Land Rover 4 0 4 6 V8 Engine Overhaul 4th Edition Rover Manual
Have a look at the manual Land Rover 4 0 4 6 V8 Engine Overhaul 4th 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 Oil pump Inner to outer rotor clearance - maximum 0.25 mm.........0.01 in Rotors to cover plate clearance - maximum 0.1 mm.......0.004 in Drive gear wear step depth - maximum 0.15 mm...........0.006 in Oil pressure relief valve Spring free length 60.0 mm........................... 2.4in Oil pressure by-pass valve Spring free length 60.0 mm........................... 2.4in Camshaft End-float 0.05 to 0.35 mm..................................0.002 to 0.014 in Maximum run-out 0.05 to 0.25 mm............................0.002 to 0.010 in 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 0.30 to 0.50 mm...........................0.012 to 0.02 in 2nd compression 0.40 to 0.65 mm..........................0.016 to 0.026 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 0.015 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 End-float on crankshaft 0.15 to 0.36 mm.......................0.006 to 0.014 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
INFORMATION DATA, TORQUE & TOOLS3 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 0.08 to 0.26 mm..................................0.003 to 0.010 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 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 - Shimmed drive plate only: 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 3 Nm.................................. 2.5lbf.ft Stage 2 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 side bolts - Numbers 11 to 15: +* Stage 1 - initial torque 13.5 Nm....................... 10lbf.ft Stage 2 - final torque 45 Nm....................... 34lbf.ft Main bearing cap side bolts - Numbers 16 to 20: +* Stage 1 - initial torque 13.5 Nm....................... 10lbf.ft Stage 2 - final torque 45 Nm....................... 34lbf.ft Main bearing cap bolts - Nos. 1 to 8: +* Stage 1 - initial torque 13.5 Nm....................... 10lbf.ft Stage 2 - final torque 72 Nm....................... 54lbf.ft 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 Flywheel bolts 78 Nm.............................. 58lbf.ft Drive plate assembly bolts 45 Nm..................... 33lbf.ft Drive plate hub aligner to crankshaft Allen bolts - Shimmed hub aligner 85 Nm................... 63lbf.ft Drive plate hub aligner to crankshaft Allen bolts - Unshimmed hub aligner 78 Nm................. 58lbf.ft Starter ring gear to crankshaft Allen bolts - Modified starter ring gear 85 Nm...................... 63lbf.ft Oil sump drain plug - Early engines fitted with pressed steel sump 45 Nm.......................... 33lbf.ft Oil sump drain plug - Later engines fitted with cast alloy sump 24 Nm............................. 18lbf.ft Oil sump nuts and bolts - Early engines fitted with pressed steel sump + 23 Nm........................ 17lbf.ft Oil sump bolts - Later engines fitted with cast alloy sump + 22 Nm............................... 16lbf.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
INFORMATION 2 TORQUE WRENCH SETTINGS Timing cover/coolant pump to cylinder block bolts + ** 22 Nm.............................. 16lbf.ft Oil pick-up pipe to oil pump bolts 10 Nm................ 8lbf.ft Oil pick-up pipe nut 22 Nm.......................... 16lbf.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 Secondary air adapters - If fitted **** 33 Nm............. 24lbf.ft + Tighten in sequence * Lightly oil threads prior to assembly. ** Coat threads with sealant, Part number STC 50552 prior to assembly. *** New bolts must be fitted **** New adapters must be fitted
INFORMATION TORQUE WRENCH SETTINGS3 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 4 TORQUE WRENCH SETTINGS SEALANTS A range of sealants is used when overhauling the engine, the sealant application, together with the appropriate part numbers is listed below. Timing cover bolts STC 50552........................... Sump to cylinder block - Early engines fitted with pressed steel sump STC 50550.......................... Sump to cylinder block - cruciform seals - Later engines fitted with cast alloy sump STC 50550.............. Sump to front cover and rear main bearing cap - Later engines fitted with cast alloy sump STC 50550......... Rear main bearing cap to cylinder block mating faceSTC 50550 ...................................... Oil pump cover plate screws and bolt STC 50552............ Cylinder head threaded core plugs STC 50552..............
