Land Rover Engine 2.0 Litre L Series. Manual — part 15
ENGINE
50
OVERHAUL
Cylinder block
1. Check that all oilways are clear and that oil
restrictor located in oilway to cylinder head is
fitted below face of cylinder block.
2. Check that main bearing cap, crankshaft rear
oil seal housing and cylinder head locating
dowels are fitted.
3. Check core plugs for leakage and corrosion,
replace as necessary.
NOTE: Seal replacement core plugs and
main oil gallery plug on rear of cylinder
block with Loctite 577, tighten main oil
gallery plug to 45 Nm. Seal dipstick tube in
cylinder block with Loctite 638.
Pistons and connecting rods - refit
1. Lubricate cylinder bores, pistons, rings and
crankshaft big-end journals with engine oil.
2. Lubricate new big-end bearing shells with
engine oil and fit to connecting rods and
bearing caps.
3. Check that piston ring gaps are positioned at
120
°
to each other and away from thrust - left
hand side of piston - viewed from front of
piston.
4. Fit suitable piston ring clamp to each piston in
turn and ensuring that pistons are in their
correct fitted order and that the arrow on piston
crown and the cast boss above the big-end is
facing towards front of cylinder block, push
pistons into their respective cylinder bores.
CAUTION: Ensure that connecting rods do
not contact cylinder bores.
5. Do not pull connecting rods fully down cylinder
bores at this stage.
6. Check that cut-out in each piston skirt is
positioned above oil squirt jet location.
7. Ensure oil squirt jets are clear and that roll pins
are inserted in jet housings.
ENGINE
OVERHAUL
51
8. Position oil squirt jets in cylinder block ensuring
that roll pins are inserted in locating holes.
9. Apply Loctite 275 to threads of new banjo
bolts.
CAUTION: Do not allow Loctite to enter oil
hole in banjo bolts.
10. Fit and tighten banjo bolts to 12 Nm.
11. Fit crankshaft and big-end bearings.
ENGINE
DATA, TORQUE & TOOLS
1
ENGINE DATA
Oil pump
Outer rotor to body clearance
0.05 to 0.10 mm
. . . . . . . . . . . . . . . . . .
Rotor lobe clearance
0.025 to 0.12 mm
. . . . . . . . . . . . . . . . . . . . . . . . .
Outer rotor end float
0.03 to 0.08 mm
. . . . . . . . . . . . . . . . . . . . . . . . .
Relief valve spring free length
38.9 mm
. . . . . . . . . . . . . . . . . .
Camshaft
Camshaft end-float
0.51 mm - max.
. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft bearing clearance
0.043 to 0.094 mm
. . . . . . . . . . . . . . . . . . .
Camshaft timing belt tensioner spring free length
65 mm
. . .
Tappets
Tappet outside diameter
34.959 to 34.975 mm.
. . . . . . . . . . . . . . . . . . . . . .
Cylinder head
Cylinder head maximum warp
0.10 mm
. . . . . . . . . . . . . . . . . .
Cylinder head bolt length
243.41 mm
. . . . . . . . . . . . . . . . . . . . . .
Valve springs
Free length
37.0 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves
Valve stem diameter:
Inlet
6.907 to 6.923 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
6.897 to 6.913 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve stem to guide clearance - maximum:
Inlet
0.056 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
0.066 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve face angle
45
°
to 45
°
30’
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head stand down:
Inlet
1.45 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
1.35 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve guides:
Inside diameter after reaming
6.950 to 6.963 mm
. . . . . . . . . . . . . . . . .
Fitted length above cylinder head
61.1 to 61.7 mm
. . . . . . . . . . . . . .
Valve seat inserts:
Seat angle
Inlet
60
°
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
58
°
to 62
°
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insert diameter
Inlet
35.697 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
31.05 to 31.55 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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