and use a stethoscope to locate source of noise.
V8i 3 FAULT DIAGNOSIS ENGINE STARTING PROBLEMS Engine fails to crank in park or neutral (Automatic Transmission) 1.Is battery in good state of charge? NO - See INTRODUCTION, Information, Jump Starting YES - Continue. 2.Is automatic transmission inhibitor switch faulty or gear selection linkage incorrectly adjusted? YES - See AUTOMATIC GEARBOX, Repair, Inhibitor Switch , NO - See Electrical Trouble Shooting Manual. If problem is not diagnosed repeat tests, starting at 1. Engine fails to crank (Manual Transmission) 1.Is battery in good state of charge? NO - See INTRODUCTION, Information, Jump Starting YES -See Electrical Trouble Shooting Manual. If problem is not diagnosed repeat tests, starting at 1. Engine cranks but fails to start 1.Is the cranking speed fast enough (120 rpm)? NO - See INTRODUCTION, Information, Jump Starting If necessary also.See Electrical Trouble Shooting Manual. YES - Continue. 2.Is there combustion in any cylinder? NO - See ELECTRICAL, Fault diagnosis, Lucas Constant Energy Ignition System - V8i See Electrical Trouble Shooting Manual. YES - Continue. 3.Are the fuel supply, tank, pump, ventilation and emission control systems in correct working order or the fuel contaminated? NO - See FUEL SYSTEM, Repair, Fuel Filter See FUEL SYSTEM, Repair, Fuel Tank See FUEL SYSTEM, Repair, Fuel pump and Sender Unit See EMISSION CONTROL, Description and operation, Emission control If problem is not diagnosed repeat tests, starting at 2.ENGINE RUNNING PROBLEMS Engine runs at high speed but will not idle (stops) Engine idle speed erratic Engine starts but stops immediately Engine stalls Engine misfires/hesitation 1.Multiport fuel injection. See Electrical Trouble Shooting Manual. See ELECTRICAL, Fault diagnosis, Lucas Constant Energy Ignition System - V8i Check brake vacuum connections.See BRAKES, Description and operation, Brake Servo Unit Check heater/ventilation unit vacuum connections. See HEATING AND VENTILATION, Description and operation, Heating and Ventilation Unit If problem is not diagnosed continue. 2.Are HT leads correctly routed and clipped? NO - See ELECTRICAL, Repair, Distributor - V8i YES - Continue. 3.Is fuel supply, tank, pump, ventilation and emission control systems in correct working order or the fuel contaminated? NO - See FUEL SYSTEM, Repair, Fuel Filter See FUEL SYSTEM, Repair, Fuel Tank See FUEL SYSTEM, Repair, Fuel Pump and Sender Unit See EMISSION CONTROL, Description and operation, Emission Control If problem is not diagnosed repeat tests, starting at 1. Engine lacks power/poor performance 1.Is throttle travel restricted or cable incorrectly adjusted? YES - Check thickness of carpets. See FUEL SYSTEM, Repair, Throttle Cable See FUEL SYSTEM, Repair, Accelerator Pedal NO - Continue. 2.Are the Ignition and Multiport Fuel Injection systems in order? NO - See Electrical Trouble Shooting Manual.A1 See ELECTRICAL, Fault diagnosis, Lucas Constant Energy Ignition System - V8i See ELECTRICAL, Repair, Distributor - V8i YES - Continue.