Land Rover Engine 2.0 Litre L Series. Manual — part 13
ENGINE
42
OVERHAUL
Crankshaft - inspection
1. Clean crankshaft, ensure all oilways are clear.
2. Check crankshaft journals for wear and ovality,
make three checks at 120
°
intervals in centre of
journals.
Crankshaft bearing journal diameters:
Main bearings = 60.703 to 60.719 mm
Big-end bearings = 57.683 to 57.696 mm
Clearance in bearings = 0.005 mm
CAUTION: Crankshaft journals may not be
reground undersize, if journals are worn,
crankshaft must be replaced. Main and
big-end bearings are only available in one size
and should always be replaced whenever
crankshaft has been removed.
3. Check thrust washers for wear and scoring,
replace as necessary:
Thrust washer thickness = 2.31 to 2.36 mm
Crankshaft - refit
CAUTION: If crankshaft end-float
exceeded 0.26 mm, new thrust washers
must be fitted.
1. Clean main bearing shell locations in cylinder
block, clean main bearing caps.
2. Check that ring dowels are fitted in main
bearing cap locations and that bolt holes are
clean and dry.
3. Check threads of main bearing cap bolts for
damage, renew bolts in pairs.
4. Lubricate new upper main bearing shells with
engine oil and ensuring that they are centrally
positioned, fit to their locations in cylinder
block.
NOTE: These bearing shells are grooved.
5. Lubricate thrust washers with engine oil and fit,
oil groove side outwards to each side of centre
- (Number 3) main bearing in cylinder block.
6. Lubricate crankshaft journals with engine oil
and using assistance, position crankshaft in
cylinder block.
CAUTION: Ensure thrust washers are not
displaced as crankshaft is fitted.
7. Lubricate new main bearing shells with engine
oil and fit to main bearing caps.
NOTE: These bearing shells are plain.
8. Fit main bearing caps ensuring that they are
correctly orientated and in their fitted order.
CAUTION: Do not apply sealant to grooves
in front - (Number 1) main bearing cap
until immediately before sump is fitted.
ENGINE
OVERHAUL
43
9. Lubricate threads of main bearing cap bolts
with engine oil, fit and lightly tighten bolts.
10. Starting from the centre - Number 3 main
bearing cap and working outwards, tighten
bolts to 112 Nm.
11. Check that crankshaft rotates smoothly.
12. Re-check crankshaft end-float. See this
section
CAUTION: If original thrust washers have
been refitted and end-float exceeds 0.26
mm, crankshaft must be removed and new
thrust washers fitted. If, with new thrust washers
fitted, end-float is still excessive, crankshaft
must be replaced.
Crankshaft rear oil seal - refit
CAUTION: Rear oil seal and housing must
be fitted prior to fitting sump.
1. Ensure oil seal running surfaces on crankshaft
and oil seal housing mating surface on cylinder
block are clean and oil free and that bolt and
dowel holes are clean and dry.
CAUTION: Do not lubricate oil seal or
running surface on crankshaft. The oil
seal is pre-lubricated at manufacture. Do
not separate protector sleeve from oil seal and
do not touch lip of seal. If seal is inadvertently
handled it must not be fitted as the coating
applied to the seal during manufacture will be
destroyed and oil leakage can result.
2. Slide oil seal protector sleeve, oil seal and
housing over end of crankshaft.
3. Position oil seal and housing on cylinder block.
NOTE: Oil seal protector will be displaced
as seal and housing are fitted.
4. Fit bolts and working in sequence shown,
tighten to 8 Nm.
ENGINE
44
OVERHAUL
5. Apply a 1 mm thick bead of sealant, Part
Number GUG 705963GM along joint line of
seal housing, rear main bearing cap and
cylinder block and around sump bolt holes in
rear main bearing cap.
CAUTION: Do not apply sealant until
immediately prior to fitting sump, do not
spread sealant bead.
Big-end bearings - refit
1. Rotate crankshaft until big-end bearing journals
are correctly positioned.
2. Lubricate crankshaft big-end journals with
engine oil.
3. Fit new big-end bearing shells to connecting
rods, lubricate shells with engine oil.
4. Taking care not to damage oil squirt jets or to
displace bearing shells, pull connecting rods on
to crankshaft journals.
5. Check that new big-end bearing shells are
correctly located on big-end bearing caps,
lubricate shells with engine oil.
6. Fit big-end bearing caps ensuring that they are
in their correct fitted order.
7. Lubricate threads of connecting rod bolts with
engine oil. Fit bolts to their respective
connecting rods and tighten to 20 Nm then a
further 90
°
.
ENGINE
OVERHAUL
45
PISTONS, CONNECTING RODS AND CYLINDER
BORES
Pistons and connecting rods - remove
1. Remove crankshaft.
2. Remove and discard banjo bolts securing oil
squirt jets to cylinder block, remove jets.
NOTE: Each jet is located by means of a
roll pin.
3. Suitably identify each piston and connecting
rod assembly to its respective cylinder bore.
4. Using assistance, lay cylinder block on its side.
5. Push each piston and connecting rod up
cylinder bore taking care to keep connecting
rod clear of bore walls; remove pistons and
connecting rods.
6. Recover big-end bearing shells from
connecting rods.
CAUTION: Big-end bearing shells should
always be replaced whenever pistons and
connecting rods are removed.
Piston rings - remove
1. Using a suitable expander, remove and discard
piston rings.
2. Use a squared off end of a broken piston ring
to clean groove in piston.
CAUTION: Do not use a wire brush or
emery cloth.
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