Land Rover 4 0 4 6 V8 Engine Overhaul 3rd Edition Rover Manual

							ENGINE
14
OVERHAUL TIMING CHAIN AND GEARS
Sump - remove
1.Remove dipstick.
2.Remove 14 bolts and 3 nuts securing sump to
cylinder block and timing cover.
3.Taking care not to damage sealing faces,
carefully release sump from timing cover and
cylinder block.
4.Remove sump.Timing cover - remove
NOTE: Timing cover, oil pump and oil
pressure relief valve are only supplied as
an assembly.
1.Using assistance, restrain flywheel/drive plate
and remove crankshaft pulley bolt; collect
spacer washer - if fitted.
2.Remove crankshaft pulley.
3.Remove sump.
4.Remove nut and washers securing oil pick-up
pipe to stud.
5.Remove 2 bolts securing oil pick-up pipe to oil
pump cover, withdraw pipe from cover; remove
and discard O ring.
6.Remove oil pick-up pipe, recover spacer from
stud. 
						

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7.Remove bolt securing camshaft sensor to
timing cover, withdraw sensor; remove and
discard O ring.
8.Release harness connector from mounting
bracket.
NOTE: New Range Rover timing cover
illustrated.
9.Noting their fitted position, remove 9 bolts
securing timing cover to cylinder block; remove
cover; collect camshaft sensor harness
mounting bracket.
NOTE: Timing cover is dowel located.
CAUTION: Do not attempt to remove oil
pump drive gear at this stage.
10.Remove and discard gasket.
11.Remove and discard oil seal from timing cover.Timing gears - remove
1.Restrain camshaft gear and remove bolt
securing gear.
2.Remove timing chain and gears as an
assembly.
3.Collect Woodruff key from crankshaft. 
						

							ENGINE
16
OVERHAUL Timing chain and gears - inspection
1.Thoroughly clean all components.
2.Inspect timing chain links and pins for wear.
3.Inspect timing chain gears for wear. Replace
components as necessary.Timing gears - refit
1.Clean gear locations on camshaft and
crankshaft, fit Woodruff key to crankshaft.
2.Temporarily fit crankshaft gear and if
necessary, turn crankshaft to bring timing mark
on gear to the twelve oclock position, remove
gear.
3.Temporarily fit camshaft gear.
4.Turn camshaft until mark on camshaft sprocket
is at the six oclock position, remove gear
without moving camshaft. 
						

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OVERHAUL17
5.Position timing gears on work surface with
timing marks aligned.
6.Fit timing chain around gears, keeping timing
marks aligned.
7.Fit gear and chain assembly.
NOTE: Timing marks must be facing
forwards.
8.Fit camshaft gear bolt, restrain camshaft gear
and tighten bolt to 50 Nm (37 lbf.ft).Timing cover - refit
NOTE: Timing cover, oil pump and oil
pressure relief valve are only supplied as
an assembly.
1.Clean sealant from threads of timing cover
bolts.
2.Clean all traces of gasket material from mating
faces of timing cover and cylinder block.
CAUTION: Use a plastic scraper.
3.Clean oil seal location in timing cover.
4.Lubricate oil pump gears and oil seal recesses
in timing cover with engine oil.
5.Apply Hylosil jointing compound to new timing
cover gasket, position gasket to cylinder block.
6.Locate toolLRT-12-090on timing cover and
oil pump drive gear.
7.Position timing cover to cylinder block and at
the same time, rotate toolLRT-12-090until
drive gear keyway is aligned with Woodruff
key.
8.Fit timing cover to cylinder block. 
						

							ENGINE
18
OVERHAUL
NOTE: New Range Rover timing cover
illustrated.
9.Position camshaft sensor harness mounting
bracket to timing cover ensuring that bracket is
positioned parallel to crankshaft centre line. Fit
bolts and tighten in sequence shown to 22 Nm
(16 lbf.ft).
CAUTION: Do not fit coolant pump bolts at
this stage.
10.Remove toolLRT-12-090.
A- Early type seal
B- Later type seal - use as replacement on all
engines
11.Lubricate new timing cover oil seal with Shell
Retinax LX grease ensuring that space
between seal lips is filled with grease.
CAUTION: Do not use any other type of
grease. 
						

