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

							ENGINE
42
OVERHAUL Later engines with modified’one-piece’starter
ring gear
1.Remove 4 bolts securing drive plate clamp
ring, remove clamp ring.
2.Remove drive plate.
3.Remove 6 Allen bolts securing starter ring gear
to crankshaft, remove ring gear.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. 
						

							ENGINE
OVERHAUL43
Drive plate and ring gear assembly - refit - Drive
plates fitted with shimmed hub aligner
CAUTION: To prevent distortion to drive
plate when bolted to torque converter,
drive plate setting height must be checked
as follows:
1.Ensure bolt holes in crankshaft are clean and
dry. Fit original selective shim and hub aligner,
fit Allen bolts and tighten to 85 Nm (63 lbf.ft).
2.Fit drive plate assembly and clamp 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.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 Allen bolts
and tighten to 85 Nm (63 lbf.ft).
7.Fit drive plate assembly and clamp 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). 
						

							ENGINE
44
OVERHAUL Drive plate and ring gear assembly - refit - Drive
plates with unshimmed hub aligner and later
engines fitted with modified’one-piece’starter
ring gear
NOTE: It is not necessary to check setting
height on drive plates fitted to the above
engines. On early engines, balance
weights are on engine side of drive plate;
replacement drive plates will have balance
weights on torque converter side.
Early engines with unshimmed hub aligner
1.Ensure bolt holes in crankshaft are clean and
dry. Fit hub aligner, fit Allen bolts and tighten to
78 Nm (58 lbf.ft).
2.Fit ring gear assembly, spacer, drive plate and
clamp 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 clamp ring bolts and tighten to 45 Nm (33
lbf.ft).
Later engines with modified’one-piece’starter
ring gear
1.Ensure bolt holes in crankshaft are clean and
dry
2.Fit starter ring gear, fit Allen bolts and tighten
to 85 Nm (63 lbf.ft).
3.Fit drive plate and clamp ring, fit bolts and
tighten to 45 Nm (33 lbf.ft.CRANKSHAFT, MAIN AND BIG-END BEARINGS
Big-end bearings - remove
1.Remove timing chain and gears.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. 
						

							ENGINE
OVERHAUL45
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.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. 
						

							ENGINE
46
OVERHAUL
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.Fittiming chain and gears.Crankshaft - remove
1.Remove flywheel or drive plate and ring gear
assembly.
2.Remove timing cover.
3.Remove timing chain and 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 Allen 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. 
						

							ENGINE
OVERHAUL47
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 cruciform seals from rear
main bearing cap.
12.Remove all traces of sealant from bearing cap
and cylinder block.
13.Remove Woodruff key from crankshaft.Knock sensor - remove
1.Remove knock sensor from cylinder block. 
						

							ENGINE
48
OVERHAUL Crankshaft position sensor - remove
1.Remove 2 bolts securing crankshaft position
sensor to gearbox adaptor plate, remove
sensor; collect spacer - if fitted.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. 
						

							ENGINE
OVERHAUL49
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.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. 
						

							ENGINE
50
OVERHAUL 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.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. 
						

							ENGINE
OVERHAUL51
7.Fit new cruciform seals to rear main bearing
cap.
CAUTION: Seals must protrude
approximately 1.5 mm (0.05 in) above
bearing cap face, do not trim off excess
material at this stage.
8.Apply a 3 mm (0.12 in) wide bead of sealant,
Part number STC 50550 to bearing cap rear
mating face on cylinder block.
CAUTION: Ensure sealant does not enter
bolt holes.
9.Lubricate rear main bearing shell and cruciform
seals with engine oil, carefully fit rear main
bearing cap assembly; fit and tighten rear 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 Allen bolt is fitted to rear
main bearing cap on RH side of cylinder block
adjacent to starter motor aperture.
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 side bolts numbers 11 to 15 -
45 Nm (34 lbf.ft)
Main bearing cap bolts numbers 1 to 8 - 72 Nm
(54 lbf.ft)
Main bearing cap bolts numbers 9 and 10 - 92
Nm (68 lbf.ft)
Main bearing cap side bolts numbers 16 to 20 -
45 Nm (34 lbf.ft)
13.Trim off excess material from rear main
bearing cap cruciform 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.