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

ENGINEOVERHAUL 25
9.Fitring clamp topiston andcompress piston
rings.
10. Fitplastic tubingtoconnecting rodbolts.
11. Insert connecting rodand piston assembly into
respective cylinderboreensuring domed
shaped bossonconnecting rodfaces towards
front ofengine onRH bank ofcylinders, and
towards rearonLH bank ofcylinders.
NOTE: Whenbothconnecting rodsare
fitted toeach journal, bosseswillface
towards eachother.
12. Pullconnecting rodontocrankshaft journal.
CAUTION: Takecarenottoscratch
crankshaft journals.
13....

ENGINE 26OVERHAUL
Flywheel
ringgear -renew
1. Drill a10 m m diameter holeaxially atbase of
tooth andinner diameter ofstarter ring,
sufficiently deepenough toweaken ringgear.
CAUTION: Donot allow drilltoenter
flywheel.
2. Secure flywheel insoft jawed vice.
3. Split ringgear using acold chisel.
WARNING: Wearsafety goggles andtake
precautions againstflyingfragments when
splitting ringgear.
4. Remove flywheelfromvice, remove oldring
gear, andplace flywheel, clutchsidedown, on
a flat surface.
5.Heat...

ENGINEOVERHAUL 27
DRIVE
PLATE ANDRING GEAR ASSEMBLY
Drive plateandring gear assembly -remove
1. Mark eachcomponent toenable reassembly in
original position.
2.Remove 4bolts securing driveplate.
3. Remove clampring,flexible driveplate, hub
aligner andringgear assembly.
4. Remove 6socket headscrews securing
crankshaft adapterplate,remove adapter plate
and selective shim.
Inspect 1. Inspect flexibledriveplateforcracks and
distortion.
2. Renew driveplateifnecessary.
3. Inspect ringgear forworn, chipped...

ENGINE 28OVERHAUL
7.
Measure existingshimand,ifnecessary, select
appropriate shimtomaintain settingheight.
Shims available:
1.20 -1.25mm
1.30 -1.35mm
1.40 -1.45mm
1.50 -1.55mm
1.60 -1.65mm
1.70 -1.75mm
1.80 -1.85mm
1.90 -1.95mm
2.00 -2.05mm
2.10 -2.15mm
8. Fitshim selected, positionadapter, ensuring
marks previously madelineup,fitsocket head
bolts andtighten tocorrect torque.
9. Fitring gear assembly, hubaligner, flexible
drive plateandclamp ring.ensuring marks
previously madelineup.
10. Apply Loctite...

ENGINEOVERHAUL 29
Big-end
bearings -Inspection
1. Check big-end bearingshellsforwear and
damage.
2. Renew big-end bearingshellsasnecessary.
NOTE: Big-end bearings areavailable in
0.254 mmand 0.508 mmundersizes.
Big-end bearings -refit
1. Fitbearing shellstoeach connecting rod.
2. Lubricate bearingshellsandcrankshaft
journals withclean engine oil.
3. Pull connecting rodsontocrankshaft journals
and remove plastictubing.
4. Fitbearing shellstoeach big-end bearingcap.
5.Lubricate bearingshellsandfitbearing...

ENGINE 30OVERHAUL
Crankshaft
-remove
1. Remove flywheelordrive plateandringgear
assembly.
2. Remove timingcover.
3. Remove timinggears.
4. Remove big-endbearings.
5.Starting atcentre mainbearing andworking
outwards, progressively slackenthenremove
10 main bearing capbolts.
6. Remove 5main bearing capsandbearing
shells, retainbearings withtheir caps.
7. Lift out crankshaft andrear oilseal. Remove
and discard oilseal.
8. Remove 5bearing shellsfromcylinder block
and retain intheir fitted order.
9. Remove...

ENGINEOVERHAUL 31
Crankshaft
dimensions:
Bearingjournalradius-all journals exceptrearmain
journal A=1.90 to2.28 mm.
Rear mainbearing journalradiusB=3.04 mm.
Bearing journaldiameter C:
Standard =58.400 to58.413mm.
0.254 mmundersize =58.146 to58.158 mm.
0.508 mmundersize =57.892 to57.904 mm.
Bearing journalwidthD:
Standard =26.975 to27.026 mm.
0.254 mmundersize =26.975 to27.026 mm.
0.508 mmundersize =27.229 to27.280 mm.
Bearing journaldiameter E:
Standard =50.800 to50.812 mm.
0.254 mmundersize =50.546...

ENGINE
32 OVERHAUL
5.
Apply EXP16A (Marston Lubricants) lubricant
to threads ofmain bearing capbolts.
6. Lubricate mainbearing shellsandfitnumbers
1 to 4 bearing caps,fitand lightly tighten bolts.
7.Fitside seals torear main bearing cap.
CAUTION: Sealsmustprotrude
approximately 1.5mm above bearing cap
face.
8. Apply Hylomar SQ32Mjointingcompound to
bearing caprear mating faceoncylinder block.
9. Lubricate bearingshellandside seals with
clean engine oil,carefully fitbearing cap
assembly.
10. Fitbolts...

ENGINESERVICE TOOLS 1
SERVICE
TOOLS
Land Rover Number RoverNumber Description
LRT-12-010* 18G1014* Protectionsleeve-crankshaft rearoilseal
LRT-12-013 18G1150 Remover/replacergudgeonpin
LRT-12-014 18G1150E Adaptorremover/replacer gudgeonpin
LRT-12-034 18G1519 Valvespring compressor
LRT-12-037 RO.274401Driftremover -valve guide
LRT-12-038 RO.600959Driftreplacer -valve guide
LRT-12-055 Distancepiece-valve guide
LRT-12-089** Replacer-timing coveroilseal
LRT-12-090** Retainer-oil pump gears
LRT-12-091**...