Land Rover : ENGINE
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rop the hood open, disconnect the screen washer hose from the reservoir and electrical leads to the engine compartment illumination lamp. Remove the fixings, hinges to hood and lift the hood clear. Set the vehicle on level ground and apply the transmission brake. De-pressurize the fuel system. (See Fuel Injection System, Section 19). Disconnect the battery terminals and remove the battery from the vehicle. Release the hose clamp and remove the radiator bottom hose to enable the cooling system to be drained. Release the hose clamps and remove the radiator top hose and expansion tank hose. Remove the fan cowl, drive belt and viscous unit/fan assembly. Release the fixings and remove the radiator. Place an absorbent cloth around the fuel feed hose at the fuel rail and release the compression nut, remove the feed hose from the rail, seal the end of the pipes with masking tape to prevent ingress of dirt. Release the hose clamp and remove the fuel return hose from the pressure regulator, seal both openings with masking tape to prevent ingress of dirt. Remove the vacuum hose from the rear of the regulator. Detach the throttle lever return springs, remove the fixings securing the kickdown cable anchor bracket to the plenum chamber bracketry and lay the assembly to one side. DO NOT DISTURB THE KICK DOWN CABLE SETTING. Disconnect the multi-plug from the air bypass valve (stepper motor).
Voir
ENGINE
REMOVAL OF THE ENGINE FROM THE VEHICLE
I. Prop the hood open, disconnect the screen washer hose from the reservoir and electrical leads to the engine compartment illumination lamp. Remove the fixings, hinges to hood and lift the hood clear. Set the vehicle on level ground and apply the transmission brake. De-pressurize the fuel system. (See Fuel Injection System, Section Disconnect the battery terminals and remove the battery from the vehicle. R e l e a s e t h e h o s e c l a m p a n d r e m o v e t h e radiator bottom hose to enable the cooling system to be drained. R e l e a s e t h e h o s e c l a m p s a n d r e m o v e t h e radiator top hose and expansion tank hose. Remove the fan cowl, drive belt and viscous unit/fan assembly. Release the fixings and remove the radiator. Place an absorbent cloth around the fuel feed hose at the fuel rail and release the compression nut, remove the feed hose from the rail, seal the end of the pipes with masking tape to prevent ingress of dirt. Release the hose clamp and remove the fuel return hose from the pressure regulator, seal both openings with masking tape to prevent ingress of dirt. Remove the vacuum hose from the rear of the regulator. Detach the throttle lever return springs, r e m o v e t h e f i x i n g s s e c u r i n g t h e cable anchor bracket to the plenum chamber bracketry and lay the assembly to one side. DO NOT DISTURB THE KICK DOWN CABLE SETTING. Disconnect the multi-plug from the air bypass valve (stepper motor).
Release the hose clamp securing the hose to the inlet neck of the plenum chamber. Disconnect the multi-plug from the air flow sensor, release the two clips securing the air cleaner to the air flow sensor, remove the sensor complete with hose from the engine compartment. 1 5 .Release the fixings and remove the air cleaner assembly from the engine compartment. Release the alternator pivot bolts and remove the drive belt, remove the alternator fixings and withdraw the alternator. Release the idler pulley between the crankshaft pulley and compressor pulley and remove the drive belt. Release the compressor from its mounting and lay to one side. DO NOT discharge the air conditioning system.
N O T E : R e l e a s e t h e b o l t s s e c u r i n g t h e compressor mounting bracket to the engine a n d r e m o v e t h e b r a c k e t t o e n a b l e a temporary lifting eye ETC 5964 to be fitted. S e c u r e t h e l i f t i n g e y e t o t h e m o u n t i n g bracket fixing points with suitable bolts of equivalent size, pitch and thread. Leave the lifting eye attached to the engine until the engine has been reinstalled in the vehicle.
1 9 .Place a drain tray underneath the vehicle to catch any power steering fluid which may seep from the steering fluid reservoir when the hose is disconnected from the steering pump. Disconnect the hose and secure the end of it above the level of the fluid reservoir to avoid the loss of any more fluid than necessary. Seal the power steering pump and pipe opening with masking tape to prevent ingress of dirt.
