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

							ENGINE
34
OVERHAUL Flywheel and starter ring gear - inspection
1.Inspect flywheel face for cracks, scores and
overheating. The flywheel can be refaced on
the clutch face providing thickness does not go
below minimum.
Flywheel minimum thicknessA= 40.45 mm
(1.6 in)
2.Inspect starter ring gear for worn, chipped and
broken teeth.
CAUTION: Do not attempt to remove
reluctor ring.
3.Renew starter ring gear if necessary.Starter ring gear - renew
1.Drill a 6 mm (0.250 in) diameter hole at root of
2 teeth.
CAUTION: Do not allow drill to enter
flywheel.
2.Secure flywheel in soft jawed vice.
3.Split ring gear using a cold chisel.
WARNING: Wear safety goggles and take
precautions against flying fragments when
splitting ring gear.
4.Remove flywheel from vice, remove old ring
gear, and place flywheel, clutch side down, on
a flat surface. 
						

							ENGINE
OVERHAUL35
5.Heat new ring gear uniformly to between 170°
and 175°C (340°and 350°F).
CAUTION: Do not exceed this
temperature.
WARNING: Take care when handling hot
ring gear.
6.Locate ring gear on flywheel with chamfered
inner diameter towards flywheel flange.
NOTE: If ring gear is chamfered on both
sides, it can be fitted either way round.
7.Press ring gear on to flywheel until it butts
against flywheel flange.
8.Allow flywheel to air cool.Flywheel - refit
1.Fit flywheel and locate on 2 dowels.
2.Fit flywheel bolts.
3.Using assistance, restrain crankshaft and
tighten flywheel bolts to 80 Nm (59 lbf.ft). 
						

							ENGINE
36
OVERHAUL DRIVE PLATE AND RING GEAR ASSEMBLY
Drive plate and ring gear assembly - remove - Up
to engine nos. 42D00593A and 46D00450A
1.Suitably identify each component to its fitted
position.
NOTE: 4.0 litre drive plate illustrated.
2.Remove 4 bolts securing drive plate assembly.
3.Remove buttress ring and drive plate
assembly.
NOTE: Drive plate assembly is dowel
located.
4.Remove 6 socket head cap screws securing
hub aligner to crankshaft, remove hub aligner
and selective shim; retain shim.
NOTE: Dowel located.Drive plate and ring gear assembly - remove -
From engine nos. 42D00594A, 46D00451A and all
engines having serial no. prefixes 47D to 51D
1.Suitably identify each component to its fitted
position.
NOTE: 4.0 litre drive plate illustrated.
2.Remove 4 bolts securing buttress ring, drive
plate, spacer and ring gear assembly to hub
aligner.
3.Remove buttress ring, drive plate, spacer and
ring gear assembly.
NOTE: Ring gear assembly is dowel
located.
4.Remove 6 socket head cap screws securing
hub aligner to crankshaft, remove hub aligner.
NOTE: Dowel located. 
						

							ENGINE
OVERHAUL37
Drive plate and ring gear - inspection
1.Inspect drive plate for cracks and distortion.
2.Renew drive plate if necessary.
3.Inspect ring gear for worn, chipped and broken
teeth.
4.Renew ring gear assembly if necessary.Drive plate and ring gear assembly - refit - Up to
engine nos. 42D00593A and 46D00450A
CAUTION: To prevent distortion to drive
plate when bolted to torque converter,
drive plate setting height must be checked
as follows:
1.Fit original selective shim and hub aligner, fit
socket head cap screws and tighten to 85 Nm
(63 lbf.ft).
2.Fit drive plate assembly and buttress ring
ensuring that reference marks are aligned; fit
bolts and tighten to 45 Nm (33 lbf.ft).
CAUTION: If a new drive plate assembly is
being fitted, paint mark on plate must face
towards torque converter.
3.Check the setting heightA.
Up to engine no. 42D00593A = 21.25 to
21.37 mm (0.83 to 0.84 in)
Up to engine no. 46D00450A = 7.69 to 7.81
mm (0.30 to 0.31 in)
4.If setting height is not as specified, remove
buttress ring, drive plate assembly, hub aligner
and selective shim. 
						

							ENGINE
38
OVERHAUL 5.Measure existing shim and, if necessary, select
appropriate shim to achieve setting height.
Shims available:
1.20 - 1.25mm (0.048 to 0.050 in)
1.30 - 1.35mm (0.051 to 0.053 in)
1.40 - 1.45mm (0.055 to 0.057 in)
1.50 - 1.55mm (0.059 to 0.061 in)
1.60 - 1.65mm (0.063 to 0.065 in)
1.70 - 1.75mm (0.067 to 0.070 in)
1.80 - 1.85mm (0.071 to 0.073 in)
1.90 - 1.95mm (0.075 to 0.077 in)
2.00 - 2.05mm (0.079 to 0.081 in)
2.10 - 2.15mm (0.083 to 0.085 in)
6.Fit shim selected, fit hub aligner; fit socket
head cap screws and tighten to 85 Nm (63
lbf.ft).
7.Fit drive plate assembly and buttress ring
ensuring that reference marks are aligned or
that paint mark on replacement drive plate is
facing towards torque converter.
8.Fit bolts and tighten to 45 Nm (33 lbf.ft).Drive plate and ring gear assembly - refit - From
engine nos. 42D00594A, 46D00451A and all
engines having serial no. prefixes 47D to 51D
NOTE: It is not necessary to check setting
height on drive plates fitted to engines
from the above numbers.
1.Fit hub aligner, fit socket head cap screws and
tighten to 85 Nm (63 lbf.ft).
2.Fit ring gear assembly, spacer, drive plate and
buttress ring ensuring that reference marks are
aligned.
CAUTION: If a new drive plate is being
fitted, paint mark must face towards
torque converter, ensure holes in plate are
aligned with clearance holes in ring gear.
3.Fit bolts and tighten to 45 Nm (33 lbf.ft). 
						

