engine oil LAND ROVER DISCOVERY 1999 Manual PDF
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 227 of 1529
ENGINE - V8
12-2-72 OVERHAUL
Bearings - connecting rods
$% 12.17.16.01
Disassembly
1.Remove oil pick up strainer.
+ ENGINE - V8, OVERHAUL, Strainer
- oil pick-up.
2.Suitably mark cylinder reference number on
each connecting rod bearing cap.
3.Remove 2 bolts securing each connecting rod
bearing cap, remove caps and recover
connecting rod bearings.
CAUTION: Keep bearing caps, bearings and
bolts in their fitted order.
4.Push each connecting rod up cylinder bore
until connecting rods are clear of crankshaft
journals.
CAUTION: Ensure that connecting rods do
not contact cylinder bores.
5.Remove bearing shells from each connecting
rod. Inspect
1.Clean crankshaft journals and bearing
locations in connecting rods.
2.Inspect connecting rod bearings for wear and
renew if necessary. Connecting rod bearings
are available in two oversizes.
lConnecting rod bearing 1st oversize = 0.254
mm (0.01 in).
lConnecting rod bearing 2nd oversize =
0.508 mm (0.02 in).
3.Check crankshaft big-end journals for wear and
scoring. Measure for ovality; taking 3
measurements at 120° intervals at each end
and at centre of journals.
lStandard journal = 55.500 to 55.513 mm
(2.20 to 2.22 in).
l1st undersize journal - 0.254 mm (0.01 in) =
55.246 to 55.259 mm (2.17 to 2.18 in).
l2nd undersize journal - 0.508 mm (0.02 in)
= 54.992 to 55.005 mm (2.16 to 2.165 in).
lJournal - max. ovality = 0.040 mm (0.002 in)
Reassembly
1.Clean connecting rod caps.
2.Lubricate connecting rod journals and bearing
shells with clean engine oil.
3.Fit bearing shells to connecting rods and caps.
4.Rotate crankshaft until connecting rod journals
are correctly positioned.
5.Taking care not to displace bearing shells, pull
connecting rods on to crankshaft journals.
6.Check that bearing shells are correctly located
in connecting rod bearing caps.
7.Fit connecting rod bearing caps, ensuring that
they are in their correct fitted order.
NOTE: The rib on the edge of the bearing cap
must face towards the front of engine on the RH
bank of cylinders and towards the rear on the
LH bank.
8.Lightly oil threads of connecting rod bolts. Fit
connecting rod bolts and tighten to 20 Nm (15
lbf.ft) then turn a further 80°.
Page 228 of 1529
ENGINE - V8
OVERHAUL 12-2-73
9.Check clearance between connecting rods on
each crankshaft journal.
l Connecting rod clearance = 0.15 to 0.36
mm (0.006 to 0.014 in).
10.Fit oil pick up strainer.
+ ENGINE - V8, OVERHAUL, Strainer
- oil pick-up.
Crankshaft and main bearings
$% 12.21.33.01
Disassembly
1.Remove crankshaft rear oil seal.
+ ENGINE - V8, OVERHAUL, Seal -
crankshaft - rear - automatic models.
2.Remove timing gear cover gasket.
+ ENGINE - V8, OVERHAUL, Gasket -
timing gear cover.
3.Remove bolt securing camshaft gear.
4.Remove timing chain and gears.
5.Remove connecting rod bearings.
+ ENGINE - V8, OVERHAUL, Bearings
- connecting rods.
Page 230 of 1529
ENGINE - V8
OVERHAUL 12-2-75
Reassembly
1.Clean main bearing locations in cylinder block
and bearing caps; ensure bolt holes are clean
and dry.
2.Clean sealant from rear main bearing cap and
mating faces.
3.Fit key to keyway.
4.Check threads of main bearing cap bolts for
damage, renew bolts in pairs.
5.Lubricate grooved main bearing shells with
clean engine oil and fit to their locations in
cylinder block.
NOTE: Ensure that the flanged bearing is fitted
to the centre position.