C o n t i n u e d
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21. t o p u m p s t e e r i n g p o w e r h e tD i s c o n n e c t power steering box hose, seal the hose and pump opening with masking tape to prevent ingress of dirt. Wipe away any fluid that may have come into contact with the chassis or steering box. R e m o v e t h e t w o c o o l a n t h o s e s a n d o n e c r a n k c a s ebreather hose from the potentiometer side of the plenum chamber. Disconnect the potentiometer multi-plug. Remove the distributor vacuum hose from the top of the plenum chamber and disconnect the vacuum supply hose to the cruise control actuator. R e m o v e t h e s i x b o l t s a n d m a n e u v e r t h e plenum chamber off the ram housing. Disconnect the hoses from around the outside of the ram housing and remove the six bolts s e c u r i n g t h e r a m h o u s i n g t o t h e i n t a k e manifold. 27. h o u s i n g r a m t h eL i f t i n t a k e t h e o f c l e a r m a n i f o l d a n d r e m o v e i t f r o m t h e e n g i n e compartment. Place a protective cover over t h e i n t a k e m a n i f o l d o p e n i n g s t o p r e v e n t ingress of dirt. 2 0 .Disconnect the fuel temperature and coolant temperature sensor multi-plugs. 2 9 .Disconnect the High tension and Low tension leads from the coil. 3 0 .Identifye a c h o rinjector multi-plug f re-assembly and disconnect the plugs from the injectors. 3 1 .Maneuver the harnesses from behind the fuel rails and place aside , clear of the engine assembly. 3 2 . w oRemove t h e tc l a m p ssecuring the a u t o m a t i c g e a r b o x o i l c o o l e r p i p e s t o t h e bottom left hand side of the engine block. 33.Remove the top and bottom nuts securing the engine mountings at either side of the cylinder block. 3 4 .Fit suitable lifting chains to the engine lifting e y e s l o c a t e d a t t h e f r o n t o f b o t h c y l i n d e r heads and the rear of the right hand cylinder illustration for recommended chain lengths).
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KEY TO CHAIN LENGTHS Front chain in.) total overall length. Front chain 330mm in.) total overall length. R/H Rear chain 457mm in.) total overall length.
1987 R O V E R
NOTE: chain dimensions are measured from the end of the lifting hook to the end of the last link in the chain. 3 5 .Fit the chain lifting eye to a suitable hydraulic hoist. Raise the hoist sufficiently high enough to enable the engine mounting rubbers to be removed, and withdraw the rubber mountings. 3 6 .Lower the hoist until the engine rests securely on the engine mounting brackets. Remove the lifting chains and hoist. 37.Disconnect the two heater hoses located on the top of the right hand rocker cover. 3 8 .Remove the ground strap from the rear of the left hand cylinder head. 3 9 .Remove the cylinder block to hood ground strap from the retaining clip at the engine compartment closure panel. 40. h ec t r i c a l h e l e r o m t a r n e s s e s fR e m o v e l l a retaining clips on and around the rear of the engine.
4 1 .Remove the gearbox breather pipe from the retaining clip at the rear right hand lifting eye. 4 2 .Remove the top two bolts securing the bell housing to cylinder block. 43. Position a suitable hydraulic floor jack under the front differential casing, raise the front of t h e v e h i c l e s u f f i c i e n t l y t o e n a b l e t w o a x l e stands to be positioned under the front axle, lower the vehicle on to the axle stands. 4 4 .Remove the bolts securing the bell housing bottom cover, detach the cover from the bell housing and remove the gasket from the bell housing face. 45. Remove the transfer box to engine block tie b a r . 46. R e m o v e t h e n u t s s e c u r i n g t h e e x h a u s t downpipes to the manifolds, remove the heat shield from the right hand side downpipe. 47. Remove the electrical leads from the rear of the starter motor solenoid, and disconnect the m u l t i - p l u g f r o m t h e o i l l e v e l s e n s o r o n t h e side of the sump. W i t h t h e a s s i s t a n c e o f a s e c o n d p e r s o n t o rotate the engine at the crankshaft pulley, rotate the crankshaft until two of the access holes in the drive plate/ring gear assembly are visible through the bellhousing bottom cover opening. 4 9 .Remove the two bolts that are visible through the access holes, which secure the flexible drive plate to the torque converter. Mark one of the access holes and one of the bolt holes with some means of identification to enable the unit to be fitted in the same position on r e - a s s e m b l y t o m a i n t a i n t h e o r i g i n a l b u i l d setting. 5 0 . r a n k s h a f t u n t i l tR o t a t e t h e c t h e w o remaining access holes are visible, and remove the two bolts.
