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Home >> Land Rover >> 2008 >> LR3 (LA) V8-4.4L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Overhaul >> Assembly >> Part 1

Part 1


Engine

Service Repair No - 00.00.00

The content of this article reflects the changes identified in TSB - LTB00119

Special Tools




Timing Setting Tool
303-645




Camshaft Setting/Locking Tool
303-530




Adapter - Crankshaft Seal Installer
303-1100-01




Adapter
303-191-03




Holding Tool Crankshaft Pulley
303-893 (LRT-12-080)




Bolts and Spacers
303-191-04




Timing Chain Tensioning Tool
303-532

Assembly - Part 1
1. Secure the engine to the engine stand
^ Align the engine to the engine stand
^ Adjust the engine stand legs into position
^ Mount the engine an engine stand
^ Fully tighten the engine stand leg nuts

NOTE: Install a new gasket.

2. Install the oil pump assembly
^ Clean the component mating faces
^ Install the gasket
^ Tighten the bolts to 10 Nm (7 ft. lbs.)





3. Install the baffle plate
^ Tighten the 6 bolts to 6 Nm (4 ft. lbs.)





NOTE: Install a new O-ring seal

4. Install the oil strainer pick-up assembly
^ Install the O-ring
^ Tighten the M6 bolt to 10 Nm (7 ft. lbs.)
^ Apply sealant to the M5 bolts
^ Tighten the M5 bolts to 6 Nm (4 ft. lbs.)





5. Install the oil pan
^ Clean the component mating faces
^ Apply a 3 mm (0.118 in.) diameter bead of sealant, to the area indicated
^ Install the bolts, but do not tighten fully at this stage





6. Tighten the oil pan bolts in the sequence shown to 20 Nm (15 ft. lbs.)





NOTE: Prevent the flexplate from rotating.

7. Install the flexplate.
^ Clean component mating faces
^ Tighten the bolts evenly in 2 stages to the sequence shown
^ Tighten the bolts to 15 Nm (11 ft. lbs.)
^ Tighten the bolts to 110 Nm (81 ft. lbs.)





8. Install coolant pump
^ Tighten the 5 bolts to 10 Nm (7 ft. lbs.)





NOTE: Some variation in the illustrations may occur, but the essential information is always correct

9. Install the knock sensor (KS)
^ Tighten the bolts to 20 Nm





10. Position the starter motor
^ Install the starter motor
^ Tighten the bolts to 45 Nm





11. Attach the engine mounting bracket





NOTE: The cylinder head gaskets must be installed over the cylinder head to block dowels

12. Install the RH cylinder head
^Clean the component mating faces
^ Clean the cylinder head locating dowels
^ Install a new cylinder head gasket
^ With assistance, install the cylinder head
^ Repeat the operation for the LH side





NOTE: Tighten the bolts 1 to 10 in the sequence shown

NOTE: LH illustrated, RH similar

13. Install the cylinder head bolts
^ Tighten the bolts to 20 Nm (15 ft. lbs.)
^ Tighten the bolts to 35 Nm (26 ft. lbs.)
^ Tighten the bolts 1 to 10, a further 90 degrees
^ Tighten the bolts 1 to 10, a further 90 degrees
^ Tighten the M8 bolts 11 and 12 to 25 Nm (18 ft. lbs.)
^ Repeat the operation for the LH side





14. Install the LH camshafts
^ Clean the component mating faces
^ Lubricate the journals and camshaft lobes
15. Install the camshaft bearing caps
^ Evenly and progressively tighten the bolts in sequence shown to 10 Nm (7 ft. lbs.)





16. Install the sproket retaining Torx bolts to the camshafts

CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or valve clearence will be incorrect

17. Measure and record the tappet clearences
^ Rotate camshafts using the Torx bolts





NOTE: Remove the camshaft bearing caps evenly and in stages

NOTE: Remove the camshaft bearing caps. Note their position, orientation and markings. Each is marked with it's position (number) and an orientation (arrow)

18. Remove the camshafts
^ Remove the 20 bolts





19. Remove the valve tappets, replace with selected tappets.
20. Install the camshafts
^ Clean the component mating faces
^ Lubricate the journals and camshaft lobes
21. Install the camshaft bearing caps
^ Evenly and progressively tighten the bolts in sequence shown to 10 Nm (7 ft. lbs.)





CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or valve clearence will be incorrect

22. Check valve tappet clearences are correct
^ Rotate the camshafts using the Torx bolts
^ Remove the camshaft Torx bolts after the check is complete





23. Repeat the operation for the RH camshafts
24. Install the special tool to the LH cylinder head





NOTE: RH illustration shown, LH similar

25. Depress the LH secondary timing chain tensioner piston
^ Using 1 mm diameter metal rod, retain the chain tensioner piston





26. Install the LH secondary timing chain tensioner
^ Tighten the bolts to 12 Nm (9 ft. lbs.)





NOTE: Lightly tighten the camshaft sprocket Torx bolts, the sprockets MUST be free to move

27. Install the LH secondary timing chainand sprockets to the camshafts
^ Install the sprocket retaining Torx bolts to the camshafts





28. Tension the secondary timing chain
^ Remove retaining rod





29. Repeat the operation for the RH camshafts

NOTE: RH illustration show, LH similar

30. Install the LH primary timing chain
^ Make sure the timing chain slack is on the tensioner side of the timing chain





31. Install the LH primary timing chain tensioner guide
^ Tighten to 12 Nm (9 ft. lbs.)





CAUTION: During the timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result

32. Install the LH primary timing chain tensioner
^ Using a 3mm diameter metal rod, retain the chain tensioner piston
^ Tighten the bolts to 12 Nm (9 ft. lbs.)
^ Remove the retaining rod





CAUTION: Using the special tool, apply force to the tool in a counter-clockwise direction, to tension the primary timing chain on its drive side

CAUTION: The intake camshaft sprocket retaing bolt MUST be tightened before the exhaust camshaft retaining bolt. Engine damage will occur if this procedure is not followed

33. Install the special tool to the exhaust camshaft sprocket
^ Tighten the intake camshaft sprocket bolt to 20 Nm (15 ft. lbs.) then a further 90 degrees.
^ Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 ft. lbs.) then a further 90 degrees.





34. Install the LH variable camshaft timing (VCT) oil control unit
^ Install the O-ring seals
^ Tighten the new bolts to 22 Nm (16 ft. lbs.)
^ Tighten the nut to 10 Nm (7 ft. lbs.)





35. Install the RH primary timing chain
^ Make sure the timing chain slack is on the tensioner side of the timing chain





36. Install the RH primary timing chain tensioner guide
^ Tighten to 12 Nm (9 ft. lbs.)





CAUTION: During the timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result

37. Install the RH primary timing chain tensioner
^ Using a 3mm diameter metal rod, retain the chain tensioner piston
^ Tighten the bolts to 12 Nm (9 ft. lbs.)
^ Remove the retaining rod





CAUTION: Using the special tool, apply force to the tool in a counter-clockwise direction, to tension the primary timing chain on its drive side

CAUTION: The intake camshaft sprocket retaing bolt MUST be tightened before the exhaust camshaft retaining bolt. Engine damage will occur if this procedure is not followed

38. Install the special tool to the exhaust camshaft sprocket
^ Tighten the intake camshaft sprocket bolt to 20 Nm (15 ft. lbs.) then a further 90 degrees.
^ Tighten the exhaust camshaft sprocket bolt to 20 Nm (15 ft. lbs.) then a further 90 degrees





39. Install the RH VCT oil control unit
^ Install the new O-ring seals
^ Tighten the new bolts to 22 Nm (16 ft. lbs.)





40. Remove the special tool from the LH cylinder head





41. Remove the special tool from the RH cylinder head





42. Remove the crankshaft locking tool
^ Remove the screw





43. Install the engine front cover
^ Clean the component mating faces
^ Apply a bead of sealant 3mm in diameter, by 12 mm long, to the 8 places indicted





44. Evenly and progessively tighten the bolts in the sequence shown to 12 Nm (9 ft. lbs.)





45. Using the special tools, install the crankshaft front seal
^ Clean the component mating faces
^ Lubricate the seal with clean engine oil
^ Use the discarded crankshaft bolt with the service tool, DO NOT use the new bolt





46. Using the special tools, install the crankshaft front seal
^ Clean the component mating faces





47. Install the crankshaft pulley
^ Lubricate with clean engine oil
48. Install the crankshaft pulley locking ring

CAUTION: The screw thread in the crankshaft pulley must be cleaned out before installing a new crankshaft pulley bolt

49. Install, but do not tighten, the new crankshaft pulley bolt

CAUTION: Under no circumstances should crankshaft setting peg 303-645, be used in the following operations, to restrain the crankshaft

50. Using the special tools, retain the crankshaft pulley
^ Tighten the crankshaft pulley bolt to 380 Nm (280 ft. lbs.)





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