6.Lubricate crankshaft journals with clean engine
oil.
7.Position crankshaft in cylinder block.
8.Lubricate plain bearing shells with clean
engine oil and fit to main bearing caps.
9.Fit main bearing caps 1 to 4 only at this stage,
ensuring that they are the correct way round
and in their fitted order.
10.Lightly lubricate threads of main bearing cap
bolts with clean engine oil.
11.Fit main bearing cap bolts but do not tighten at
this stage. Do not fit side bolts at this stage.12.Lubricate new cruciform seals with engine oil
and fit to rear main bearing cap.
CAUTION: Do not trim off excess from
cruciform seals at this stage.
13.Apply a 3 mm (0.12 in) wide bead of sealant,
Part No. STC 50550 to bearing cap rear mating
faces on cylinder block.
CAUTION: Ensure sealant does not enter
bolt holes.
14.Carefully fit rear main bearing cap assembly, fit
but do not tighten bolts.
CAUTION: Ensure engine oil does not enter
the side bolt holes in the bearing cap. Do
not trim off excess material from cruciform
seals at this stage.
15.Lubricate 'Dowty' washers with engine oil and
fit to side bolts.
16.Fit but do not tighten side bolts. Rear side
bolts are Allen headed.
17.Using the sequence shown, tighten main
bearing cap bolts as follows:
lInitial torque - all main bearing cap bolts and
side bolts - 13.5 Nm (10 lbf.ft).
lFinal torque - main bearing cap side bolts 11
to 15 - 45 Nm (34 lbf.ft).
lFinal torque - main bearing cap bolts 1 to 8
- 72 Nm (54 lbf.ft).
lFinal torque - main bearing cap bolts 9 and
10 - 92 Nm (68 lbf.ft).
lFinal torque - main bearing cap side bolts 16
to 20 - 45 Nm (34 lbf.ft).
18.Trim off excess material from cruciform seals.
Page 231 of 1529
ENGINE - V8
12-2-76 OVERHAUL
19.Attach a DTI to front of cylinder block, move
crankshaft rearwards, position stylus of gauge
on end of crankshaft and zero gauge.
20.Move crankshaft forwards, measure and
record end-float obtained.
l Crankshaft end-float = 0.08 to 0.26 mm
(0.003 to 0.01 in).
21.Fit connecting rod bearings.
+ ENGINE - V8, OVERHAUL, Bearings
- connecting rods.
22.Clean timing chain and gears.
23.Clean ends of crankshaft and camshaft.
24.Lubricate timing chain assembly with clean
engine oil.
25.Align timing marks and fit timing chain
assembly.
26.Fit camshaft gear bolt and tighten to 50 Nm (37
lbf.ft).
27.Fit timing gear cover gasket.
+ ENGINE - V8, OVERHAUL, Gasket -
timing gear cover.
28.Clean crankshaft pulley.
29.Fit crankshaft pulley.
30.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
31.Remove tool LRT-12-080 from crankshaft
pulley.
32.Clean oil filter and mating face.
33.Lubricate oil filter seal and fit filter to oil pump.
34.Ensure drive belt pulleys are clean and
damage free.
35.Fit auxiliary drive belt to pulleys.
36.Fit crankshaft rear oil seal.
+ ENGINE - V8, OVERHAUL, Seal -
crankshaft - rear - automatic models.
Page 233 of 1529
ENGINE - V8
12-2-78 OVERHAUL
Reassembly
1.Clean camshaft bearings in block.
2.Clean camshaft.
3.Wipe camshaft bearing faces and lobes.
4.Clean thrust plate and mating face.
5.Lubricate camshaft bearings with clean engine
oil.
6.Fit camshaft, take care not to damage camshaft
bearings.
7.Lubricate thrust plate and mating face with
clean engine oil.
8.Position thrust plate, fit and tighten bolts to 22
Nm (17 lbf.ft).
9.Fit timing chain and gears.
