Land Rover 4 0 4 6 V8 Engine Overhaul 4th Edition Rover Manual

ENGINE
32
OVERHAUL PISTONS, CONNECTING RODS, PISTON RINGS
AND CYLINDER BORES
Pistons and connecting rods - remove
1.Remove cylinder head(s).
2.Remove big-end bearings.
3.Remove carbon ridge from top of each cylinder
bore.
4.Suitably identify each piston to its respective
cylinder bore.
5.Push connecting rod and piston assembly to
top of cylinder bore and withdraw assembly.
6.Repeat above procedure for remaining pistons.
CAUTION: Big-end bearing shells must be
replaced whenever they are removed.Piston...

ENGINE
OVERHAUL33
Piston rings - inspection
1.Temporarily fit new compression rings to
piston.
NOTE: If replacement pistons are to be
fitted, ensure rings are correct for piston.
The 2nd compression ring marked’TOP’must be
fitted, with marking uppermost, into second
groove. The 1st compression ring fits into top
groove and can be fitted either way round.
2.Check compression ring to groove clearance:
1st compression ringA= 0.05 to 0.10 mm
(0.002 to 0.004 in).
2nd compression ringB= 0.05 to 0.10 mm
(0.002...

ENGINE
34
OVERHAUL 13.Dismantle toolLRT-12-013and remove piston,
connecting rod and gudgeon pin.
NOTE: Keep each piston and gudgeon pin
with their respective connecting rod.
14.Repeat above operations for remaining
pistons.Pistons - inspection
1.Clean carbon from pistons.
2.Inspect pistons for distortion, cracks and
burning.
3.Measure and record piston diameter at 90°to
gudgeon pin axis and 10 mm (0.4 in) from
bottom of skirt.
4.Check gudgeon pin bore in piston for signs of
wear and overheating.
NOTE:...

ENGINE
OVERHAUL35
Gudgeon pins - inspection
NOTE: Gudgeon pins are only supplied as
an assembly with replacement pistons.
1.Check gudgeon pins for signs of wear and
overheating.
2.Check clearance of gudgeon pin in piston.
Gudgeon pin to piston clearance = 0.006 to
0.015 mm (0.0002 to 0.0006 in).
3.Check overall dimensions of gudgeon pin.
Overall length = 60.00 to 60.50 mm (2.35 to 2.4
in).
Diameter - measured at each end and centre
of pin = 23.995 to 24.00 mm (0.94 to 0.95 in).Cylinder liner bore -...

ENGINE
36
OVERHAUL Pistons - refit
CAUTION: Pistons have a 0.5 mm (0.02 in)
offset gudgeon pin which can be identified
by an arrow mark on the piston crown.
This arrow MUST always point to the front of the
engine.
1.Assemble pistons to connecting rods with
arrow on piston pointing towards domed
shaped bosses on connecting rod for RH bank
of cylinders, and arrow pointing away from
dome shaped bosses for LH bank of cylinders.
2.Clamp hexagon body ofLRT-12-013in vice.
3.Screw large nut back until flush with...

ENGINE
OVERHAUL37
Piston to cylinder bore clearance - checking
1.Starting with number 1 piston, invert piston and
with arrow on piston crown pointing towards
REAR of cylinder block, insert piston in cylinder
liner.
2.Position piston with bottom of skirt 30 mm (1.2
in) from top of cylinder block.
3.Using feeler gauges, measure and record
clearance between piston and left hand side of
cylinder - viewed from front of cylinder block:
Piston to bore clearance = 0.015 to 0.045 mm
(0.001 to 0.002 in)
4.Repeat...

ENGINE
38
OVERHAUL
9.Fit ring clamp to piston and compress piston
rings.
NOTE: Connecting rods shown in final
fitted positions.
10.Insert connecting rod and piston assembly into
respective cylinder bore ensuring domed
shaped boss on connecting rod faces towards
front of engine on RH bank of cylinders, and
towards rear on LH bank of cylinders.
11.Fit big-end bearing caps and bearing shells.
12.Fit cylinder head(s).FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
1.Restrain flywheel and remove 6 bolts...

ENGINE
OVERHAUL39
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:...

ENGINE
40
OVERHAUL
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.Ensure bolt holes are clean and dry....

ENGINE
OVERHAUL41
DRIVE PLATE AND RING GEAR ASSEMBLY
Drive plate and ring gear assembly - remove -
Drive plates fitted with shimmed hub aligner
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 clamp ring and drive plate assembly.
NOTE: Drive plate assembly is dowel
located.
4.Remove 6 socket head Allen bolts securing
hub aligner to crankshaft, remove hub aligner
and selective shim; retain shim....