Land Rover 4 0 4 6 V8 Engine Overhaul 3rd Edition Rover Manual
Have a look at the manual Land Rover 4 0 4 6 V8 Engine Overhaul 3rd Edition 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+.
INFORMATION 2 DATA, TORQUE & TOOLS Piston rings Ring to groove clearance: 1st compression 0.05 to 0.10 mm...........................0.002 to 0.004 in 2nd compression 0.05 to 0.10 mm..........................0.002 to 0.004 in Ring fitted gap: 1st compression 0.3 to 0.5 mm...........................0.01 to 0.02 in 2nd compression 0.40 to 0.65 mm..........................0.016 to 0.03 in Oil control rails 0.38 to 1.40 mm............................0.014 to 0.05 in Oil control ring width 3.00 mm.........................0.12 in - maximum Pistons Piston diameter: Production - Grade A 93.970 to 93.985 mm........................3.700 to 3.7002 in Production - Grade B* 93.986 to 94.0 mm.......................3.7003 to 3.701 in Clearance in bore 0.02 to 0.045 mm...........................0.001 to 0.002 in Gudgeon pins Length 60.00 to 60.50 mm....................................2.35 to 2.4 in Diameter 23.995 to 24.000 mm..................................0.94 to 0.95 in Clearance in piston 0.006 to 0.015 mm..........................0.0002 to 0.0006 in Connecting rods Length between centres: 4.0 litre 155.12 to 155.22 mm..................................6.10 to 6.11 in 4.6 litre 149.68 to 149.78 mm..................................5.89 to 5.91 in Cylinder bore Cylinder bore: Grade A piston fitted 94.00 to 94.015 mm........................3.700 to 3.701 in Grade B piston fitted 94.016 to 94.030 mm........................3.7014 to 3.702 in Cylinder bore maximum ovality 0.013 mm.................0.0005 in Crankshaft Main journal diameter 63.487 to 63.500 mm........................2.499 to 2.52 in Minimum regrind diameter 62.979 to 62.992 mm...................2.509 to 2.510 in Maximum out of round 0.040 mm......................0.002 in Big-end journal diameter 55.500 to 55.513 mm......................2.20 to 2.22 in Minimum regrind diameter 54.992 to 55.005 mm...................2.16 to 2.165 in Maximum out of round 0.040 mm......................0.002 in End-float 0.10 to 0.20 mm..................................0.004 to 0.008 in Maximum run-out 0.08 mm............................0.003 in Main bearings Main bearing diametrical clearance 0.010 to 0.048 mm..............0.0004 to 0.002 in Oversizes 0.254, 0.508 mm................................0.01, 0.02 in
INFORMATION DATA, TORQUE & TOOLS3 Big-end bearings Big-end bearing diametrical clearance 0.015 to 0.055 mm...........0.0006 to 0.0021 in Oversizes 0.254, 0.508 mm................................0.01, 0.02 in End-float on journal 0.15 to 0.36 mm..........................0.006 to 0.01 in Flywheel Flywheel minimum thickness 40.45 mm................... 1.6in Drive plate Drive plate setting height: Up to engine no. 42D00593A - 4.0 litre 21.25 to 21.37 mm.........0.83 to 0.84 in Up to engine no. 46D00450A - 4.6 litre 7.69 to 7.81 mm.........0.30 to 0.31 in * Grade B piston supplied as service replacement
INFORMATION TORQUE WRENCH SETTINGS1 ENGINE Crankshaft pulley bolt 270 Nm........................ 200lbf.ft Camshaft gear bolt 50 Nm.......................... 37lbf.ft Camshaft thrust plate bolts 25 Nm.................... 18lbf.ft Rocker cover bolts: + Stage 1 4 Nm.................................. 3lbf.ft Stage 2 8 Nm.................................. 6lbf.ft Stage 3 - re-torque to: 8 Nm....................... 6lbf.ft Rocker shaft to cylinder head bolts 38 Nm.............. 28lbf.ft Cylinder head bolts: +* Stage 1 20 Nm................................. 15lbf.ft Stage 2 Then 90 degrees................................. Stage 3 Further 90 