+ ENGINE - V8, OVERHAUL, Timing
chain and gears.
10.Immerse tappets in engine oil. Before fitting,
pump the inner sleeve of tappet several times
using a push rod to prime the tappets.
11.Clean tappet bores.
12.Lubricate tappets and tappet bores with clean
engine oil.
13.Fit tappets.
14.Clean push rods.
15.Lubricate tappet end of push rods with clean
engine oil.
16.Fit push rods.
17.Clean bases of rocker pillars and mating faces.
18.Clean contact surfaces on rockers and valves.
19.Lubricate contact surfaces on rockers and
valves with clean engine oil.
20.Fit rocker shafts and engage push rods. Ensure
rockers shafts are fitted to the correct cylinder
head.
21.Fit and progressively tighten rocker shaft bolts
to 40 Nm (30 lbf.ft).
22.Fit inlet manifold gasket.
+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.
Page 243 of 1529
EMISSION CONTROL - V8
17-2-10 DESCRIPTION AND OPERATION
Crankcase Emission Control System
The concentration of hydrocarbons in the crankcase of an engine is much greater than that in the vehicle's exhaust
system. In order to prevent the emission of these hydrocarbons into the atmosphere, crankcase emission control
systems are employed and are a standard legal requirement.
The crankcase ventilation system is an integral part of the air supply to the engine combustion chambers and it is
often overlooked when diagnosing problems associated with engine performance. A blocked ventilation pipe or filter
or excessive air leak into the inlet system through a damaged pipe or a leaking gasket can affect the air:fuel mixture,
performance and efficiency of the engine. Periodically check the ventilation hoses are not cracked and that they are
securely fitted to form airtight connections at their relevant ports.
The purpose of the crankcase ventilation system is to ensure that any noxious gas generated in the engine crankcase
is rendered harmless by complete burning of the fuel in the combustion chamber. Burning the crankcase vapours in
a controlled manner decreases the HC pollutants that could be emitted and helps to prevent the development of
sludge in the engine oil as well as increasing fuel economy.
A spiral oil separator is located in the stub pipe to the ventilation hose on the right hand cylinder head rocker cover,
where oil is separated and returned to the cylinder head. The rubber ventilation hose from the right hand rocker cover
is routed to a port on the right hand side of the inlet manifold plenum chamber where the returned gases mix with the
fresh inlet air passing through the throttle butterfly valve. The stub pipe on the left hand rocker cover does not contain
an oil separator, and the ventilation hose is routed to the throttle body housing at the air inlet side of the butterfly valve.
The ventilation hoses are attached to the stub pipe by metal band clamps.
Page 261 of 1529
EMISSION CONTROL - V8
17-2-28 DESCRIPTION AND OPERATION
The air delivery pipe is a flexible plastic type, and is connected to the air pump outlet via a plastic quick-fit connector.
The other end of the flexible plastic pipe connects to the fixed metal pipework via a short rubber hose. The part of the
flexible plastic pipe which is most vulnerable to engine generated heat is protected by heat reflective sleeving. The
metal delivery pipe has a fabricated T-piece included where the pressurised air is split for delivery to each exhaust
manifold via the SAI control valves.
The pipes from the T-piece to each of the SAI control valves are approximately the same length, so that the pressure
and mass of the air delivered to each bank will be equal. The ends of the pipes are connected to the inlet port of each
SAI control valve through short rubber hose connections.
The T-piece is mounted at the rear of the engine (by the ignition coils) and features a welded mounting bracket which
is fixed to the engine by two studs and nuts.
The foam filter in the air intake of the SAI pump provides noise reduction and protects the pump from damage due to
particulate contamination. In addition, the pump is fitted on rubber mountings to help prevent noise which is generated
by pump operation from being transmitted through the vehicle body into the passenger compartment.
If the secondary air injection (SAI) pump is found to be malfunctioning, the following fault codes may be stored in the
ECM diagnostic memory, which can be retrieved using Testbook/T4:
NOTE: Refer to 'SAI System Fault Finding' and 'Checking Malfunctions on SAI System' at the end of this section to
determine root cause of fault codes.
