TVR AJP8 User manual

Main Engine Assembly

~.Jpa
Modification
Block Modifications -Early Engines Only
Firstly the lower bellhousing mounting
t ad d h] , on ach side of the blo
need modifiying. (LeftPosition
shown)
(Right Position shown)
Modification 1is to drill through the
tapped hole at the front of the casting to
diameter S.5mm...
... and then tap through, MJ 0 x 1.5 x 2.5 mm
deep.

Modification
Modification
ModifiCJltion
~ .... pa
tito drill out the pump mounting
hol to 8.5mm...
... and th s then need th edges
deburring on both the front sid
... and then on the rear side.
Main Assembly
Engine - Main Assembly
Number the main bearing cup with an
engraver at the edges.

Mnin Assembly
Main Assf'lnbly
Main Assembly
Ml1iIJ Assembly
Start with the one neare tthe timing end
as shown.
Once this
has b n done the caps need to
be removed, starting from the front of the
block...
.. and work ba wards.
To remove the final cap, gently tap it with
aoft faced hammer on the ideo

~...JP El
MJIin Assembly
Main Assembly
Mod~ficali(ln
xt the oil feed holes for th main
barings ne dto be deburred ...
... and any sharp edges on the baring
bOT sneed to be removed.
Modification
The edges on the thrustbearingbore
need to be chamfered l.5mm x 45 u
In order for the fly wheel timing disc to
miss the oil gallery, the casting needs
relieving ahown.

Modification
In order for the fly wh el timing disc 0
turn, the oil gallery f ed n eds relieving.
Modification
Maill Assc1IIblt,
Rlieve th sump mounting flange 0 that
th wte transf r pipe clears the flang ...
... as hown.
Main Assembly
N xt remove th main oil gallery plug
and ...

L'....JP El
Main Assembly
Main Assembly
Main A~sembly
Main ASSl'm/lll1
... bru h out with arifle bru h, to remove
any burrs, etc.
Making ure
to brush the main oil gallery
feed.
In
order to remove any oil or greasy
residue place the modified block and
bearing caps in the parts washer.
Then
dry the block, making sure to blow
down the oil galleries with an air line.

El
Main Assembly
Main Assembly
Main Assembly
Ma/ll Asscl11/J1y
Make sure they r fr from any wate
or dbri .
ext apply PI'FE tape to the main oil
gallery
bung ...
... fit and torque to 20 ft lb .
Now mount engine on stand and insert
the four cylinder head dowels to the
block.

Main Asembly
~...JP El
Dgre ethe head studs with spirit wipe,
dryand apply loctite.
TIghten onto
the block to atorque of
25ft Ibs
in the order shown in the
diagram below. (
Le. - in length.)
Maifl Assembly
WORK ..
90mm
f-h
5~mm
1
1
, I
135mm
168mm
1"•••J
I
I
-I
I
50mm
I
125mm
Repeat for the outer head studs to a
torque of 15 Et lbs.

El
Marn Assembly
Main Assembly
Main Asst'IIl/Jl.'l
Malll Assm,bl.'l
Once fitted, the h ad tuds should be
level as
hown in th picture.
Next fj tthe halftiro bearing as well as
th idl rpinion.
Using aoft driftinsert
the jackshaft front
bearing.
Break the
sharp edges on the bottom of
the liners and wash.

~..JP El
Main Assembly
Malll AS~i'I11blil
Next apply silicone to the liners as
flOwn.
... and then slide onto the block tapping
home with asoft mallet
until fully eated.
Ensuring that on the RH
bank from the
front of the engine the large cutaways are
facing towards the rear
and on the LH
bank they are facing towards the front of
the engine.
Oean the thread in front of the crankshaft
throughly with spiritwipe ...
... and dry with ablow gun.

Main Assembly
~..JP El
Cl an the ank no pinion.
Insert
the drive key, and eloc pins.
Mam A5~embly
Main Asscmhly
Next clean and degrea ethe nose pinion
bolt
and dry ...
... then pply loctite studlock.

~....Jpa
Main Assembly
Fit the no pinion and torque the bolt to
80 ft Ibs.
Mnill ASSl'lI/bly
Ma;1I ASSl'1Il111y
Check no e pinion runs true to the crank
with dial gauge~ it should be under 2
thou.
Fit the crank to the crank balance and
draw on afitting line as hown with
marker pen. This is used to ensure the
crank has not moved whilst balancing.
Clamp on and make sure the flywheel
bolts,
dowel and spigot bush are fitted.
Run crank at 900 rpm on setting 5.

~ .... pa
Grind any metal off th webs arequired
nsuring to use aback
and forth motion
along the web and not sid -to-side
motion acro s the wb.
Maill Assembly
Main Assembly
Main Assl'mhltj
Grind ny metal offthe web as required.
epe t on fine setting (10) until balanced.
Wash crank
and thoroughly clean out
with arifle brush, remembering to clean
out all oil ways.

~..Jpa
Marll Assembly
MaJlI AS5Cmh/l!
Then blow through with an air gun.
Invert theblock and wipe the bearing
jourrials clean.
Wipe the
new bearings with atissue
soaked
in spirit wipe, making sur they
are thoroughly clean.
Noting the po ition of the tang ...

~""PEl
Main Assembly
Main Assembly
Mnrn 'tSSl'mhlll
... then fit to the bloc ...
... pu rung horn as hown. Fit the re tof
the hells rememb ring that No.4 is a
thrust hell.
Lubricate the main bearing with Nulon
...
... and lower crank. into place.

~..Jpa
Maill Assembly
Main Assembly
Check that it rotates freely between finger
and thumb.
Plastigauge one of the main bearings by
placing2strips on th bearing hell
shown.
Fit the main bearingcap.
Torque
down to 50 ft Ibs.
DO NOT ROTATE THE CRANK
Remove the cap
...

Main Assembly
Main Assembly
!vlnm Assembly
~..Jpa
... and check 1arance with the card.This
hould be 11/2 -21/2 thou.
When ele rnee is O.K.lubricate each
main shell and fit the caps, torqu ing to
50 ft lbs. cl< th crank still rotates
fr ly.
eel< thrust clearance.
Thi should be 0.005 to 0.007.

Mail, Assembly
~""PB
Che thru tclearance.
Main Asembly
Weigh pistonswith gudgeon pins and
select 8 that are within Ig ofeach other.
Check the piston ring gaps
by inserting
th ring into the bore and measuring with
feeler gauge. This should be:-
Top Ring 15 thou
min /17 thou max
2nd Ring 9
thou min / 11 thou max
Next wa hthe rings in spirit wipe
and fit
starting with oil control ring first,
then
the 2nd and first rings.

~..JPB
Main A5sembly
Main Assembly
Main Assembly
Main Ascmbly
Masure the ring EndfIoat which hould
ba minium of 1thou.
Wa hpist ns
and fit cir lip to one ideo
xt fit th rings to the istons noting
that each i engraved TOP on one ide
this ide has to be facing upwards when
fitting.
Select amatched
set ofcon-rods, wash,
dry and lubricate the littl nd. Ch ck
that the gudgeon pin iasliding fit and
number 1to 8 with an engraver on both
halve of the big end on the outside f the
big end bolts.