degrees................................. Lifting eye to cylinder head bolts 40 Nm................ 30lbf.ft Connecting rod bolts: Stage 1 20 Nm.................................. 15lbf.ft Stage 2 Further 80 degrees.................................. Main bearing cap bolts - Nos. 1 to 8: + Stage 1 - initial torque 13.5 Nm....................... 10lbf.ft Stage 2 - final torque 72 Nm....................... 53lbf.ft Rear main bearing cap bolts - Nos. 9 and 10: + Stage 1 - initial torque 13.5 Nm....................... 10lbf.ft Stage 2 - final torque 92 Nm....................... 68lbf.ft Main bearing cap side bolts - Nos. 11 to 20: + Stage 1 - initial torque 13.5 Nm....................... 10lbf.ft Stage 2 - final torque 45 Nm....................... 33lbf.ft Flywheel bolts 80 Nm.............................. 59lbf.ft Drive plate assembly bolts 45 Nm..................... 33lbf.ft Drive plate hub aligner to crankshaft socket head cap screws 85 Nm................................. 63lbf.ft Oil sump drain plug 45 Nm.......................... 33lbf.ft Oil sump nuts and bolts + 23 Nm..................... 17lbf.ft Oil pump cover plate screws ** 4 Nm................. 3lbf.ft Oil pump cover plate bolt ** 8 Nm.................... 6lbf.ft Spark plugs 20 Nm................................ 15lbf.ft Timing cover/coolant pump to cylinder block bolts +22Nm........................................ 16lbf.ft Oil pick-up pipe to oil pump bolts 8 Nm................ 6lbf.ft Oil pick-up pipe nut 24 Nm.......................... 18lbf.ft Knock sensors to cylinder block 16 Nm................ 12lbf.ft Camshaft sensor to timing cover bolt 8 Nm............ 6lbf.ft Crankshaft position sensor bolts 6 Nm................ 4lbf.ft Oil cooler connections 15 Nm........................ 11lbf.ft + Tighten in sequence * Lightly oil threads prior to assembly. ** Coat threads with Loctite 222 prior to assembly.
INFORMATION 2 TORQUE WRENCH SETTINGS GENERAL For bolts and nuts not otherwise specified M5 4 Nm....................................... 3lbf.ft M6 6 Nm....................................... 4lbf.ft M8 18 Nm....................................... 13lbf.ft M10 35 Nm...................................... 26lbf.ft M12 65 Nm...................................... 48lbf.ft M14 80 Nm...................................... 59lbf.ft M16 130 Nm...................................... 96lbf.ft 1/4UNC/UNF 9 Nm............................... 7lbf.ft 5/16 UNC and UNF 25 Nm.......................... 18lbf.ft 3/8UNC and UNF 40 Nm............................ 30lbf.ft 7/16 UNC and UNF 75 Nm.......................... 55lbf.ft 1/2UNC and UNF 90 Nm............................ 66lbf.ft5/8UNC and UNF 135 Nm............................ 100lbf.ft
INFORMATION SERVICE TOOLS1 SERVICE TOOLS Land Rover Number Rover Number Description LRT-12-013 18G1150 Remover/replacer - gudgeon pin LRT-12-126/1 - Adapter - remover/replacer - gudgeon pin LRT-12-126/2 - Adapter - remover/replacer - gudgeon pin LRT-12-126/3 - Parallel sleeve - gudgeon pin LRT-12-034 18G1519A Valve spring compressor LRT-12-037 RO274401 Drift - remover - valve guide LRT-12-038 RO600959 Drift - replacer - valve guide LRT-12-055 - Distance piece - valve guide LRT-12-089 - Replacer - timing cover oil seal LRT-12-090 - Retainer - oil pump gears LRT-12-091 - Replacer - crankshaft rear oil seal LRT-12-095 - Protection sleeve - crankshaft rear oil seal LRT-12-501 MS76B Basic handle set - valve seat cutters LRT-12-503 MS150-8.5 Adjustable valve seat pilot LRT-12-515 RO605774A Distance piece - valve guide LRT-12-517 - Adjustable valve seat cutter Service tools must be obtained direct from the manufacturers: V.L. Churchill, P.O. Box No 3, London Road, Daventry, Northants, NN11 4NF England.