							ENGINE
OVERHAUL39
CRANKSHAFT, MAIN AND BIG-END BEARINGS
Big-end bearings - remove
1.Remove sump.
2.Remove nut and washers securing oil pick-up
pipe to stud.
3.Remove 2 bolts securing oil pick-up pipe to oil
pump cover, withdraw pipe from cover; remove
and discard O ring.
4.Remove oil pick-up pipe, recover spacer from
stud.
5.Suitably identify bearing caps to their
respective connecting rods.
6.Remove 2 bolts securing each bearing cap.
7.Remove bearing cap and bearing shell.
NOTE: Keep bearing caps and bolts in
their fitted order.
8.Push each piston up its respective bore and
remove shells from connecting rods.
NOTE: Big-end bearing shells must be
replaced whenever they are removed. 
						

							ENGINE
40
OVERHAUL Big-end bearings - refit
1.Fit bearing shells to each connecting rod.
NOTE: Big-end bearings are available in
0.254 mm (0.01 in) and 0.508 mm (0.02 in)
oversizes.
2.Lubricate bearing shells and crankshaft
journals with engine oil.
3.Pull connecting rods on to crankshaft journals.
4.Fit bearing shells to each big-end bearing cap.
NOTE: If crankshaft has been reground,
ensure appropriate oversize bearing shells
are fitted.
5.Lubricate bearing shells and fit bearing caps
ensuring reference marks on connecting rods
and bearing caps are aligned.
NOTE: Rib on edge of bearing cap must
face towards front of engine on RH bank
of cylinders and towards rear on LH bank
of cylinders.
6.Fit bearing cap bolts and tighten to 20 Nm (15
lbf.ft) then a further 80 degrees.
7.Check connecting rods move freely sideways
on crankshaft. Tightness indicates insufficient
bearing clearance or misaligned connecting
rod.
8.Check clearance between connecting rods on
each crankshaft journal.
Connecting rod clearance = 0.15 to 0.36 mm
(0.006 to 0.014 in).
9.Clean oil strainer and oil pick-up pipe.
10.Smear a new O ring with engine oil and fit to
oil pick-up pipe.
11.Position oil pick-up pipe spacer on number 4
main bearing cap stud.
12.Fit oil pick-up pipe ensuring that end of pipe is
correctly inserted in oil pump body.
13.Fit oil pick-up pipe to oil pump body bolts and
tighten to 8 Nm (6 lbf.ft).
14.Fit washers and nut securing oil pick-up pipe to
stud; tighten nut to 24 Nm (18 lbf.ft).
15.Fit sump. 
						

							ENGINE
OVERHAUL41
Crankshaft - remove
1.Remove flywheel or drive plate and ring gear
assembly.
2.Remove timing cover.
3.Remove timing gears.
4.Remove big-end bearings.
5.Make suitable reference marks between each
main bearing cap and cylinder block.
6.Starting at centre main bearing and working
outwards, progressively slacken then remove
10 main bearing cap bolts.
CAUTION: Keep bolts in their fitted order.
7.Starting at centre main bearing and working
outwards, progressively slacken then remove 5
LH side hexagonal head bolts and 4 RH side
hexagonal head bolts and one socket head cap
bolt; remove and discard Dowty washers.
8.Remove 5 main bearing caps, remove and
discard bearing shells.
NOTE: Number 4 main bearing cap is
drilled to accommodate oil pick-up pipe
stud.9.Lift out crankshaft; remove and discard rear oil
seal.
10.Remove and discard 5 bearing shells from
cylinder block.
CAUTION: Main bearing shells must be
replaced whenever they are removed.
11.Remove and discard side seals from rear main
bearing cap.
12.Remove all traces of sealant from bearing cap
and cylinder block.
13.Remove Woodruff key from crankshaft. 
						

							ENGINE
42
OVERHAUL Knock sensor - remove
1.Remove knock sensor from cylinder block.Crankshaft position sensor - remove
1.Remove 2 bolts securing crankshaft position
sensor to gearbox adaptor plate, remove
sensor; collect spacer - if fitted. 
						

							ENGINE
OVERHAUL43
Crankshaft - inspection
1.Clean crankshaft and blow out oil passages.
2.Support crankshaft front and rear bearing
journals on vee blocks, and using a DTI,
measure run-out on centre main bearing.
Maximum permitted run-out = 0.08 mm (0.003
in).
If run-out exceeds permitted maximum,
crankshaft is unsuitable for regrinding and
should be replaced.
3.Measure each journal for overall wear and
ovality, take 3 measurements at 120°intervals
at each end and centre of journals.
Main bearing journal diameter = 63.487 to
63.500 mm (2.499 to 2.52 in)
Maximum out of round = 0.040 mm (0.002 in).
Big-end bearing journal diameter = 55.500 to
55.513 mm (2.20 to 2.22 in)
Maximum out of round = 0.040 mm (0.002 in).
If measurements exceed permitted maximum,
regrind or fit new crankshaft.
NOTE: Ovality checks should be made at
120°intervals around each journal.
Crankshaft main and big-end bearings are
available in 0.254 mm (0.01 in) and 0.508 mm
(0.02 in) oversizes.