Land Rover Engine 1.8 Litre K Series. Manual — part 15
ENGINE
46
OVERHAUL
Main bearings selection
Main bearings size
Bearing ladder
Grade 1
Grade 2
Grade 3
Crankshaft main journals
Grade A
BLUE - BLUE
RED - BLUE
RED - RED
Grade B
BLUE - GREEN
BLUE - BLUE
RED - BLUE
Grade C
GREEN - GREEN
BLUE - GREEN
BLUE - BLUE
Colour code on edge of bearing
Thickness progression:
GREEN - Thin
BLUE
- Intermediate
RED
- Thick
CAUTION: If two bearing colours are to be
used, thicker bearing must be fitted to
bearing ladder. When original crankshaft
is to be refitted, bearing shells must be as
selected from table, DO NOT FIT UNDERSIZE
BEARINGS.
Main bearings type
1
2
3
4
5
Block
Plain
Grooved
Grooved
Grooved
Plain
Ladder
Plain
Plain
Plain
Plain
Plain
ENGINE
OVERHAUL
47
Big-end bearings selection
1. Record big-end journal code letters from
crankshaft rear web.
First letter is number 1 big-end bearing.
Record big-end bearing bore code numbers;
this will be 5, 6 or 7, located on the connecting
rod bearing cap.
2. Check crankshaft big-end journal diameters:
Big-end journal diameter = 47.986 to 48.007
mm
Maximum out of round = 0.010 mm
Big-end journal tolerance:
Grade A = 48.000 to 48.007 mm
Grade B = 47.993 to 48.000 mm
Grade C = 47.986 to 47.993 mm
Clearance in bearings = 0.021 to 0.049 mm
Big-end/connecting rod end-float = 0.10 to 0.25
mm
3. Select the appropriate big-end bearing shells
from the table.
4. Replace crankshaft if outside tolerance.
Big-end bearings size
Big-end bore
Grade A
Grade B
Grade C
Crankshaft big-end journals
Grade 5
BLUE - BLUE
RED - BLUE
RED - RED
Grade 6
BLUE - YELLOW
BLUE - BLUE
RED - BLUE
Grade 7
YELLOW - YELLOW
BLUE - YELLOW
BLUE - BLUE
Colour code on edge of bearing
Thickness progression:
YELLOW - Thin
BLUE - Intermediate
RED - Thick
If two bearing colours are to be used, thicker bearing
must be fitted to big-end bearing cap.
ENGINE
48
OVERHAUL
Crankshaft, main and big-end bearings - refit
1. Clean all sealant surfaces on block, bearing
ladder and oil rail.
Use foam action gasket remover and a plastic
scraper - DO NOT USE A METAL SCRAPER
ON SEALING SURFACES.
Ensure all oilways are clear.
Examine shoulder location on each big end
bolt, renew if damaged.
Check that core plug at each end of oil rail is in
good condition, renew as necessary.
2. Fit selected main bearing shells into cylinder
block and bearing ladder as indicated in the
table.
3. Fit thrust washers into block, each side of
Number 3 main bearing with oil grooves facing
outwards.
4. Lubricate crankshaft main journals with engine
oil. Hold crankshaft with big-end journals
horizontal and using assistance, lower
crankshaft on to main bearings.
5. Clean sealing surfaces on cylinder block and
bearing ladder using suitable solvent.
6. Apply a continuous bead of sealant, Part
Number GUG 705963GM to paths shown on
cylinder block then spread to an even film
using a roller.
CAUTION: To avoid contamination,
assembly should be completed
immediately after application of sealant.
ENGINE
OVERHAUL
49
7. Lubricate main journals with engine oil. Fit
bearing ladder to block, fit bolts ensuring that
flanged head bolt is fitted at position 10.
Tighten bolts in sequence shown to 5 Nm then
in same sequence to 30 Nm.
CAUTION: With bearing ladder fitted,
crankshaft will be tight; do not rotate
crankshaft more than absolutely
necessary until cylinder head bolts are tightened
to the correct torque.
8. Fit cylinder liners and pistons.
CAUTION: Ensure that cylinder liner
retainer clamps LRT-12-144 and nylon
nuts are fitted immediately cylinder liners
are inserted into cylinder block.
9. Lubricate crankshaft big-end journals and
bearing shells with engine oil. Carefully pull
each connecting rod into place, fit big-end caps
noting that featherways abut, fit and lightly
tighten dowel bolts in their original fitted order.
10. Tighten big-end dowel bolts in pairs to 20 Nm +
45
°
.
NOTE: Until the cylinder head is fitted,
crankshaft will prove difficult to rotate
once big-end bolts are tightened.
11. Using feeler gauges, check that end-float of
each big-end bearing/ connecting rod is
between 0.10 to 0.25 mm.
12. Apply continuous beads of sealant, Part
Number GUG 705963GM to paths on oil rail as
shown, then spread to an even film using a
roller.
CAUTION: To avoid contamination,
assembly should be completed
immediately after application of sealant.
13. Using assistance, position cylinder block on its
side and temporarily remove cylinder liner
retainer clamps LRT-12-144.
CAUTION: Take care not to disturb
cylinder liners with retainer clamps
removed
14. Fit oil rail to bearing ladder, tighten nuts to 9
Nm.
CAUTION: A new oil rail together with a
plastic suction pipe must be fitted if a
thread for cylinder head bolts is damaged.
Thread inserts (Helicoil) are not acceptable.
15. Fit cylinder retainer clamps LRT-12-144,
tighten bolts sufficiently to retain clamps.
16. Clean oil pick-up pipe and strainer.
17. Fit new ’O’ ring and secure oil pick-up pipe,
tighten bolts to 12 Nm.
CAUTION: Bolts used must be M6 x 20.
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