Range-Rover-Manual-Engine.pdf

ENGINE

13.

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.

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.

REMOVAL OF THE ENGINE FROM THE VEHICLE

14.

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.

15.

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).

16.

17.

18.

,.‘.

NOTE: Release the bolts securing the

compressor mounting bracket to the engine

and remove the bracket to enable a

temporary lifting eye ETC 5964 to be fitted.

Secure the lifting eye to the mounting

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.

10.

19.

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.

11.

20.

12.

Continued

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,;' ,' 'y?.,

1987 MNbt

ROVER

‘_

21.

Disconnect the power steering pump to

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.

Remove the two coolant hoses and one

crankcase

breather

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.

Remove the six bolts and maneuver the

plenum chamber off the ram housing.

Disconnect the hoses from around the outside

of the ram housing and remove the six bolts

securing the ram housing to the intake

manifold.

Lift the ram housing clear of the intake

manifold and remove it from the engine

compartment. Place a protective cover over

the intake manifold openings to prevent

ingress of dirt.

Disconnect the fuel temperature and coolant

temperature sensor multi-plugs.

Disconnect the High tension and Low tension

leads from the coil.

Identify each injector multi-plug for

re-assembly and disconnect the plugs from the

injectors.

Maneuver the harnesses from behind the fuel

rails and place aside , clear of the engine

assembly.

Remove the two clamps securing the

automatic gearbox oil cooler pipes to the

bottom left hand side of the engine block.

Remove the top and bottom nuts securing the

engine mountings at either side of the cylinder

block.

Fit suitable lifting chains to the engine lifting

eyes located at the front of both cylinder

heads and the rear of the right hand cylinder

head.(See illustration for recommended chain

lengths).

KEY TO CHAIN LENGTHS

27.

L/H Front chain 356min

(14 in.) total overall length.

R/H Front chain 330mm

(13 in.) total overall length.

R/H Rear chain 457mm

(18 in.) total overall length.

20.

NOTE: All chain dimensions are measured

from the end of the lifting hook to the end

of the last link in the chain.

29.

30.

35.

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.

Lower the hoist until the engine rests securely

on the engine mounting brackets. Remove the

lifting chains and hoist.

Disconnect the two heater hoses located on

the top of the right hand rocker cover.

Remove the ground strap from the rear of the

left hand cylinder head.

Remove the cylinder block to hood ground

strap from the retaining clip at the engine

compartment closure panel.

Remove all electrical harnesses from the

retaining clips on and around the rear of the

engine.

31.

36.

32.

37.

33.

38.

34.

39.

40.

,.:,

‘, :,

41.

Remove the gearbox breather pipe from the

retaining clip at the rear right hand lifting eye.

Remove the top two bolts securing the bell

housing to cylinder block.

Position a suitable hydraulic floor jack under

the front differential casing, raise the front of

the vehicle sufficiently to enable two axle

stands to be positioned under the front axle,

lower the vehicle on to the axle stands.

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.

Remove the transfer box to engine block tie

bar.

Remove the nuts securing the exhaust

downpipes to the manifolds, remove the heat

shield from the right hand side downpipe.

Remove the electrical leads from the rear of

the starter motor solenoid, and disconnect the

multi-plug from the oil level sensor on the

side of the sump.

With the assistance of a second person to

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.

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

re-assembly to maintain the original build

setting.

Rotate the crankshaft 180” until the two

remaining access holes are visible, and remove

the two bolts.

42.

43.

44.

RRl8OBE

45.

46.

51.

Remove the remaining bell housing to cylinder

block bolts.

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.

Fit the engine lifting eyes, locate the chain

lifting eye into the floor crane.

Remove the starter motor ground strap from

the chassis.

Place a hydraulic floor jack under the gearbox

bell housing to support the gearbox when the

engine and gearbox are separated.

Carefully raise the crane a little, ease the

engine to gearbox joint faces apart, steady the

engine on the crane.

Ensure there are no restricting electrical

harnesses, hoses, pipes, or components that

will prevent the engine being raised clear of

the engine compartment.

Slowly-raise the engine clear of the engine

compartment, move the engine away from

vehicle and place on a suitable engine stand.

52.

47.

53.

40.

54.

55.

‘_

‘,.

49.

56.

57.

’

.‘.

.:’

58.

50.

:., ::

FllTlNG 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.

Continued

REVISED: jUNE 87

., ,.‘,.

61. With assistance, maneuver the engine until the

bottom two engine bolt holes align with the

appropriate two holes in the bell housing. Fit

the two bolts and partially tighten. Ensure that

:he two cylinder block dowels locate in their

respective holes in the bell housing.

Remove the hydraulic floor jack and lower the

hoist until the engine rests securely on the

engine mounting brackets.

Fit the top two bell housing to engine cylinder

block securing bolts. Tighten to the specified

torque (see section OC-Torque values).

Fit the remaining bell housing to cylinder

block bolts, and tighten to the specified

torque (including the two bottom bolts).(see

section 06.Torque values).

With assistance from a second person to

rotate the crankshaft pulley, line up the

previously marked drive plate access hole with

the respective bolt hole in the torque

converter. Fit the two bolts and tighten to the

specified torque (see section 06-Torque

values).

Rotate the crankshaft 180” and fit the

remaining two bolts to the flexible drive plate,

tighten to the specified torque (see section

OC-Torque values).

Fit new gasket and refit the bottom cover,

tighten the bolts to the specified torque (see

section OCTorque values).

Fit new exhaust flange gaskets, fit the exhaust

to the manifold.

DISMANTLE AND OVERHAUL THE ENGINE

. .

Remove the engine from the vehicle and clean the

exterior. In the interests of safety and efficient

working secure the engine to an approved engine

stand. Drain the sump oil into a suitable container.

62.

Special tools:

63.

R0605351 - Guide bolts

186537 - Torque wrench

18G1150 - Piston pin remover/replacer - Basic

tool

18G1150E - Adaptor remover/replacer - piston

16C106A - Spring compressor

R0600959 - Drift - Valve guide replacement -

intake and exhaust

MS76 - Valve cutter handle set

MS621 - Valve seat cutter

R0605774A - Distance piece for valve guide

R0274401A - Drift for guide removal - intake

and exhaust

64.

65.

66.

R01014

- Crankshaft rear seal sleeve

REMOVE THE INTAKE MANIFOLD

67.

Release the hose clamp securing the hose to

the rear of the water pimp

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.

68.

69. Refit all harnesses, ground straps breather

pipes and hoses to their correct locations at

the rear of the engine.

Raise the engine and refit the engine

mounting rubbers, tighten the nuts to the

specified torque (see section 06-Torque

values).

Remove the temporary lifting eye ETC 5964

and reverse the instructions 1 to 32, ensuring

that all electrical plugs and harnesses are fitted

to their correct locations.

70.

71.

REVISED: JUNE 87

:..,..

Evenly loosen and remove the twelve bolts

securing the intake manifold to the cylinder

heads.

Lift the intake manifold from the cylinder

heads.

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 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.

Remove exhaust manifolds

1. Bend back the lock tabs, and remove the eight

bolts securing each manifold, and withdraw

the manifolds and gaskets.

.:, :.

Withdraw the pushrods and retain in the

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.

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, in the event of bearing failure or

severe corrosion to the pump impeller

vanes, fit a new water pump assembly.

Continued’

REVISED: SEPT. 90

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