REVISED:
5 1 .the remaining bell housing to cylinderRemove block bolts. 5 2 .Raise the vehicle off the axle stands using a suitable hydraulic floor jack under the front axle, remove the stands and lower the vehicle to rest on its road wheels. 5 3 .Fit the engine lifting eyes, locate the chain lifting eye into the floor crane. 5 4 .Remove the starter motor ground strap from the chassis. 5 5 .Place a hydraulic floor jack under the gearbox bell housing to support the gearbox when the engine and gearbox are separated. 5 6 . h e t a s e e i t t l e , a lC a r e f u l l y r a i s e t h e c r a n e engine to gearbox joint faces apart, steady the engine on the crane. 5 7 . r e n h e r e aE n s u r e t l e c t r i c a l e s t r i c t i n g e o r harnesses, hoses, pipes, or components that will prevent the engine being raised clear of the engine compartment. 5 8 .Slowly-raise the engine clear of the engine compartment, move the engine away from vehicle and place on a suitable engine stand. THE ENGINE TO THE VEHICLE
59. Fit the lifting chains to the lifting eyes on the engine as previously described in the removal procedure. 60. Raise the engine on a floor crane and lower it into the engine compartment, ensuring that all harnesses, hoses, pipes and components are clear of the engine assembly.
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Continued
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6 1 .assistance, maneuver the engine until theWith bottom two engine bolt holes align with the appropriate two holes in the bell housing. Fit the two bolts and partially tighten. Ensure that
two cylinder block dowels locate in their respective holes in the bell housing. 62. Remove the hydraulic floor jack and lower the hoist until the engine rests securely on the engine mounting brackets. 63. Fit the top two bell housing to engine cylinder block securing bolts. Tighten to the specified torque (see section values). 6 4 . tF i t t o c y l i n d e r h e r e m a i n i n g b e l l h o u s i n g b l o c k b o l t s , a n d t i g h t e n t o t h e s p e c i f i e d torque (including the two bottom section values). 6 5 . r o m a s s s i s t a n c e f e r s o n t e c o n d pW i t h a o r o t a t e t h e c r a n k s h a f t p u l l e y , l i n e u p t h e previously marked drive plate access hole with t h e r e s p e c t i v e b o l t h o l e i n t h e t o r q u e converter. Fit the two bolts and tighten to the s p e c i f i e d t o r q u e ( s e e s e c t i o n values). 6 6 . R o t a t e t h e c r a n k s h a f t 1 8 0 a n d f i t t h e remaining two bolts to the flexible drive plate, tighten to the specified torque (see section values). 67. Fit new gasket and refit the bottom cover, tighten the bolts to the specified torque (see section values). 6 8 .Fit new exhaust flange gaskets, fit the exhaust to the manifold. 69. R e f i t a l l h a r n e s s e s , g r o u n d s t r a p s b r e a t h e r pipes and hoses to their correct locations at the rear of the engine. 7 0 . tR a i s e a n g i n e e h e e f i t t n d r n g i n e h e e m o u n t i n g r u b b e r s , t i g h t e n t h e n u t s t o t h e s p e c i f i e d t o r q u e ( s e e s e c t i o n values). 7 1 .Remove the temporary lifting eye ETC 5964 and reverse the instructions1to 32, ensuring that all electrical plugs and harnesses are fitted to their correct locations.