NOTE: The electrical test of the SAI pump powerstage only indicates that there is a problem with the relay or the
power supply to the relay. It does not indicate the state of the SAI pump itself (i.e. broken or not connected).
As a result of a SAI pump powerstage malfunction, other fault codes may also become stored in the ECM memory.
These may include the following P codes.
NOTE: A malfunction of the SAI pump powerstage is logically expected to result in both engine banks reporting the
same fault.
NOTE: Refer to 'SAI System Fault Finding' and 'Checking Malfunctions on SAI System' at the end of this section to
determine root cause of fault codes.
Secondary Air Injection (SAI) Pump Relay
The secondary air injection pump relay is located in the engine compartment fusebox. The engine control module
(ECM) is used to control the operation of the SAI pump via the SAI pump relay. Power to the coil of the relay is supplied
from the vehicle battery via the main relay and the ground connection to the coil is via the ECM.
Power to the SAI pump relay contacts is via fusible link FL2 which is located in the engine compartment fusebox.
P-code Description
P0418Secondary Air Injection System – Relay 'A' circuit malfunction (SAI pump
powerstage fault, e.g. - SAI pump relay fault or relay not connected / open circuit /
harness damage).
P-code Description
P1412Secondary Air Injection System – Malfunction Bank 1 LH (Insufficient SAI flow
during passive test)
P1414Secondary Air Injection System – Low air flow Bank 1 LH (Insufficient SAI flow
during active test)
P1415Secondary Air Injection System – Malfunction Bank 2 RH (Insufficient SAI flow
during passive test)
P1417Secondary Air Injection System – Low air flow Bank 2 RH (Insufficient SAI flow
during active test)
Page 267 of 1529
EMISSION CONTROL - V8
17-2-34 DESCRIPTION AND OPERATION
Crankcase Emission Control Operation
Oil laden noxious gas in the engine crankcase is drawn through a spiral oil separator located in the stub pipe to the
ventilation hose on the right hand cylinder head rocker cover, where oil is separated and returned to the cylinder head.
The rubber ventilation hose from the right hand rocker cover is routed to a port on the right hand side of the inlet
manifold plenum chamber, where the returned gases mix with the fresh inlet air passing through the throttle butterfly
valve. The stub pipe on the left hand rocker cover does not contain an oil separator, and the ventilation hose is routed
to the throttle body housing at the air inlet side of the butterfly valve. The mass of fresh air which is drawn in from the
atmospheric side of the throttle butterfly to mix with the returned crankcase gas depends on the throttle position and
the engine speed.
1Hose – RH rocker cover to inlet manifold
2Inlet manifold
3Throttle body
4Air intake
5Hose – LH rocker cover to inlet manifold
6LH rocker cover breather tube
(without oil separator)7LH rocker cover baffle
8RH rocker cover baffle
9RH rocker cover breather tube
10Oil separator (integral with breather tube)
When the engine is running in cruise conditions or at idle, manifold pressure is low and the majority of gases are drawn
into the inlet manifold through the oil / vapour separator in the RH rocker cover stub pipe. At the same time, filtered
air is drawn from the throttle body into the engine via the LH rocker cover.
During periods of driving at Wide Open Throttle (WOT), pressure at either side of the throttle disc equalizes (manifold
depression collapses). The larger ventilation opening at the throttle housing positioned in the fast moving stream of
intake air, now offers more 'pull' than the small opening in the RH rocker cover and the flow of ventilation reverses,
drawing gases from the LH rocker cover into the throttle body for subsequent burning in the combustion chambers.
Page 276 of 1529
EMISSION CONTROL - V8
DESCRIPTION AND OPERATION 17-2-43
Secondary Air Injection System
Operation
When the engine is started, the engine control module checks the engine coolant temperature and if it is below 55°
C, the ECM grounds the electrical connection to the coil of the secondary air injection (SAI) pump relay.
