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 seatinsert asnecessary. 7.
Check valvestemtoguide clearance.
Valve stemtoguide clearance D:
Inlet =0.25 to0.66 mm
Exhaust =0.38 to0.78 mm
8. Check condition ofvalve springs:
Free length =48.30 mm
Fitted length =40.40 mm
Load atfitted length =339 ±10N
Load atvalve openlength =736 ±22N
CAUTION: Valvesprings mustbereplaced
as acomplete set.
Valve guide -renew
1. Using valveguide remover, LRT-12-037 press
valve guide outfrom combustion chamberside
of cylinder head.
NOTE:Service valveguides are0.025mm
oversize onoutside diameter toensure
interference fit.
2. Lubricate newvalve guide withengine oiland
place inposition.    
						

							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 inseat insert, untilthin
enough tobreak usingacold chisel.
CAUTION: Donot damage counterbore.
2. Heat cylinder headevenly toapproximately
65 °C.
3. Using asuitable mandrel, pressnewinsert fully
into counterbore.
4. Allow cylinder headtoair cool.   
						

							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
cutter headwithangled endofblade
downwards, facingwork,asillustrated. Check
that cutter blades areadjusted sothat middle
of blade contacts areaofmaterial tobe cut.
Use light pressure andremove onlyminimum
of material necessary.     
						

							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. Thoroughly cleancylinder head,blowout
oilways andcoolant passages.
6. Fitnew valve stemoilseals, lubricate valve
stems, fitvalves, valvesprings andcaps,
compress valvesprings usingLRT-12-034 and
fit collets.
7. Using awooden dowelandmallet, lightlytap
each valve stemtwoorthree times toseat
valve capand collets. Cylinder
head-refit
1. Clean cylinder blockfaces usingasuitable
release agentandplastic scraper; ensurethat
bolt holes incylinder blockareclean anddry.
CAUTION: Donot use metal scraper or
machined surfacesmaybedamaged.
2.
Engine numbers withoutsuffixB:Thoroughly
clean threads ofcylinder headbolts.
CAUTION: Cylinderheadbolts -Cylinder
head bolts fitted toengines withoutsuffix
B added toserial number arenot
interchangeable withthose fittedtoengines with
suffix Badded toserial number.
3.Fitcylinder headgasket withtheword TOP
uppermost.
NOTE: Gasket mustbefitted dry.
CAUTION: EngineswithoutsuffixBhave a
steel gasket whilstengines withsuffix B
have acomposite gasket.Thetwotypes of
gasket arenot interchangeable anditis essential
to ensure thatthecorrect typeofgasket isfitted.
4. Carefully fitcylinder headandlocate on
dowels.
5. Lightly oilthreads ofcylinder headbolts.    
						

							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 shown,tightencylinder head
bolts to:
Stage 1-Correct torque
Stage 2-90 °
Stage 3-Further 90°
All engines
10. Fitrocker shaftassembly.
TIMING CHAINANDGEARS
Distributor -remove
1. Remove distributor cap.
2. Rotate crankshaft untilcentre lineofrotor arm
is aligned withNo.1spark plugsegment in
distributor capand No.1piston isat TDC.
3. Scribe analignment markbetween distributor
body andclamp.
4. Remove nutsecuring distributor clamp.
5. Remove distributor.
6. Remove clamp.
7. Remove anddiscard Oring from distributor.     
						

							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.
3.Remove boltsandnutsecuring timingcoverto
cylinder block.
4. Release andremove timingcover.
5. Remove anddiscard gasket.
6. Remove anddiscard oilseal from timing cover.    
						

							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
gears-remove
1. Restrain camshaft gearandremove bolt
securing gear,collect washer.
2. Remove distributor drivegearandspacer.
3.Remove timingchainandgears asan
assembly.
4. Collect Woodruff keysfromcamshaft and
crankshaft.
Timing gears-inspection
1. Thoroughly cleanallcomponents.
2. Inspect distributor drivegearforwear.
3. Inspect timingchainlinksandpins forwear.
4. Inspect timingchainsprockets forwear. Renew
parts asnecessary.      
						

							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 fitcamshaft gearwithmarking F
facing forwards.
5. Turn camshaft untilmark oncamshaft sprocket
is at the sixoclock position, removegear
without moving camshaft.
6.Position timinggearsonwork surface with
timing marks upwards andaligned.
7. Fittiming chainaround gears,keeping timing
marks aligned.
8. Fitgear andchain assembly.
NOTE: Timing marksandFmark on
camshaft gearmust befacing forwards.
9.Fitspacer tocamshaft withflange facing
forwards.
10. Fitdistributor drivegeartocamshaft with
grooved facetowards camshaft gear.
11. Fitcamshaft gearboltand washer, restrain
camshaft gearandtighten bolttocorrect
torque.     
						

							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 threads oftiming coverboltswithLoctite
242 sealant.
8. Fittiming cover, fitbolts andnutand tighten to
correct torque.
9. Fitcrankshaft pulley.
10. Fitspacer washer topulley bolt,fitbolt and
tighten tocorrect torque. Timing
cover-refit -Engine numbers withsuffix
B
NOTE: Timing cover,oilpump andoil
pressure reliefvalve areonly supplied as
an assembly.
1. Clean sealant fromthreads oftiming cover
bolts.
2. Clean alltraces ofgasket material frommating
faces oftiming coverandcylinder block.
CAUTION: Useaplastic scraper.
3. Clean oilseal location intiming cover.
4. Lubricate oilpump gearsandoilseal recesss
in timing coverwithengine oil.
5. Apply Hylosil jointing compound tonew timing
cover gasket, position gaskettocylinder block.
6. Position oilpump drivegearintiming cover
with groove towards frontoftiming cover.
7.Locate toolLRT-12-090 ontiming coverandoil
pump drivegear.
8. Position timingcovertocylinder blockandat
the same time,rotate toolLRT-12-090 until
drive gearkeyway isaligned withWoodruff
key.
9. Fittiming covertocylinder block.
10. Smear threads oftiming coverboltswith
Loctite 242sealant, fitbolts andtighten
progressively tothe correct torque.
NOTE: Donot fitcoolant pumpboltsat
this stage.
11. Remove toolLRT-12-090.    
						

							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, tightenprogressively tocorrect
torque.
5. Fitand tighten screwsecuring dipsticktubeto
LH rocker cover.
6. Fitdipstick. Distributor
-refit
1. Ensure timingpointer isaligned with30mark
on crankshaft pulleyandNo.1 piston ison the
compression stroke.
2. Engine numbers withoutsuffixB:Position
oil pump driveshafttongue atthe tentofour
position.
3. Lubricate anew Oring with engine oiland fit
to distributor.
4. Turn distributor driveuntilrotor armis
approximately 30°anti-clockwise fromNo.1
spark plugsegment indistributor cap.
5. Insert distributor intotiming cover, engage
drive gearandpush distributor downuntilO
ring enters bore;position distributor clampon
stud.