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DISMANTLE AND OVERHAUL THE ENGINE Remove the engine from the vehicle and clean the e x t e r i o r . I n t h e i n t e r e s t s o f s a f e t y a n d e f f i c i e n t working secure the engine to an approved engine stand. Drain the sump oil into a suitable container. Special tools:
R0605351 bolts Guide 186537Torque wrench Piston pin remover/replacer Basic
Adaptor remover/replacer piston pin Spring compressor R 0 6 0 0 9 5 9 Drift Valve guide replacement intake and exhaust MS76Valve cutter handle set MS621Valve seat cutter Distance piece for valve guide Drift for guide removal intake and exhaust R01014 Crankshaft rear seal sleeve REMOVE THE INTAKE MANIFOLD
Release the hose cl ecuring the hose to the rear of the water Detach the retaining clips from the top of the injectors. Remove the four bolts securing the fuel rail to the manifold. Withdraw the fuel rail and injectors.
REVISED: JUNE 87
Evenly loosen and remove the twelve bolts securing the intake manifold to the cylinder h e a d s . 6 .the intake manifold from the cylinderLift h e a d s . 7 .Wipe away any surplus coolant lying on the manifold gasket and remove the gasket clamp bolts and remove the clamps. Lift off the gasket and seals.
Remove exhaust manifolds
1. Bend back the lock tabs, and remove the eight bolts securing each manifold, and withdraw the manifolds and gaskets.
Remove water pump
1.Remove the fifteen bolts and withdraw the water pump and joint washer.
NOTE: The water pump is not a serviceable item, i n t h e e v e n t o f b e a r i n g f a i l u r e o r s e v e r e c o r r o s i o n t o t h e p u m p i m p e l l e r vanes, fit a new water pump assembly.
REVISED:
REMOVE AND OVERHAUL ROCKER SHAFTS AND VALVE GEAR Remove the spark plug leads from the spark plugs and retaining clips, release the four screws and lift off the rocker covers. Remove the four rocker shaft retaining bolts and lift off the assembly.
W i t h d r a w t h e a n d r e t a i n i n t h e sequence removed. Remove the hydraulic tappets and place to one side with their respective pushrods. If a tappet cannot be removed leave in position until the camshaft is removed.
SEPT. 90
C o n t i n u e d ’
5
ENGINE
Dismantle rocker shafts
5 .Remove the cotter pin from one end of the rocker shaft. 6 . h e tW i t h d r a w n d a o m p o n e n t s cl l o w i n g o f r e t a i n t h e m i n t h e c o r r e c t s e q u e n c e f o r re-assembly: 7 .A plain washer. 8 .A wave washer. Rocker arms. 1 0 .Brackets. 11.Springs. 12, w e a r , i n c o m p o n e n t f o rE x a m i n e e a c h particular the rockers and shafts. Discard weak or broken springs.
1 7 . 1 8
T a p p e t s M U S T r o t a t e a n d a c i r c u l a r w e a r condition is normal. Tappets with this wear pattern can be refitted provided there are no other defects. In the case of a non-rotating tappet, fit a new replacement and check camshaft lobes for wear; also ensure the new tappet rotates freely in the cylinder block.
Fit a new hydraulic tappet if the area where t h e contacts is rough or otherwise damaged. Fit a new if it is bent or has a rough or damaged ball end or seat.
Assemble rocker shafts
Inspect tappets and 21.Both shafts must be assembled so that the 1 3 . i n s p e c t i a p p e t ; tH y d r a u l i c groove is at the one o’clock identification u t e r o n d a n n e r s u r f a c e s o f t h e b o d y f o r b l o w h o l e s a n d position with the push rod end of the rockers scoring. Replace hydraulic tappet if body is to the right. roughly scored or grooved, or has a blow hole extending through the wail in a position to permit oil leakage from the lower chamber. 1 4 .The prominent wear pattern just above the lower end of the body should not be considered a defect unless it is definitely grooved or scored. is caused by side thrust of the cam against the body while the tappet is moving vertically in its bore. 1 5 . h e tI n s p e c t c a m c o n t a c t s u r f a c e o f t h e t a p p e t s . F i t n e w t a p p e t s i f t h e s u r f a c e i s excessively worn or damaged. 1 6 .A hydraulic tappet body that has been rotating will have a round wear pattern and a non-rotating tappet body will have a square the shafts and rockers areCAUTION: If wear pattern with a very slight depression nearincorrectly assembled and fitted to the engine, the centre. o i lt h es u p p l y e b i l l w h a f t s s o c k e r r h e tt o restricted.
