Range-Rover-Manual-Engine, Land Rover
[ Pobierz całość w formacie 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.
6.
,.‘.
:.
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.
7.
8.
9.
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
'- . .
., '_
,;'
,' 'y?.,
1
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.
-.
2
,.:,
‘,
:,
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
3
REVISED: jUNE 87
3
., ,.‘,.
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
pin
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.
4
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
6.
1.
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.
7.
2.
8.
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
5
;-
[ Pobierz całość w formacie PDF ]