ENGINE CONTENTS Page DESCRIPTION AND OPERATION CYLINDER BLOCK COMPONENTS 3.................................... CYLINDER HEAD COMPONENTS 5..................................... OPERATION 6...................................................... OVERHAUL ROCKER SHAFTS 1.................................................. Rocker shafts - remove 1.............................................. Rocker shafts - dismantling 2........................................... Inspecting components 2.............................................. Rocker shafts - assembling 3........................................... Rocker shafts - refit 3................................................. CYLINDER HEAD 4.................................................. Cylinder head - remove 4.............................................. Valves and springs - remove 5.......................................... Cylinder head - inspection 5............................................ Valves, valve springs and guides - inspection 6............................. Valve guides - renew 8................................................ Valve seat inserts - inspection 9......................................... Valve seat inserts - renew 10........................................... Valve seats and seat inserts - refacing 10.................................. Valves - lapping-in 12................................................. Valves and springs - refit 12............................................ Cylinder head - refit 13................................................ TIMING CHAIN AND GEARS 14......................................... Sump - remove 14.................................................... Timing cover - remove 14.............................................. Timing gears - remove 15.............................................. Timing chain and gears - inspection 16.................................... Timing gears - refit 16................................................. Timing cover - refit 17................................................. Sump - refit 19....................................................... OIL PUMP AND OIL PRESSURE RELIEF VALVE 20........................ Oil pump - remove 20................................................. Oil pressure relief valve - remove 21...................................... Oil pump - inspection 22............................................... Oil pressure relief valve - inspection 23.................................... Oil pump - refit 23.................................................... Oil pressure relief valve - refit 24......................................... CAMSHAFT AND TAPPETS 24......................................... Camshaft end-float - check 24.......................................... Camshaft and tappets - remove 25....................................... Camshaft and tappets - inspection 26..................................... Camshaft and tappets - refit 26.......................................... PISTONS, CONNECTING RODS, PISTON RINGS AND CYLINDER BORES 27... Pistons and connecting rods - remove 27.................................. Piston rings - remove 27............................................... Piston rings - inspection 28............................................. Pistons - remove 28.................................................. Pistons - inspection 29................................................ Gudgeon pins - inspection 29........................................... Cylinder liner bore - inspection 30........................................
ENGINE CONTENTS Page Pistons - refit 31..................................................... Piston to cylinder bore clearance - checking 32............................. Pistons and connecting rods - refit 32..................................... FLYWHEEL AND STARTER RING GEAR 33............................... Flywheel - remove 33................................................. Flywheel and starter ring gear - inspection 34............................... Starter ring gear - renew 34............................................. Flywheel - refit 35.................................................... DRIVE PLATE AND RING GEAR ASSEMBLY 36........................... Drive plate and ring gear assembly - remove - Up to engine nos. 42D00593A and 46D00450A 36................................................... Drive plate and ring gear assembly - remove - From engine nos. 42D00594A and 46D00451A and all engines having serial no. prefixes from 47D to 51D 36.... Drive plate and ring gear - inspection 37................................... Drive plate and ring gear assembly - refit - Up to engine nos. 42D00593A and 46D00450A 37...................................................... Drive plate and ring gear assembly - refit - From engine nos. 42D00594A and 46D00451A and all engines having serial no. prefixes from 47D to 51D 38........ CRANKSHAFT, MAIN AND BIG-END BEARINGS 39........................ Big-end bearings - remove 39........................................... Big-end bearings - refit 40.............................................. Crankshaft - remove 41................................................ Knock sensor - remove 42............................................. Crankshaft position sensor - remove 42................................... Crankshaft - inspection 43.............................................. Crankshaft spigot bearing - renew 44..................................... Crankshaft - refit 45................................................... Crankshaft end - float - check 47......................................... Knock sensor - refit 47................................................ Crankshaft position sensor - refit 48......................................
ENGINE DESCRIPTION AND OPERATION1 This page is intentionally left blank