INFORMATION SERVICE TOOLS1 SERVICE TOOLS Land Rover Number Description LRT-12-013 Remover/replacer - gudgeon pin................................ LRT-12-014 Adapter remover/replacer - gudgeon pin................................ LRT-12-034 Valve spring compressor................................ LRT-12-037 Drift - remover - valve guide................................ LRT-12-039A Drift - replacer - valve guide............................... LRT-12-080 Crankshaft pulley retaining tool................................ 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-12-126/1 Bush - remover/replacer - gudgeon pin.............................. LRT-12-126/2 Adapter - remover/replacer - gudgeon pin.............................. LRT-12-183 Sump alignment tool - 2 off................................ LRT-12-208 Distance piece - valve guide................................ LRT-99-003 Driver handle................................ The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently and safely. Where special tools are specified,only these tools should be used to avoid the possibility of personal injury or damage to the components.Also, the amount of time they save can be considerable. Special tools bulletins will be issued periodically giving details of new tools as they are introduced. All orders and enquiries from the United Kingdom and European countries except Germany, Austria, Switzerland and Spain and countries not in the following list should be sent direct to: SPX UK Ltd., Genoa House, Everdon Park, Daventry, Northants, England, NN11 5YJ Telephone: 00 44 (0) 132 7303467/303455 Fax: 00 44 (0) 1327 706632 e-mail: [email protected] Overseas orders for the following countries should be placed with the local XPS distributor. Germany, Austria and Switzerland SPX Europe GMBH, Porschestrasse 4, 63512 Hainburg, Germany, Telephone: 0049 61829590 Fax: 0049 6182959299
INFORMATION 2 SERVICE TOOLS Spain SPX Iberica SA, C/Francisco Aritio 158 nave 72 (Nudo Oeste), 19004 Guadalajara, Spain Telephone: 0034 949208381 Fax: 0034 949208327 North America SPX Corporation, 665, Eisenhower Drive, Owatonna, MN 55060, USA Telephone: 0018 772979110 Fax: 0018 005787375 SPX Australia, 28, Clayton Road, Notting Hill, Victoria 3168, Australia, Telephone: 00 (61) 00395446222 Fax: 00 (61) 0395445222 e-mail: [email protected] Japan and East Asia Jatek Ltd., 5 - 53, Minawacho 2-chome, Kohoku-ku, Yokohama, Kanagawa 223-0051, Japan Telephone: 0081 455627700 Fax: 0081 455627800
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 6............................................ Valves, valve springs and guides - inspection 7............................. Valve guides - renew 9................................................ Valve seat inserts - inspection 10........................................ Valve seat inserts - renew 11........................................... Valve seats and seat inserts - refacing 11.................................. Valves - lapping-in 12................................................. Engines fitted with secondary air injection (SAI) 13.......................... Valves and springs - refit 13............................................ Cylinder head - refit 14................................................ TIMING CHAIN AND GEARS 15......................................... Sump - remove 15.................................................... Timing cover - remove 15.............................................. Timing gears - remove 17.............................................. Timing chain and gears - inspection 17.................................... Timing gears - refit 18................................................. Timing cover - refit 19................................................. Sump - refit 21....................................................... OIL PUMP 24....................................................... Oil pump - remove 24................................................. Oil pressure by-pass valve - remove 25................................... Oil pressure relief valve - remove 25...................................... Oil pump - inspection 26............................................... Oil pressure by-pass valve - inspection 27................................. Oil pressure relief valve - inspection 27.................................... Oil pump - refit 28.................................................... Oil pressure by-pass valve - refit 28...................................... Oil pressure relief valve - refit 29......................................... CAMSHAFT AND TAPPETS 29......................................... Camshaft end-float - check 29.......................................... Camshaft and tappets - remove 30....................................... Camshaft and tappets - inspection 31..................................... Camshaft and tappets - refit 31.......................................... PISTONS, CONNECTING RODS, PISTON RINGS AND CYLINDER BORES 32... Pistons and connecting rods - remove 32.................................. Piston rings - remove 32............................................... Piston rings - inspection 33.............................................