Page 260 of 1007
ENGINE - K SERIES KV6
OVERHAUL 12-3-83
2.Using sequence shown, remove 8 M8 bolts
securing lower crankcase to cylinder block.
3.Remove remaining M8 bolt and 2 M6 bolts
securing lower crankcase to cylinder block.
4.Remove lower crankcase.
5.Using sequence shown, remove and discard 16
bolts securing bearing ladder to cylinder block.
NOTE: Short length bolts are fitted to the outer
edge of the bearing ladder.
6.Release bearing ladder from dowels and
remove from cylinder block.7.Remove main bearing shells and 2 thrust
washer halves from bearing ladder, keep main
bearing shells in fitted order; discard thrust
washers.
8.Temporarily fit crankshaft pulley bolt.
9.Remove 4 dowel bolts and remove big end
bearing caps from No 1 and No 2 connecting
rods. Keep bearing caps in order.
NOTE: Number stamped below bearing cap
bolt is bearing bore size code. Number
stamped on connecting rod is cylinder number
and letter is weight code.
CAUTION: Do not remove cylinder clamps
LRT-12-144 unless pistons and connecting
rods are to be removed.
10.Release connecting rods from crankshaft.
11.Remove bearing shells from connecting rod
and cap.
12.Rotate crankshaft using pulley bolt, remove
bolts securing remaining connecting rod
bearing caps. Remove bearing caps and
bearing shells from caps. Keep bearing caps in
their fitted order.
M12 6858
M12 6835
Page 275 of 1007
ENGINE - K SERIES KV6
12-3-98 OVERHAUL
13.Check cylinder head face for warping, across
centre and from corner to corner.
+ GENERAL DATA, Engine - KV6
Petrol.
14.Check cylinder head height.
+ GENERAL DATA, Engine - KV6
Petrol.
Note: Provided that cylinder head height is kept
within limits, cylinder heads may be refaced.
15.Check condition of valve springs and measure
free length of springs.
+ GENERAL DATA, Engine - KV6
Petrol.16.Remove carbon deposits from exhaust valve
guides using a 6 mm diameter reamer inserted
from combustion side of cylinder head.
17.Remove carbon from inlet valve guides, inlet
and exhaust valves and valve seat inserts.
Remove all loose carbon on completion.
18.Check and record existing valve stem
diameters 'A', replace any valve with stem
diameter less than specified.
+ GENERAL DATA, Engine - KV6
Petrol.
19.Check inlet and exhaust valve to guide
clearances 'B' using the following procedures.
Page 282 of 1007
ENGINE - K SERIES KV6
OVERHAUL 12-3-105
3.Remove oil pressure relief valve plug.
Note: If a hexagonal plug and sealing washer
are fitted, discard washer.
4.Remove spring and valve.
5.Check that valve and bore are free from scoring
and corrosion.
Note: Light corrosion may be removed using
grade 600 emery cloth soaked in engine oil.
6.Check free length of spring.
+ GENERAL DATA, Engine - KV6
Petrol.
7.Check that valve slides freely in bore.
CAUTION: If valve is scored, renew relief
valve as an assembly. If valve bore is
scored, renew oil pump as an assembly.Reassembly
1.Clean cover plate and mating face of cylinder
block; ensure bolt holes are clean and dry.
2.Clean running surface on crankshaft.
3.Remove all traces of sealant from relief valve
plug, Torx screws and tapped holes in pump
body.
CAUTION: Do not use a tap.
4.Lubricate relief valve, spring and bore with
clean engine oil.
5.Fit relief valve and spring.
6.If a hexagonal plug and sealing washer were
fitted, fit new sealing washer to plug.
7.Apply sealant, Part No. STC 50552 to plug
threads; fit plug and tighten to 25 Nm (18 lbf.ft).
8.Lubricate pump rotors and recess with clean
engine oil.
9.Fit inner and outer rotors ensuring that
identification mark on outer rotor is facing
outwards and that reference marks are aligned.
10.Lubricate new cover plate sealing ring with
clean engine oil.
11.Fit cover plate seal and cover plate.
12.Apply sealant, Part No. STC 50552 to threads
of Torx screws, fit and tighten screws.
13.Check that pump rotates freely.
Refit
1.Fit oil pump gasket.
+ ENGINE - K SERIES KV6, REPAIRS,
Gasket - oil pump.
Page 613 of 1007
DOORS
76-1-8 REPAIRS
Rubber/felt - glass channel - front door
$% 76.31.13
Remove
1.Remove exterior mirror.
+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
2.Lower door glass.
3.Remove inner seal.
4.Carefully release seal from door flange, starting
from the cheater panel, working along the waist
rail and around the door flange.Refit
1.Lubricate corners of seal with soapy water.
CAUTION: This seal assembly uses an
internal metal former. Take care not to bend
the seal during fitment, or the former will
become kinked.
2.Starting at the rearmost top corner of the glass
aperture, seat the seal onto the flange,
ensuring that the radius of the seal matches the
door profile.
3.Secure seal to flange across cantrail and down
'A' post.
4.Secure seal in corner at base of 'A' post.
5.Carefully pull 'B' post length of seal away from
flange until bottom corner is just clear of flange,
seal will then locate over flange. Ensure seal
has not become twisted. Starting from the top,
push the seal onto the flange.
NOTE: The bottom radius should match the
door profile.
6.Secure the seal to the bottom flange by rotating
the seal onto the flange and pushing evenly on
its length along the waist rail.
7.Fit inner seal.
8.Raise and lower glass to check seal fit.
9.Fit exterior mirror.
