Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 1996 Rover Manual

ENGINEOVERHAUL 5
Valves,
valvesprings andguides -inspection
1. Clean cylinder head,valvesprings, valvesand
valve guide bores.
2. Check existing valvestemandhead diameters.
3. Check valvestemtoguide clearance using
new valves.
4.Renew valvesandguides asnecessary.
Valve headdiameter A:
Inlet =39.75 to40.00 mm
Exhaust =34.226 to34.48 mm
Valve stemdiameter B:
Inlet =8.664 to8.679 mm
Exhaust =8.651 to8.666 mm
5. Check installed heightofeach valve.
Valve installed heightC= 47.63 mm
6. Renew valve/valve...

ENGINE 6OVERHAUL
3.Using LRT-12-038 partiallypressguideinto
cylinder head,remove tool.
4. FitLRT-12-515 overvalve guide andcontinue
to press guideintocylinder headuntiltool
contacts springseat.Remove tool.
Valve guideinstalled heightA=24.13 mm
Valve seatinsert -inspection
1. Check valveseatinserts forpitting, burning
and wear. Replace insertsasnecessary. Valve
seatinsert -renew
NOTE: Service valveseatinserts are
available 0.25mmoversize onoutside
diameter toensure interference fit.
1.Grind acrescent...

ENGINEOVERHAUL 7
Valve
seats-renew
1. Check condition ofvalve seats andvalves that
are tobe reused.
2. Remove carbonfromvalves andvalve seats.
3.Reface valvesasnecessary. Ifa valve hasto
be ground toaknife-edge toobtain atrue seat,
fit anew valve.
Valve seating faceangle A=4 5°
4. Cut valve seats usingLRT-12-501 with
LRT-12-503 andLRT-12-504.
Valve seat:
Width A:Inlet =37.03 mm
Exhaust =31.50 mm
Width B=1.5 -2.00 mm
Angle C=7 0°
Angle D=4 6°± 15
Angle E=2 0°
5. Ensure cutterblades arecorrectly fittedto...

ENGINE 8OVERHAUL
Valves
andsprings -refit
1. Lap each valve toits seat using finegrinding
paste.
2. Clean valveandseat.
3.Coat valve seatwithasmall quantity of
engineers blue,insert valveandpress itinto
position severaltimeswithout rotating. Remove
valve andcheck foreven andcentral seating.
Seating position shownbyengineers blue
should beincentre ofvalve face.
4.Check valveinstalled heightifvalve seats have
been recutornew valves orvalve seatinserts
have been fitted.
Valve installed heightA=47.63 mm
5....

ENGINEOVERHAUL 9
Enginenumbers withoutsuffixB
NOTE: RHcylinder headillustrated
6. Fitcylinder headbolts:
Long bolts: 1,3and 5.
Medium bolts:2,4,6,7,8,9,and 10.
Short bolts:11,12,13and 14.
7. Using sequence shown,progressively tighten
cylinder headboltstocorrect torque.
Engine numbers withsuffix B
NOTE: RHcylinder headillustrated
8. Fitnew cylinder headbolts:
Long bolts: 1,3and 5
Short bolts:2,4,6,7, 8,9and 10
NOTE: Therearenobolts fitted inthe four
lower holes ineach cylinder head. 9.
Using sequence...

ENGINE 10OVERHAUL
Sump
-remove
1. Remove dipstick.
2. Remove screwsecuring dipsticktubetoLH
rocker cover.
3.Remove 16bolts securing sumptocylinder
block.
NOTE: Engine numbers withsuffix B,17
bolts areused tosecure sumptocylinder
block.
4. Carefully releasesumpfromcylinder block.
CAUTION: Takecarenottodamage
sealing facesofcylinder blockandsump.
5. Remove sump. Timing
cover-remove -Engine numbers without
suffix B
1. Remove crankshaft pulleyboltand collect
spacer washer.
2. Remove crankshaft pulley....

ENGINEOVERHAUL 11
Timing
cover-remove -Engine numbers with
suffix B
NOTE: Timing cover,oilpump andoil
pressure reliefvalve areonly supplied as
an assembly.
1. Using assistance, restrainflywheel andremove
crankshaft pulleybolt;collect spacer washer.
2. Remove crankshaft pulley.
3.Noting theirfitted position, removebolts
securing timingcovertocylinder block;remove
cover.
NOTE: Dowellocated.
4.Remove oilpump drivegear.
5. Remove anddiscard gasket.
6. Remove anddiscard oilseal from timing cover. Timing...

ENGINE 12OVERHAUL
Timing
gears-refit
1. Clean gearlocations oncamshaft and
crankshaft, fitWoodruff keys.
2.Check camshaft Woodruffkeyisfully engaged
in keyway.
CAUTION: Spacebetween Woodruff key
and keyway actsasan oilfeed. Itis
therefore mostimportant thatkeyis
properly seatedandparallel toaxis ofcamshaft.
Overall dimension Amust notexceed 30.15
mm.
3. Temporarily fitcrankshaft gear,andif
necessary turncrankshaft tobring timing mark
on gear tothe twelve oclock position, remove
gear.
4. Temporarily...

ENGINEOVERHAUL 13
Timing
cover-refit -Engine numbers without
suffix B
1. Clean sealant fromthreads ofcover bolts.
2. Clean alltraces ofold gasket material from
timing coverandmating faceofcylinder block.
CAUTION: Useaplastic scraper.
3. Use alint free cloth andthoroughly cleanoil
seal location intiming cover.
4. Lubricate newoilseal sealing surfaces with
engine oil.
5.Locate sealtotiming coverandpress sealin
squarely untilflush withfront faceoftiming
cover.
6. Position newgasket tocylinder block.
7. Coat...

ENGINE 14OVERHAUL
12.Lubricate newtiming coveroilseal withengine
oil.
13. Fittiming coveroilseal using toolLRT-12-089.
14. Fitcrankshaft pulley,fitbolt and spacer
washer; tightenbolttocorrect torque.
Sump -refit
1. Remove alltraces ofold sealant frommating
faces ofcylinder blockandsump.
2.Clean mating faceswithsuitable solventand
apply a2m m bead ofHylosil whitesilicone
sealant tosump jointface asshown.
3. Fitsump, takingcarenottodamage sealant
bead.
4. Fitsump boltsandworking fromthecentre
outwards,...