Rover's Vikingship Overhaul of the Rover V8 engine
part three
Rover's Vikingship

If you have technical Rover V8 problems aks Rene Winters


This part of site is an attempt to organize and add to the web resources for the Rover SD1 to form a cohesive and easily usable guide for those of us without easy access to expert repair and/or advice. It is not offered in any way as a definitive source and we take no responsibility for any errors that may exist.
Webmaster Rene Winters

Piston/Connecting Rod Overhaul

Next remove the pistons and connecting rods. Rotate the crankshaft so that the appropriate journal is at B.D.C. Release the big end bolts and remove the cap.
Screw the guide bolts, 605351, into the connecting rod to retain the upper big end bearing shell. Then push the piston and connecting rod assembly up the bore and withdraw it from the top of the engine. Store each assembly with its bearing cap and lower shell.
During factory assembly of the engine the pistons are selectively fitted within a 0.0015 in range to their bores to ensure a perfect fit. Each piston and its appropriate bore is marked with a letter from ZABCD. Z is the smallest, D the largest. Take care to refit the appropriate piston to its bore.
New pistons for service purposes are available in one standard size only. This size is 0.025 mm (0.001 in) oversize above the D size. Oversize pistons are also available in one size only, 0.508 mm (0.020 in) oversize.
The engine is available in 3 different compression ratios 8.13 9.35 and 9.75. This is catered for by different depths of the domes in the piston crowns. So make sure you select the correct pistons when fitting new ones.
The compression ratio can be found stamped on the block above its unit number.

The gudgeon pin is a semi-floating type using an interference fit in the little end as a location. So you will need special tools to remove and refit the gudgeon pins. Here we see special tool 605350 in use with a press to remove the pin.
When refitting the gudgeon pin, press the pin until it abuts the shoulder of the guide. Check that the piston moves freely and that no I damage has occurred during pressing.
Alternatively special tool 18G 1150 can be used in a similar manner.
Check the appropriate bore dimension to make sure that the piston will fit. When correct the bore dimension taken at right angles to the gudgeon pin at a depth from 90 to 100 mm from the top should exceed the piston dimension taken at the bottom of the skirt by 0.018 to 0.033 mm (0.0007 to 0.0013 in).
If new rings only are to be fitted, deglaze the bore with a hone taking care not to increase the diameter. If oversize pistons are to be fitted, the block must be bored out to suit.

If the original pistons are to be refitted, remove the rings and then clean the pistons, removing all the carbon and deposits, paying particlar attention to the piston ring grooves.
Before fitting the rings to the piston, check them in their appropriate bores, holding them square with a piston. Measure the gap between the ring ends. If the gap exceeds the upper limit of 0.60 mm (0.022 in) replace it. If the gap is less than the lower limit of 0.46 mm (0.017 in) carefully file the end of the ring with a fine cut file until the gap is correct.
Fit the rings to the piston and check that the clearance between each compression ring and its groove is within 0.08 to 0.13 mm (0.003 to 0.005 in).
One final check should be carried out to the pistons and connecting rods, namely the big ends. These should be checked using Plastigauge.

When using the Plastigauge, tighten the big end bolts to 4.0 to 4.9 kgf m (30 to 35 Ibf ft). The correct clearance for new or overhauled components is 0.015 to 0.055 mm (0.0006 to 0.0022 in). If the bearings have already been in service, then new shells should be fitted if the clearance exceeds 0.08 mm (0.003 in).
All that remains to be removed is the crankshaft. If a manual gearbox is fitted, remove the flywheel. If an automatic gearbox is fitted remove the drive plate.
Finally remove the main bearing caps and shell bearings storing them in fitted order. Lift out the crankshaft.

Clean the crankshaft and inspect it checking the dimensions f the journals with those in the relevant data. If necessary the crank can be reground. Only one size, 0.508 mm (0.020 in), f oversize bearing shell is available. Make sure that all f the oil galleries are clear of obstructions.
If any doubt exists concerning the dimensions f the journal in relation to its bearing shell, always use Plastigauge to check the clearance.

The V8 overhaul part I
The V8 overhaul part II
The V8 overhaul part IV
The V8 overhaul part V

Torque Wrench Setttings of the V8



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