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

ENGINEOVERHAUL 15
6.
Engine
numbers withoutsuffixB:Locate
slotted adaptor tooil pump driveshafttongue.
7. Check thatcentre lineofrotor armisaligned
with No.1 spark plugsegment indistributor cap
and reference marksondistributor bodyand
clamp arealigned; reposition distributor if
necessary.
8. Remove rotorarm.
9. Rotate distributor toposition pick-upopposite
nearest reluctortooth.
10.Fitdistributor clampnutensuring that
counterbored portionistowards clamp;tighten
nut.
11. Fitrotor arm.
CAUTION:...

ENGINE 16OVERHAUL
OIL
PUMP -ENGINE NUMBERS WITHOUT
SUFFIX B
Oil pump -remove
1. Remove sump.
2. Remove distributor.
3. Remove timingcover.
4. Remove oilcooler adapter -if fitted.
5. Remove oilpressure reliefvalve plug,discard
sealing washer.
6. Withdraw pressurereliefvalve spring and
valve.
7. Remove oilpressure switch,discard sealing
washer.
8. Remove boltssecuring oilpump cover.
9. Remove cover,remove anddiscard gasket.
10. Withdraw oilpump gears. Oil
pump -inspection
1. Throughly cleanoilpump...

ENGINEOVERHAUL 17
Oil
pump -refit
1. Lubricate reliefvalve, spring, andbore in
housing withclean engine oil.
2. Fitrelief valve andvalve spring.
3. Fitnew sealing washer toplug, fitplug and
tighten tocorrect torque.
4. Pack oilpump housing withPetroleum Jelly.
CAUTION: Useonly Petroleum Jelly,no
other grease issuitable.
5. Fitoilpump gearsensuring thatPetroleum
Jelly isforced intoevery cavity between teeth
of gears.
CAUTION: Unlesspumpisfully packed
with Petroleum Jellyitmay notprime itself
when...

ENGINE 18OVERHAUL
Oil
pressure reliefvalve -remove
1. Remove circlip.
2. Remove reliefvalve plug,remove anddiscard
O ring.
3. Remove reliefvalve spring andpiston. Oil
pump -inspection
1. Thoroughly cleanoilpump drivegear, cover
plate, rotors andhousing. Removealltraces of
Loctite fromcover platesecuring screws;
ensure tappedholesintiming coverareclean
and free from oil.
2. Check mating surfaces ofcover plate,rotors
and housing forscoring.
3. Assemble rotorsandoilpump drivegearin
housing ensuring...

ENGINEOVERHAUL 19
6.Place astraight edgeacross housing.
7. Using feelergauges, checkclearance between
straight edgeandrotors:
Maximum clearance =0.1 mm
Oil pressure reliefvalve -inspection
1. Clean reliefvalve components andpiston bore
in timing cover.
2. Check pistonandbore forscoring andthat
piston slidesfreelyinbore withnoperceptible
side movement.
3. Check reliefvalve spring fordamage and
distortion; checkspring freelength:
Spring freelength =60.0 mm Oil
pump -refit
1. Lubricate rotors,oilpump...

ENGINE 20OVERHAUL
CAMSHAFT
ANDTAPPETS
Camshaft andtappets -remove
1. Remove rockershaftassemblies.
2. Remove pushrods andstore infitted order.
3. Remove timingchainandgears.
4.Remove tappetsandretain withtheir
respective pushrods.
NOTE:Iftappets cannotberemoved due
to damaged camshaftcontactarea,
proceed asfollows:
5. Lift tappets inpairs tothe point where
damaged faceisabout toenter tappet bore
and fitrubber bandstoretain tappets. Repeat
until alltappets areretained clearofcamshaft
lobes. Thetappets...

ENGINEOVERHAUL 21
Camshaft
andtappets -refit
1. Lubricate camshaftjournalswithclean engine
oil and carefully insertcamshaft intocylinder
block.
2. Immerse tappetsinclean engine oil.Before
fitting, pumptheinner sleeve oftappet several
times using apushrod, toprime tappet and
reduce tappetnoisewhenengine isfirst
started.
3. Lubricate tappetboreswithclean engine oil
and fittappets inremoved order.
NOTE:Sometappet noisemaybeevident
on initial start-up. Ifnecessary, runthe
engine at2500 rev/min forafew...

ENGINE 22OVERHAUL
Pistons
-remove
1. Clamp hexagon bodyofLRT-12-013 invice.
2. Screw largenutback untilflush withendof
centre screw.
3. Push centre screwforward untilnutcontacts
thrust race.
4. Locate pistonadapter LRT-12-014 withitslong
spigot insideboreofhexagon body.
5. Fitparallel sleeve,grooved endfirst, onto
centre screwandsmear outside diameter with
engine oil.
6. Locate pistonandconnecting rodassembly on
centre screwanduptoadapter LRT-12-014.
7. Fitremover/replacer bushofLRT-12-014 on
centre...

ENGINEOVERHAUL 23
Cylinder
bore-inspection
1. Measure cylinderborewear intwo axis 40to
50 mm from topofbore.
Piston tocylinder boreclearance =0.018 to
0.033 mm.
NOTE: Pistons areavailable inservice
standard sizeand0.508 mmoversize.
Service standard sizepistons aresupplied
0.0254 mmoversize. Whenfitting newservice
standard sizepistons, checkforcorrect pistonto
bore clearance, honeboreifnecessary.
CAUTION: Thetemperature ofpiston and
cylinder blockmustbethe same toensure
accurate measurement. Whenreboring...

ENGINE 24OVERHAUL
8.
Fitgudgeon pinonto centre screwandinto
piston boreuptoconnecting rod.
9. Fitremover/replacer bushwithflanged end
towards gudgeon pin.
10. Screw thestop nutonto centre screwand
position pistonagainst faceofadaptor
LRT-12-014.
11. Lubricate centrescrewthreads andthrust race
with graphited oil,fit,and screw largenutupto
thrust race.
12. Adjust stopnutleaving clearance B,between
nut and remover/replacer bush.
Clearance B=0.8 mm.
13. Lock thestop nutsecurely withlockscrew.
14. Settorque...