+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
Page 658 of 1007
EXTERIOR FITTINGS
REPAIRS 76-2-17
Moulding - roof - 5 door
$% 76.43.68
Remove
1.Remove tail door glass side finisher.
+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
2.Remove roof finisher caps or roof rack side rail.
+ EXTERIOR FITTINGS, REPAIRS,
Side rail - integral roof rack - 5 door.
3.Using a suitable hooked tool in the front foot
hole of the roof finisher, slide the finishers 2
forward clips rearward from the roof channel.
4.Slide the clip rear of the foot hole forward from
the roof channel.
5.Slide the remaining 7 clips from the roof
channel.
6.Remove nut securing rear end of roof finisher
and remove finisher.
7.Remove clips from roof finisher.Refit
1.Fit clips to roof finisher.
2.Fit finisher to roof channel with forward 2 clips.
3.Slide finisher to align with screen. Feed forward
clip below screen seal.
4.Fit remaining clips to roof channel.
5.Fit nut and secure rear end of finisher.
6.Ensure full length of finisher is correctly seated
in roof channel.
7.Fit roof finisher caps or roof rack side rail.
+ EXTERIOR FITTINGS, REPAIRS,
Side rail - integral roof rack - 5 door.
8.Fit tail door glass side finisher.
+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
Page 736 of 1007
BODY DIMENSIONS
BODY DIMENSIONS 77-1-1
BODY DIMENSIONS BODY DIMENSIONS
Dimensional Information
Measurement Types
The following dimensional information is shown so as to assist the technician in the diagnosis and repair of body
panels. The information is shown in two different ways. There are X,Y,Z dimensions and actual point to point
dimensions.
The X,Y,Z dimensions are the measuring planes used within Land Rover for the measurement of body panels. The
whole bodyshell is within a parallel grid system, see illustrations below.
The X plane is an imaginary vertical plane starting at the front of the vehicle. It is at right angles to the centre line of
the vehicle and measures distances along the length of the vehicle.
The Y plane is an imaginary plane through the centre of the vehicle. All Y dimensions start from this plane. As a rule,
body dimensions are symmetrical about the centre line.
The Z plane is set at a fixed distance parallel to the underside of the vehicle. All Z dimensions start from this plane.
The point to point measurements are actual distances between two points. These points can be holes or intersection
points. Where holes are taken, the point of measurement is always from the hole centre.
Measurements shown are in millimetres and inches. The measurements shown in brackets are in inches.
The tolerance for the basic geometry of the vehicle is ± 1.0 mm (0.040). This includes tooling holes, all fixing holes
and apertures.
The tolerance for matching panel form and break lines is ± 0.5 mm (0.020).
Page 741 of 1007
BODY DIMENSIONS
77-1-6 BODY DIMENSIONS
Under body information
Item From To Length
A Front crossmember, jig location hole Front subframe, rear mounting hole 1197.3 (47.137)
B Front crossmember, jig location hole Front subframe, rear mounting hole 985.7 (38.807)
C Front Subframe, front mounting hole `LH` Front subframe, front mounting hole `RH` 772.0 (30.393)
D Front subframe, front mounting hole Front subframe, rear mounting hole 295.3 (11.625)
E Front subframe, front mounting hole Front subframe, rear mounting hole 772.5 (30.413)
F Front subframe, rear mounting hole `RH` Front subframe rear mounting hole `LH` 660.0 (25.984)
G Front subframe, rear mounting hole Rear longitudinal front, jig location hole 1577.3 (62.098)
H Front subframe, rear mounting hole Rear subframe, front mounting hole 2129.9 (83.854)
J Rear longitudinal front, jig location hole Rear subframe, front mounting hole 983.0 (38.700)
K Rear subframe, front mounting hole `LH` Rear subframe front mounting hole `RH` 930.0 (36.614)
L Rear longitudinal front, jig location hole Rear subframe, front mounting hole 403.4 (15.881)
M Rear subframe, front mounting hole Rear crossmember, jig location hole 822.3 (32.374)
N Rear subframe, front mounting hole Rear crossmember, jig location hole 1199.5 (47.224)
Page 742 of 1007
BODY DIMENSIONS
BODY DIMENSIONS 77-1-7
Under body information
Item From To Length
A Sidemember, forward jig location hole `LH` Sidemember, forward jig location hole `RH` 962 (37.874
B Sidemember, forward jig location hole Front subframe, rear mounting hole 1216.0 (47.874
C Spring location, inboard fixing hole `LH` Spring location, inboard fixing hole `RH` 1029.8 (40.543)
D Spring location, inboard fixing hole Front subframe, rear mounting hole 396.4 (15.606)
E Spring location, inboard fixing hole Front subframe, rear mounting hole 914.8 (36.015)
F Link arm fix, `LH` Link arm fix, `RH` 926.2 (36.464)
G Rear longitudinal front, jig location hole Rear subframe, front mounting hole 403 (15.866)
H Link arm fix Rear subframe, front mounting hole 1072.2 (42.212)
J Rear subframe, front mounting hole Spring location, rear hole 364.2 (14.338)
K Rear subframe, front mounting hole Spring location, rear fixing hole 1125.7 (44.318)
L Rear subframe, front mounting hole Rear longitudinal rear, jig location hole 1213.0 (47.755
M Spring location, rear fixing hole `LH` Spring location, rear fixing hole `RH` 1220.0 (48.031
N Rear subframe, front mounting hole Rear longitudinal rear, jig location hole 700.7 (27.586)
P Rear longitudinal rear, jig location hole `LH` Rear longitudinal rear, jig location hole `RH` 1054.0 (41.496)