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12.Fit timing cover oil seal using toolLRT-12-089.
13.Smear a new O ring with engine oil and fit to
oil pick-up pipe.
14.Position oil pick-up pipe spacer on number 4
main bearing cap stud.
15.Fit oil pick-up pipe ensuring that end of pipe is
correctly inserted in oil pump body.
16.Fit oil pick-up pipe to oil pump body bolts and
tighten to 8 Nm (6 lbf.ft).
17.Fit washers and nut securing oil pick-up pipe to
stud, tighten nut to 24 Nm (18 lbf.ft).
18.Smear a new O ring with engine oil and fit to
camshaft sensor.
19.Insert camshaft sensor into timing cover, fit bolt
and tighten to 8 Nm (6 lbf.ft).
20.Position camshaft sensor harness connector
on mounting bracket.
21.Fit sump.
22.Fit crankshaft pulley, fit bolt and spacer washer
- if fitted; tighten bolt to 270 Nm (200 lbf.ft).
NOTE: Crankshaft pulleys which
incorporate a mud flinger can be fitted to
all engines.Sump - refit
1.Remove all traces of old sealant from mating
faces of cylinder block and sump.
2.Clean mating faces with suitable solvent and
apply a bead of Hylosil Type 101 or 106
sealant to sump joint face as shown:
Bead width - areas A, B, C and D = 12 mm (0.5
in)
Bead width - remaining areas = 5 mm (0.20 in)
Bead length - areas A and B = 32 mm (1.23 in)
Bead length - areas C and D = 19 mm (0.75 in)
CAUTION: Do not spread sealant bead.
Sump must be fitted immediately after
applying sealant.
3.Fit sump, taking care not to damage sealant
bead. 
						

							ENGINE
20
OVERHAUL
4.Fit sump bolts and nuts and working in
sequence shown, tighten to 23 Nm (17 lbf.ft).
5.Fit sump drain plug and tighten to 45 Nm (33
lbf.ft).
6.Fit dipstick.OIL PUMP AND OIL PRESSURE RELIEF VALVE
NOTE: Overhaul procedures for the oil
pump and oil pressure relief valve are
limited to carrying out dimensional
checks. In the event of wear or damage being
found, a replacement timing cover and oil pump
assembly must be fitted.
Oil pump - remove
1.Remove timing cover.
CAUTION: Do not attempt to remove oil
pump drive gear from inner rotor at this
stage.
2.Remove 7 screws and bolt securing oil pump
cover plate, remove plate. 
						

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OVERHAUL21
3.Make suitable alignment marks on inner and
outer rotors, remove rotors and oil pump drive
gear as an assembly.Oil pressure relief valve - remove
1.Remove circlip.
2.Remove relief valve plug, remove and discard
O ring.
3.Remove relief valve spring and piston. 
						

							ENGINE
22
OVERHAUL Oil pump - inspection
1.Thoroughly clean oil pump drive gear, cover
plate, rotors and housing. Remove all traces of
Loctite from cover plate securing screws;
ensure tapped holes in timing cover are clean
and free from oil.
2.Check mating surfaces of cover plate, rotors
and housing for scoring.
3.Assemble rotors and oil pump drive gear in
housing ensuring that reference marks are
aligned.
4.Using feeler gauges, check clearance between
teeth of inner and outer rotors:
Maximum clearance = 0.25 mm (0.01 in)
5.Remove oil pump drive gear, check depth of
any wear steps on gear teeth:
Wear step maximum depth = 0.15 in (0.006 in)
6.Place a straight edge across housing.
7.Using feeler gauges, check clearance between
straight edge and rotors:
Maximum clearance = 0.1 mm (0.004 in). 
						

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Oil pressure relief valve - inspection
1.Clean relief valve components and piston bore
in timing cover.
2.Check piston and bore for scoring and that
piston slides freely in bore with no perceptible
side movement.
3.Check relief valve spring for damage and
distortion; check spring free length:
Spring free length = 60.0 mm (2.4 in).Oil pump - refit
1.Lubricate rotors, oil pump drive gear, cover
plate and housing with engine oil.
2.Assemble rotors and drive gear in housing
ensuring that reference marks are aligned.
3.Position cover plate to housing.
4.Apply Loctite 222 to threads of cover plate
screws and bolt.
5.Fit cover plate screws and bolt and tighten to:-
Screws - 4 Nm (3 lbf.ft)
Bolt - 8 Nm (6 lbf.ft)
6.Fit timing cover.