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

							ENGINE
44
OVERHAUL Crankshaft dimensions:
Bearing journal radius - all journals except rear main
journalA= 1.90 to 2.28 mm (0.075 to 0.09 in).
Rear main bearing journal radiusB= 3.04 mm (0.12
in).
Bearing journal diameterC:
Standard = 63.487 to 63.500 mm (2.499 to 2.52 in).
0.254 mm (0.01 in) undersize = 63.233 to 63.246
mm (2.511 to 2.512 in).
0.508 mm (0.02 in) undersize = 62.979 to 62.992
mm (2.509 to 2.510 in).
Bearing journal widthD:
Standard = 26.975 to 27.026 mm (1.061 to 1.064 in).
Bearing journal diameterE:
Standard = 55.500 to 55.513 mm (2.20 to 2.22 in).
0.254 mm (0.01 in) undersize = 55.246 to 55.259
mm (2.17 to 2.18 in).
0.508 mm (0.02 in) undersize = 54.992 to 55.005
mm (2.16 to 2.165 in).
CAUTION: if crankshaft is to be replaced,
ensure replacement is correct for engine
being overhauled. Crankshafts are not
interchangeable between 4.0 and 4.6 litre
engines.
1.Check crankshaft spigot bearing for wear,
renew if necessary.Crankshaft spigot bearing - renew
1.Carefully extract old spigot bearing.
2.Clean bearing recess in crankshaft.
3.Fit new bearing flush with, or to a maximum of
1.6 mm (0.06 in) below end face of crankshaft.
4.Ream bearing to correct inside diameter.
Spigot bearing inside diameter = 19.177 +
0.025 - 0.000 mm (0.75 + 0.001 - 0.000 in).
5.Remove all traces of swarf. 
						

							ENGINE
OVERHAUL45
Crankshaft - refit
1.Clean main bearing caps, bearing shell
recesses and mating surfaces of cylinder
block.
CAUTION: Ensure bolt holes in cylinder
block and main bearing caps are clean
and dry.
2.Fit new upper main bearing shells, with oil
holes and grooves, in cylinder block, ensuring
flanged shell is fitted in centre position.
NOTE: If crankshaft has been reground
ensure appropriate oversize bearing shells
are fitted.
3.Lubricate main bearing shells with engine oil
and position crankshaft in cylinder block.
4.Fit new main bearing shells to bearing caps.
5.Lubricate main bearing shells with engine oil.
6.Fit numbers 1 to 4 main bearing caps ensuring
that reference marks made during dismantling
are aligned, fit and tighten main bearing cap
bolts to 5 Nm (4 lbf.ft).
NOTE: Do not fit side bolts at this stage.
7.Fit side seals to rear main bearing cap.
CAUTION: Seals must protrude
approximately 1.5 mm (0.05 in) above
bearing cap face.
8.Apply a 3 mm (0.12 in) wide bead of Hylomar
PL32 jointing compound to bearing cap rear
mating face on cylinder block.
CAUTION: Ensure sealant does not enter
bolt holes.
9.Lubricate rear main bearing shell and side
seals with engine oil, carefully fit rear main
bearing cap assembly; fit and tighten main
bearing cap bolts to 5 Nm (4 lbf.ft).
CAUTION: Ensure that engine oil does not
enter side bolt holes in bearing cap.
10.Smear new Dowty washers with engine oil and
fit to main bearing cap side bolts.
11.Fit and tighten RH then LH side bolts to 5 Nm
(4 lbf.ft) ensuring that socket head cap bolt is
fitted to rear main bearing cap on RH side of
cylinder block adjacent to starter motor
aperture. 
						

							ENGINE
46
OVERHAUL
12.Using sequence shown, tighten bolts to:
Stage 1 - Initial torque
Main bearing cap bolts - 13.5 Nm (10 lbf.ft)
Main bearing cap side bolts - 13.5 Nm (10
lbf.ft)
Stage 2 - Final torque
Main bearing cap bolts numbers 1 to 8 - 72 Nm
(53 lbf.ft)
Main bearing cap bolts numbers 9 and 10 - 92
Nm (68 lbf.ft)
Main bearing cap side bolts 11 to 20 - 45 Nm
(33 lbf.ft)
13.Trim off excess material from rear main
bearing cap side seals.
14.Clean seal location and running surface on
crankshaft.
15.Clean seal protectorLRT-12-095and lubricate
with engine oil.
16.Lubricate oil seal lip with engine oil.
17.Position seal protectorLRT-12-095to
crankshaft.
18.Fit seal using toolLRT-12-091.
19.Fit Woodruff key to crankshaft.
20.Check crankshaft end-float.
NOTE: If 0.508 mm (0.02 in) oversize main
bearings have been fitted, it may be
necessary to machine thrust faces of
crankshaft centre main bearing location to
achieve correct end-float. Ensure an equal
amount of material is removed from each thrust
face.
21.Fit big-end bearings.
22.Fit timing cover and gears.
23.Fit flywheel or drive plate and ring gear
assembly.
24.Fit sump. 
						

							ENGINE
OVERHAUL47
Crankshaft end - float - check
1.Set-up DTI to measure end float.
2.Move crankshaft forwards and zero gauge.
3.Move crankshaft rearwards, record end-float
reading obtained.
Crankshaft end-float = 0.10 to 0.20 mm (0.004
to 0.008 in).
4.Remove DTI.
NOTE: Crankshaft end-float is controlled
by thrust faces on upper half of centre
main bearing shell. If crankshaft has been
reground and 0.508 mm (0.02 in) oversize main
bearing shells are to be fitted, it may be
necessary to machine thrust faces of crankshaft
centre main bearing journal to achieve correct
end-float. Ensure an equal amount of material is
removed from each thrust face.Knock sensor - refit
1.Clean threads of knock sensor and mating
threads in cylinder block.
2.Fit knock sensor and tighten to 16 Nm (12
lbf.ft).
CAUTION: Do not apply any type of
sealant to threads. 
						

							ENGINE
48
OVERHAUL Crankshaft position sensor - refit
1.Position crankshaft position sensor and spacer
- if fitted to gearbox adaptor plate, fit bolts and
tighten to 6 Nm (4 lbf.ft).