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
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
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.