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REVISED: SEPT. 90
22. Fit a cotter pin to one end of the rocker shaft. 23. Slide a plain washer over the long end of the shaft to contact the cotter pin. 24. Fit a wave washer to contact the plain washer.
2 5 .Early type rocker arms are angled. They must be fitted so that the valve end of the rocker arms angle away from each other as shown. 2 6 .On later type rocker arms the valve end is offset and must be fitted as shown. 2 7 . late types of rocker armsEarly and interchangeable provided the complete set is c h a n g e d .
2 8 . A s s e m b l e t h e r o c k e r a r m s , b r a c k e t s a n d springs to the rocker shaft. 29. Compress the springs, brackets and rockers, and fit a wave washer, plain washer and cotter pin to the end of the rocker shaft. 30. Fit the locating bolts through the brackets and place the assemblies to one side.
REVISED:
REMOVE AND OVERHAUL THE CYLINDER HEADS Evenly loosen the fourteen cylinder head bolts reversing the tightening order. Before removing the heads mark them relative to the LH and RH side of the engine. Lift off the cylinder heads and discard the g a s k e t .
Dismantle cylinder heads 4.Remove the spark plugs. Using the valve spring compressor 106A or a suitable alternative, remove the valves, s p r i n g s a n d u m b r e l l a s e a l s , r e t a i n t h e m i n sequence for refitting. Discard the umbrella seals fitted to the inlet valves only.
SEPT.
90
Continued
7
E N G I N E
6. Clean the combustion chambers with a soft w i r e b r u s h . 7.Clean the valves. 8. Clean the valve guide bores.
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Regrind or fit new valves as necessary. a valve must be ground to a knife-edge to obtain a true seat, fit a new valve. The correct angle for the valve seating face is ees degr The correct angle for the seat is degrees and the seat witness should be towards the outer edge.
Check the valve guides and fit replacements as necessary.Using the valve guide remover 274401, drive out the old guides from the valve spring seat face of the cylinder head.
Fit new valve guides
1 9 8 7 R O V E R
NOTE: Service valve guides are 0.025 mm ( 0 . 0 0 1 i n ) l a r g e r o n t h e o u t s i d e d i a m e t e r t h a n t h e o r i g i n a l e q u i p m e n t t o e n s u r e interference fit.
Lubricate the new valve guide and place in p o s i t i o n .
A.Using guide drift R0600959 partially drive the guide into the head. R e m o v e t h e d r i f t R 0 6 0 0 9 5 9 a n d p l a c e d i s t a n c e p i e c e o v e r t h e v a l v e g u i d e , continue to drift the guide into the cylinder until drift contacts the distance piece. C.Alternatively drift the guide into the cylinder head until it protrudes abovemm in) thevalve spring recess in the head.
Examine and fit new valve seats
Check the valve seats for wear, pits and burning and fit new inserts if necessary.
REVISED: SEPT. 90
1 6 .Remove the old seat inserts by grinding them away until they are thin enough to be cracked and pried out. 1 7 . t v e n l y oHeat the cylinder head e approximately 65°C 1 8 .Press the new insert into the recess in the cylinder head.
NOTE: r e e a t s a l v e v an s e r t s iS e r v i c e available in two over-sizes 0.25 and 0.50 m m ( 0 . 0 1 0 a n d 0 . 0 2 0 i n ) l a r g e r o n t h e outside diameter to ensure interference fit.
1 9 .Using service tool MS621 if necessary, cut the valve seats to degrees. 2 0 .The nominal seat width is 1.5 mm (0.059 in). If the seat exceeds 2.0 mm (0.078 in) it should be reduced to the specified width by the use of 20 and 70 cutters. 2 1 .The inlet valve seat diameter: ‘A’ is 37.03 mm in) and the exhaust valve seat is 31.50 mm (1.240).
REVISED:
E N G I N
22. Ensure that the cutter blades are correctly fitted to the cutter head with the angled end of the blade downwards facing the work, as illustrated. Check that the cutter blades are adjusted so that the middle of the blade contacts the area of material to be cut. Use the key provided in the hand set MS76. Use light pressure and remove only the minimum material necessary.
