Land Rover Engine 1.8 Litre K Series. Manual — part 16
ENGINE
50
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18. Clean sealing surface on sump flange using
suitable solvent.
19. Apply a 2 mm wide x 0.25 mm thick continuous
bead of sealant, Part Number GUG 705963GM
to sump flange as shown then spread to an
even film using a roller.
CAUTION: To avoid contamination,
assembly should be completed
immediately after application of sealant.
Do not use RTV or any sealant other than that
specified.
20. Screw alignment pins LRT-12-146 into holes
shown.
21. Carefully lower sump over pins and on to
bearing ladder.
22. Fit 2 bolts into holes shown, tighten to 4 Nm.
23. Fit 10 bolts into remaining holes, lightly tighten
all bolts.
CAUTION: Ensure 2 M8 x 60 bolts are
fitted in original locations.
24. Remove alignment pins LRT-12-146, fit and
lightly tighten remaining 2 bolts.
25. Using a straight edge, check that machined
face of sump flange is level with rear face of
cylinder block. Check in 3 positions and if
necessary, tap sump gently to re-position.
26. Using sequence shown, tighten bolts to:
M8 x 25 - 25 Nm
M8 x 60 - 30 Nm
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27. Apply a continuous bead of sealant, Part No.
GAC 8000 to replacement oil seal as shown.
CAUTION: Do not apply oil or grease to
any part of the oil seal or running surface
of crankshaft. Seal must be fitted
immediately after applying sealant.
28. Position oil seal to cylinder block.
29. Fit oil seal replacer tool LRT-12-136 to
crankshaft, retain tool using 3 slave bolts.
30. Tighten replacer bolts to press oil seal into
cylinder block.
NOTE: Do not remove replacer for one
minute to allow seal to relax.
31. Remove tool LRT-12-136.
CAUTION: Allow sealant to cure for 30
minutes before rotating crankshaft.
32. Fit flywheel.
33. Fit oil pump and new crankshaft front oil seal.
34. Fit crankshaft timing gear.
35. Fit cylinder head assembly, do not fit spark
plugs at this stage.
36. Fit a new camshaft timing belt.
37. Clean joint surfaces. Use a new gasket and fit
dipstick tube, tighten bolts to 10 Nm.
NOTE: Ensure bolts securing dipstick tube
to bearing ladder are flanged head and do
not exceed 12 mm in length.
38. Support engine and using a socket and
suitable torque gauge on crankshaft pulley bolt,
check that crankshaft can be rotated in a
clockwise direction without undue binding;
rotational torque should not exceed 31 Nm.
39. Fit spark plugs, tighten to 25 Nm.
40. After installation in vehicle, run engine at idle
speed for 15 minutes before road testing.
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PISTONS, RINGS & CYLINDER LINERS
Pistons and connecting rods - remove
1. Suitably identify each piston assembly with its
respective cylinder liner.
2. Remove big-end bearings.
3. Using assistance, position cylinder block on its
side.
CAUTION: Ensure that feet of cylinder
liner retainer clamps LRT-12-144 do not
protrude over cylinder bores.
4. Remove ridge of carbon from top of each
cylinder liner bore.
5. Push pistons to top of their bores.
6. Carefully push out each piston assembly taking
care that big-ends do not contact surface of
cylinder liners.
7. Refit caps on to connecting rods, lightly tighten
dowel bolts.
CAUTION: Removal of pistons will
necessitate removal and re-sealing of
cylinder liners.
Piston rings - checking
1. Using an expander, remove and discard old
piston rings.
2. Use squared off end of broken piston ring and
clean ring grooves.
3. Check new ring to groove clearance:
Top compression ring A = 0.040 to 0.072 mm
2nd compression ring B = 0.030 to 0.062 mm
Oil control rails C = 0.010 to 0.180 mm
4. Check new ring fitted gap 20 mm from top of
cylinder liner bore:
CAUTION: Ensure rings are kept square to
liner bore and that they are suitably
identified to the bore in which they are
checked and fitted to the piston for that bore.
Top compression ring = 0.20 to 0.35 mm
2nd compression ring = 0.28 to 0.48 mm
Oil control rails = 0.15 to 0.40 mm
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Pistons - inspection
1. Check pistons for distortion and cracks.
2. Measure and record piston diameter at right
angle to gudgeon pin and 8 mm from bottom of
skirt.
3. Check piston diameter with figures given.
4. Measure and record piston diameter in line
with gudgeon pin hole and 8 mm from bottom
of skirt.
5. Check piston ovality with figures given.
6. Repeat above procedures for remaining
pistons.
Grade A = 79.975 to 79.990 mm
Grade B = 79.991 to 80.005 mm
Maximum ovality = 0.3 mm
Service pistons are grade A and B
NOTE: Piston grades A or B are stamped
on crown of piston.
Piston to cylinder liner bore clearance - checking
1. Starting with number 1 piston, invert piston and
connecting rod and with word FRONT or arrow
on piston crown facing towards REAR of
cylinder block, insert piston in cylinder liner.
2. Position piston with bottom of skirt 30 mm from
top of cylinder block.
3. Using feeler gauges, measure and record
clearance between piston and left hand side of
cylinder liner - viewed from front of cylinder
block.
4. Repeat above procedure for remaining pistons.
Clearance in cylinder bore = 0.01 to 0.04 mm
NOTE: Pistons and connecting rods are
only supplied as an assembly.
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