Range Rover. Manual — part 34
BMW DIESEL
27
REPAIR
30. Attach suitable lifting eye to upper rear inlet
manifold stud.
31. Attach hoist to lifting eyes. Remove cylinder
head, remove and discard LH rear cylinder head
bolt.
NOTE: 2 ring dowels locate cylinder head
to block.
CAUTION: To avoid damaging timing chain
guide, ensure cylinder head is lifted as
squarely as possible.
32. Remove cylinder head gasket.
33. Check number of thickness identification holes
before discarding gasket.
CAUTION: Check cylinder head for
warping, see Cylinder head warp check.
If crankshaft, pistons or connecting rods
have been renewed, new cylinder head gasket
thickness must be determined using the following
Piston Protrusion Check procedure. If above items
have not been disturbed, continue at Refit using
gasket with same thickness identification as
original.
12
ENGINE
NEW RANGE ROVER
28
REPAIR
Piston Protrusion - Check
34. Ensure cylinder block face and piston crowns
are clean.
35. Position a dial gauge with suitable base to
cylinder block.
36. Preload and zero gauge on cylinder block face.
37. Move gauge onto piston crown. Measure
protrusion of No. 1 piston in two positions as
shown. Take average of readings. Record
results.
38. Repeat protrusion check on piston No. 6.
39. Remove timing pin LRT-12-108 from flywheel.
40. Record protrusion of remaining pistons. Ensure
that readings are taken at exactly TDC.
NOTE: Top Dead Centre must be located
using dial gauge.
41. Calculate average piston protrusion to determine
required gasket thickness:
Up to 0.76 mm = 2 identification holes
Over 0.76 mm = 3 identification holes
NOTE: If any piston protrudes more then
0.81mm, a gasket with 3 identification
holes must be fitted.
Cylinder head warp - check
42. Remove all traces of carbon and gasket material
from cylinder head.
43. Using a straight edge and feeler gauges, check
cylinder head for distortion along lines shown in
illustration and compare with figures given:
Longitudinal warp A = 0.1 mm (0.004 in)
Lateral warp B = 0.05 mm (0.002 in)
44. Replace cylinder head if figures obtained exceed
those given.
NOTE: Cylinder heads may not be refaced.
BMW DIESEL
29
REPAIR
Refit
CAUTION: If crankshaft timing pin
LRT-12-108 has been removed, ensure that
FIP is on correct stroke, with dimple on
FIP sprocket visible, before refitting pin.
45. Ensure all mating faces are clean.
46. Check cylinder block ring dowels for condition
and correct location.
47. Apply 1.5mm bead of Unipart sealant STC 3373
to joint lines of cylinder block and timing cover.
48. Fit cylinder head gasket of correct thickness.
49. Fit tool LRT-12-112 to ensure camshaft is in
correct position. If necessary, turn camshaft
using spanner on cast hexagon.
CAUTION: Do not turn camshaft if cylinder
head is fitted to cylinder block.
NOTE: Fit a lightly oiled, new cylinder
head bolt in LH rear location.
50. Position cylinder head on cylinder block. Ensure
timing chain guide is not fouled and rear LH bolt
enters bolt hole in cylinder block. Locate cylinder
head on ring dowels.
51. Disconnect lifting chains. Remove lifting eye.
52. Lightly lubricate new cylinder head bolts. Fit
bolts. Tighten, in sequence shown, in the
following stages.
Stage 1 = 80 Nm (59 lbf.ft)
Stage 2 = Loosen by 180
°
Stage 3 = 50 Nm (37 lbf.ft)
Stage 4 = Tighten 90
°
Stage 5 = Tighten 90
°
Stage 6 = Run engine for 25 minutes
Stage 7 = Stop engine, allow to cool
Stage 8 = Tighten 90
°
NOTE: Tighten using angular torque
wrench.
53. Secure cylinder head to timing cover with bolts
and nut.
M7 -
15 Nm (11 lbf.ft)
M8 -
20 Nm (15 lbf.ft)
54. Fit camshaft timing chain tensioner rail.
55. Using new ’O’ rings, fit tensioner and guide rail
pins.
56. Engage timing chain with camshaft sprocket.
Position sprocket on camshaft.
57. Fit NEW camshaft sprocket bolt.
NOTE: Important; if engine has covered
more than 20,000 km (12,500 miles), insert
a feeler gauge of 4.61 mm (0.18 in)
thickness between cylinder head face and inlet
manifold side of LRT-12-112 prior to tightening
bolt.
58. With LRT-12-112 fitted to camshaft, tighten
camshaft sprocket bolt to
20 Nm (15 lbf.ft).
59. Using a suitable torque angle gauge, further
tighten bolt by 35
°
.
60. Remove LRT-12-112.
61. Using tool LRT-12-115, lever tensioner rail to
slack position. Remove LRT-12-114 from
tensioner plunger.
62. Using a new sealing washer, refit access plug.
12
ENGINE
NEW RANGE ROVER
30
REPAIR
63. Remove LRT-12-108 from flywheel. Fit plastic
plug.
64. Connect cooling hoses. Secure with clips.
65. Align damper to tensioner. Secure with bolt.
66. Lever tensioner to slack position. Engage drive
belt over alternator pulley.
Vehicles without EGR
67. Using a new ’O’ ring, fit camshaft end cover.
NOTE: Apply Loctite 577 sealant to
threads of LH camshaft end cover bolt.
68. Align harness trunking to cylinder head. Secure
camshaft end cover and harness trunking with
bolts.
All Vehicles
69. Connect No. 4 injector needle lift sensor.
70. Connect leads to glowplugs.
71. Connect ECT sensor and temperature gauge
sensor.
72. Remove plugs. Connect leak-off pipe to No. 1
injector.
73. Remove plug, fit intake hose to turbocharger.
Secure with clip.
74. Position new gasket on exhaust manifold. Fit
turbocharger.
75. Secure with bolts.
45 Nm (33 lbf.ft)
76. Fit exhaust manifold heat shield.
See
MANIFOLD AND EXHAUST SYSTEM, Repair.
77. Fit camshaft cover.
See this section.
78.
Vehicles with EGR: Fit EGR vacuum pump. See
EMISSION CONTROL, Repair.
79. Fit high pressure fuel pipes.
See FUEL
SYSTEM, Repair.
80. Fit fan cowl.
See COOLING SYSTEM, Repair.
81. Reconnect battery negative lead.
VALVES AND TAPPETS
Service repair no - 12.29.59
Remove
1. Remove camshaft.
See this section.
2. Remove inlet manifold.
See MANIFOLD AND
EXHAUST SYSTEM, Repair.
3. Remove exhaust manifold.
See MANIFOLD
AND EXHAUST SYSTEM, Repair.
4. Remove injectors.
See FUEL SYSTEM, Repair.
5. Remove glow plugs.
See FUEL SYSTEM,
Repair.
6. Remove cylinder head.
See this section.
7. Remove tappets and store in their fitted order.
8. Insert protective sleeve LRT-12-101 in tappet
bore.
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