ST1 024M
23.Coat the valve seat with a small quantity of ‘engineers’ blue, revolve a properly ground valve against the seat. A continuous fine line should appear round the valve. If there is a gap of not more than mm it can be corrected by lapping. 2 4 . o f c e l l o p h a n eAlternatively, i n s e r t a s t r i p between the valve and seat, hold the valve d o w n b y t h e s t e m a n d s l o w l y p u l l o u t t h e c e l l o p h a n e . t h e r e i s a d r a g t h e s e a l i s satisfactory in that spot. Repeat this in at least eight places. Lapping-in will correct a small open spot.
JUNE
87
C o n t i n u e d
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valves to cylinder head 25. Before fitting the valves and springs the height o f e a c h v a l v e a b o v e t h e h e a d m u s t b e checked. Insert each valve in turn in its guide and while holding the head firmly against the seat, measure the height of the stem above the valve spring seat surface. This dimension m u s t n o t e x c e e d 4 7 . 6 3 m m ( 1 . 8 7 5 i n ) . I f necessary fit a new valve or grind the end of the valve stem. 26. Lubricate thevalvestems and assemble the valves, fit new umbrella seals and springs, fit the caps, compress the springs and caps using spring compressor and secure the springs in place with the Note that the u m b r e l l a s e a l s a r e o n l y f i t t e d t o t h e i n l e t valves.
Reclaiming cylinder head threads
Damaged or stripped threads in the cylinder head can be salvaged by fitting as follows:
Holes A These three holes may be drilled 0.3906 i n d i a . x 0 . 9 3 7 + 0 . 0 4 0 i n d e e p . T a p p e d w i t h Helicoil Tap No. 6 CPBor6CS x 0.875 in deep UNC insert).
1
0
REVISED:
ROVER
H o l e s These eight holes may be drilled 0.3906 i n d i a . x 0 . 8 1 2 + 0 . 0 4 0 i n d e e p . T a p p e d w i t h Helicoil Tap No. 6 CBB 0.749 in deep UNC insert). Holes C These four holes may be drilled 0.3906 in dia x 0.937 + 0.040 in deep. Tapped with Helicoil Tap No. 6 CPB or 6CS x 0.875 in deep UNC insert). Holes D These four holes may be drilled 0.261 in dia x 0.675 + 0.040 in deep. Tapped with Helicoil Tap No. 4 CPB or 4CS x 0.625 in deep UNC insert). Holes E These six holes may be drilled 0.3906 in dia x 0.937 + 0.040 in deep. Tapped with Helicoil Tap No. 6 CPB or 6CS x 0.875 in deep UNC insert).
NOTE: Right-hand cylinder head illustrated.
H
Exhaust manifold face Intake manifold face Front face Rear face
Front of engine
87
1987-88-89
REMOVE THE FLEXIBLE DRIVE PLATE AND RING GEAR ASSEMBLY
NOTE: To ensure the following components a r e r e - a s s e m b l e d i n t h e i r c o r r e c t r a d i a l p o s i t i o n s , s c r i b e e a c h c o m p o n e n t w i t h a n identification line to enable each part to be re-assembled in the correct relationship to one another.
Remove the four retaining bolts. Withdraw the clamp ring, flexible drive plate, hub aligner and ring gear assembly. Remove the six socket head bolts securing the c r a n k s h a f t a d a p t o r p l a t e a n d s h i m t o t h e crankshaft flange. Withdraw the crankshaft adaptor plate and shim. Inspect the ring gear assembly for distortion, cracks, chipped or badly worn teeth. If ring gear is in poor condition fit a complete new assembly.
REMOVE TIMING GEAR COVER AND WATER P U M P
1.Place an oil drip-tray beneath the timing cover and remove the oil filter element. 2. Remove the crankshaft pulley bolt and special washer and withdraw the pulley.
Remove the two bolts securing the sump to the bottom of the timing cover. Remove the remaining timing cover retaining bolts and withdraw the cover complete with oil pump.
REVISED: SEPT.
C o n t i n u e d
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