Land Rover Engine 1.8 Litre K Series. Manual — part 17
ENGINE
54
OVERHAUL
Piston rings - refit
CAUTION: Ensure that piston rings are
fitted to piston for the cylinder bore in
which they were checked.
1. Fit oil control spring.
2. With ’TOP’ or identification markings to top of
piston, use an expander to fit piston rings in
sequence; oil control, 2nd and top
compression.
3. Ensure rings are free to rotate, position
compression ring gaps A and B at 120
°
to
each other and away from thrust side - left
hand side of piston when viewed from front.
Position oil control ring gap C and spring gap D
at 30
°
on opposite side of gudgeon pin axis.
Cylinder liners - inspection
1. Measure wear and taper in two axes 65 mm
from top of cylinder liner bore.
RED grade A = 80.000 to 80.015 mm
BLUE grade B = 80.016 to 80.030 mm
Service liners are grade A and B.
Cylinder liner grade will be found marked on
outside diameter of liner.
CAUTION: Cylinder liners with excessively
glazed, worn, scratched orscored bores
must be replaced, do not attempt to hone
or remove glazing from bore.
ENGINE
OVERHAUL
55
Later engines
•
A/B - Cylinder liner bore/grade
•
V/Z - Cylinder liner step height
NOTE: Cylinder liners fitted to later
engines have their step heights graded on
production. The step heights, V or Z
together with the liner part number and colour
code are marked on the outside diameter of the
liner. If cylinder liner(s) are to be replaced, the
replacement liner(s) must have the same step
height as the original liner(s). Both step heights
are available in red and blue grades of liner.
Cylinder liners - remove
1. Remove pistons.
2. Remove cylinder liner clamps LRT-12-144.
3. Using assistance, position cylinder block on its
side.
CAUTION: If original cylinder liners are to
be refitted, use a felt tipped pen to make
suitable alignment marks between liner
and cylinder block. Do not etch or stamp liners.
4. Using hand pressure, push cylinder liners out
towards cylinder head face of cylinder block;
remove liners.
CAUTION: Keep cylinder liners in their
fitted order.
ENGINE
56
OVERHAUL
Cylinder liners - refit
NOTE: To enable cylinder liner retainer
clamps to be fitted when liners are
inserted in cylinder block, crankshaft and
bearing ladder must be fitted.
1. Fit crankshaft and bearing ladder.
2. Using assistance, support cylinder block on 2
wooden blocks.
3. Remove sealant from cylinder block and if
original cylinder liners are to be refitted, from
shoulder of liners.
4. Clean cylinder liners and wipe dry.
CAUTION: Ensure that if original cylinder
liners are to be refitted, reference marks
made during dismantling are not erased.
5. Apply a 2.0 mm thick continuous bead of
sealant, Part No. GGC 102 around shoulder of
cylinder liner.
CAUTION: Do not use any other type of
sealant.
6. Keeping cylinder liner ’square’ to cylinder
block, push liner fully down until shoulder of
liner seats against cylinder block. Do not drop
liners into position.
CAUTION: If original cylinder liners are to
be refitted, align reference marks made
during dismantling before liner is pushed
fully down.
7. Fit cylinder liner retainer clamps LRT-12-144.
8. Fit pistons.
Pistons and connecting rods - refit
1. Using assistance, support base of cylinder
block on 2 wooden blocks.
2. Ensure that cylinder liner retainer clamps
LRT-12-144 are fitted and that feet of clamps
do not protrude over cylinder liner bores.
3. Lubricate cylinder bores, pistons and rings with
engine oil, ensure ring gaps are correctly
spaced.
4. Fit selected bearing shells into big-end bearing
caps and connecting rods.
5. Fit a suitable piston ring clamp to each piston
in turn and with ’FRONT’ mark on piston to
engine front, push piston into bore until flush
with top face of cylinder liner.
Remove ring clamp.
CAUTION: If original pistons are to be
fitted, ensure that each piston is inserted
in its correct cylinder liner. Do not push
pistons below top face of cylinder liner until
big-end bearings and caps are to be fitted.
6. Fit big-end bearings.
ENGINE
DATA, TORQUE & TOOLS
1
DATA
Oil pump
Outer rotor to housing clearance
0.28 to 0.36 mm
. . . . . . . . . . . . . . . .
Inner rotor tip clearance
0.05 to 0.13 mm
. . . . . . . . . . . . . . . . . . . . . . .
Rotor end float
0.02 to 0.06 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief valve spring free length
38.9 mm
. . . . . . . . . . . . . . . . . .
Cooling system
Thermostat fully open
100
°
C
. . . . . . . . . . . . . . . . . . . . . . . .
Nominal setting
85
°
to 91
°
C
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshafts
Camshaft end-float
0.06 to 0.19 mm
. . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit
0.3 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft bearing clearance
0.060 to 0.094 mm
. . . . . . . . . . . . . . . . . . .
Service limit
0.15 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tappets
Tappet outside diameter
32.959 to 32.975 mm.
. . . . . . . . . . . . . . . . . . . . . .
Cylinder head
Cylinder head maximum warp
0.05 mm
. . . . . . . . . . . . . . . . . .
Cylinder head height:
New
118.95 to 119.05 mm.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reface limit
0.20 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve springs
Free length
50.0 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitted length
37.0 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load - valve closed
250
±
12 N
. . . . . . . . . . . . . . . . . . . . . . . . . .
Load - valve open
450
±
18 N
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves
Valve stem diameter:
Inlet
5.952 to 5.967 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
5.947 to 5.962 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve guides:
Inside diameter
6.000 to 6.025 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve stem to guide clearance:
Inlet
0.033 to 0.063 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit
0.07 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
0.038 to 0.078 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit
0.11 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve stem fitted height:
New
38.93 to 39.84 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit
40.10 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve guides
Fitted height
6.0 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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