A 12V battery supply is fed to the inertia switch via fuse 13 in the engine compartment fusebox. When the inertia
switch contacts are closed, the feed passes through the switch and is connected to the coil of the Main relay. An earth
connection from the Main relay coil is connected to the ECM. When the ECM completes the earth path, the coil
energises and closes the contacts of the Main relay.
The Main and Secondary Air Injection (SAI) pump relays are located in the engine compartment fusebox. When the
contacts of the Main relay are closed, a 12V battery supply is fed to the coil of the SAI pump relay. An earth connection
from the coil of the SAI pump relay is connected to the ECM. When the ECM completes the earth path, the coil
energises and closes the contacts of the SAI pump relay to supply 12V to the SAI pump via fusible link 2 in the engine
compartment fusebox. The SAI pump starts to operate, and will continue to do so until the ECM switches off the earth
connection to the coil of the SAI pump relay.
The SAI pump remains operational for a period determined by the ECM and depends on the starting temperature of
the engine, or for a maximum operation period determined by the ECM if the target engine coolant temperature has
not been reached in the usual time.
When the contacts of the main relay are closed, a 12V battery supply is fed to the SAI solenoid valve via Fuse 2 in
the engine compartment fusebox.
The ECM grounds the electrical connection to the SAI vacuum solenoid valve at the same time as it switches on the
SAI pump motor. When the SAI vacuum solenoid valve is energised, a vacuum is provided to the operation control
ports on both of the vacuum operated SAI control valves at the exhaust manifolds. The control vacuum is sourced
from the intake manifold depression and routed to the SAI control valves via a vacuum reservoir and the SAI vacuum
solenoid valve.
The vacuum reservoir is included in the vacuum supply circuit to prevent vacuum fluctuations caused by changes in
the intake manifold depression affecting the operation of the SAI control valves.
When a vacuum is applied to the control ports of the SAI control valves, the valves open to allow pressurised air from
the SAI pump to pass through to the exhaust ports in the cylinder heads for combustion.
When the ECM has determined that the SAI pump has operated for the desired duration, it switches off the earth paths
to the SAI pump relay and the SAI vacuum solenoid valve. With the SAI vacuum solenoid valve de-energised, the
valve closes, cutting off the vacuum supply to the SAI control valves. The SAI control valves close immediately and
completely to prevent any further pressurised air from the SAI pump entering the exhaust manifolds.
The engine coolant temperature sensor incurs a time lag in respect of detecting a change in temperature and the SAI
pump automatically enters a 'soak period' between operations to prevent the SAI pump overheating. The ECM also
compares the switch off and start up temperatures, to determine whether it is necessary to operate the SAI pump.
This prevents the pump running repeatedly and overheating on repeat starts.
Other factors which may prevent or stop SAI pump operation include the prevailing engine speed / load conditions.
Page 293 of 1529
EMISSION CONTROL - V8
17-2-60 REPAIRS
Air Manifold - LH - Secondary Air
Injection (SAI)
$% 17.25.17
Remove
1.Remove SAI control valve.
+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
2.Disconnect 2 air manifold unions from adapters
in cylinder head.
CAUTION: Take care that air manifold pipes
are not damaged during removal of union
nuts.
3.Remove 2 nuts securing air manifold bracket to
inlet manifold.
4.Remove air manifold.Refit
1.Clean air manifold and cylinder head adapters.
2.Apply a small amount of engine oil to top of air
manifold union nuts and around air manifold
pipes.
3.Position air manifold and finger tighten both
union nuts.
CAUTION: Finger tighten union nuts as far
as possible, damage to air manifold pipes or
adapters may result if this is not done.
4.Tighten air manifold unions to 25 Nm (18 lbf.ft).
CAUTION: Ensure that air manifold pipes
are not distorted during tightening
operation.
5.Fit nuts securing air manifold to inlet manifold
and tighten to 25 Nm (18 lbf.ft).
6.Fit SAI control valve.
+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
M17 0234
4
3
2
2