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. Fitbig-end bearingcapsandbearing shells.
14. Fitcylinder head(s). FLYWHEEL Flywheel-
remove
1.Restrain crankshaft andremove 6bolts
securing flywheel.
2. Remove flywheel.
Inspect
1. Inspect flywheel faceforcracks, scoresand
overheating. Theflywheel canberefaced
providing thickness doesnotgobelow
minimum. Flywheel minimum thickness A=39.93 mm
2. Inspect ringgear forworn, chipped andbroken
teeth.
3. Renew ringgear ifnecessary.      
						

							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 newringgear uniformly tobetween
170 °and 175°C.
CAUTION: Donot exceed this
temperature.
6. Locate ringgear onflywheel withchamfered
inner diameter towardsflywheel flange.
NOTE:Ifring gear ischamfered onboth
sides, itcan befitted either wayround.
7. Press ringgear ontoflywheel untilitbutts
against flywheel flange.
8. Allow flywheel toair cool.
Flywheel -refit
1. Fitflywheel andlocate on2dowels.
2. Fitflywheel bolts.
3. With assistance, restraincrankshaft and
tighten flywheel boltstocorrect torque.   
						

							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 andbroken
teeth.
4. Renew ringgear assembly ifnecessary. Drive
plateandring gear assembly -refit
CAUTION: Toprevent distortion toflexible
drive platewhen bolted totorque
converter, driveplatesetting heightmust
be checked asfollows:
1. Fitexisting shimandcrankshaft adapterplate.
2. Fitsocket headscrews andlightly tighten.
3. Fitring gear assembly, hubaligner, driveplate
and clamping ring,fitbolts andlightly tighten.
4. Check thesetting height.
Drive platesetting heightA=8.08 to8.20 mm.
5. Remove bolts,remove clampring,flexible
drive plate, hubaligner andringgear
assembly.
6. Remove socketheadscrews, remove
crankshaft adapterandshim.    
						

							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 242tothreads ofbolts, fitbolts
and tighten tocorrect torque.
CRANKSHAFT, MAINANDBIG-END BEARINGS
Crankshaft end-float -check
1. Set-up DTItomeasure endfloat.
2. Move crankshaft forwardsandzero gauge.
3. Move crankshaft rearwards, recordend-float
reading obtained.
Crankshaft end-float=0.10 to0.20mm.
4. Remove DTI.
NOTE:Crankshaft end-floatiscontrolled
by thrust facesonupper halfofcentre
main bearing shell. Big-end
bearings -remove
1. Remove sump.
2.Remove 2bolts securing oilstrainer.
3. Remove strainer,removeanddiscard gasket.
4. Suitably identifybearing capstotheir
respective connecting rods.
5.Remove 2nuts securing eachbearing cap.
6. Remove bearingcapand bearing shell.
CAUTION: Keepbearing capsandshells
in their fitted order.
7. Fitalength ofplastic tubingovereach
connecting rodbolt.
8. Push eachpiston upitsrespective boreand
remove shellsfromconnecting rods.
CAUTION: Keepbearing shellsintheir
fitted order.    
						

							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 caps
ensuring reference marksonconnecting rods
and bearing capsarealigned.
NOTE: Ribonedge ofbearing capmust
face towards frontofengine onRH bank
of cylinders andtowards rearonLH bank
of cylinders.
6. Fitbearing capnuts andtighten tocorrect
torque.
7. Check connecting rodsmove freelysideways
on crankshaft. Tightnessindicatesinsufficient
bearing clearance ormisaligned connecting
rod.
8. Check clearance betweenconnecting rodson
each crankshaft journal.
Connecting rodclearance =0.15 to0.37 mm.
9. Clean oilstrainer.
10. Clean gasket mating facesonstrainer and
cylinder block.
11. Fitgasket tostrainer, positionstrainer, fitbolts
and tighten tocorrect torque.
12. Fitsump.    
						

							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 anddiscard sideseals fromrearmain
bearing cap.
10. Remove Woodruff keyfrom crankshaft. Crankshaft
-inspection
1. Clean crankshaft andblow outoilpassages.
2. Support crankshaft frontandrear bearings on
vee blocks, andusing aDTI, measure run-out
on centre mainbearing.
Maximum permittedrun-out=0.08 mm.
If run-out exceeds permitted maximum,
crankshaft isunsuitable forregrinding and
should berenewed.
3. Measure eachjournal foroverall wearand
ovality. Main bearing journaldiameter =58.409 to
58.422 mm
Maximum outofround =0.040 mm.
Big-end bearingjournaldiameter =50.800 to
50.812 mm
Maximum outofround =0.040 mm.
If measurements exceedpermitted maximum,
regrind orfitnew crankshaft.
NOTE: Ovality checks shouldbemade at
120 °intervals aroundeachjournal.
Crankshaft mainbearings areavailable in
0.254 mmand 0.508 mmundersizes. Whenfitting
0.508 mmundersize bearings,centremain
bearing, whichcontrols crankshaft end-float,has
thrust facesincreased inthickness by0.254 mm.
Therefore if0.508 mmundersize bearingsare
fitted, 0.127mmmust bemachined offeach
thrust faceofcentre mainbearing journalto
maintain correctradius.   
						

							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 to50.559 mm.
0.508 mmundersize =50.292 to50.305 mm. Crankshaft
spigotbearing -renew
1. Carefully extractoldspigot bearing.
2. Clean bearing recessincrankshaft.
3. Fitnew bearing flushwith,ortoamaximum of
1.6 mm below endface ofcrankshaft.
4. Ream bearing tocorrect insidediameter.
Spigot bearing insidediameter =19.177 +
0.025 mm.
5. Remove alltraces ofswarfe.
Crankshaft -refit
1. Clean mainbearing caps,bearing shell
recesses andmating surfaces ofcylinder
block.
2. Fitupper mainbearing shells,withoilholes
and grooves, incylinder block,ensuring
flanged shellisfitted incentre position.
3. Lubricate bearingshellswithclean engine oil
and position crankshaft incylinder block.
4. Fitmain bearing shellstobearing caps.     
						

							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 andlightly tighten.
11. Clean seallocation andrunning surfaceon
crankshaft.
12.
Engine numbers withoutsuffixB:Clean seal
protector LRT-12-010 andlubricate withengine
oil.
13.
Engine numbers withsuffix B:Clean seal
protector LRT-12-095 andlubricate withengine
oil.
14. Lubricate oilseal lipwith engine oil.
NOTE: Sealprotector LRT-12-095
illustrated.
15. Position sealprotector tocrankshaft.
16.
Engine numbers withoutsuffixB:Fitoilseal
squarely usinghandpressure onlyuntilfully
seated inrecess.
17.
Engine numbers withsuffix B:Fitseal using
tool LRT-12-091.
18. Tighten mainbearing capbolts tocorrect
torque.
19. FitWoodruff keytocrankshaft.
20. Check crankshaft end-float.
21. Fitbig-end bearings.
22. Fittiming coverandgears.
23. Fitflywheel ordrive plateandringgear
assembly.   
						

							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** Replace-crankshaft rearoilseal
LRT-12-095** Protectionsleeve-crankshaft rearoilseal
LRT-12-501 MS76BBasichandle set-valve seatcutters
LRT-12-503 MS150-8.5Adjustablevalveseatpilot
LRT-12-504 MS76-621Adjustablevalveseatcutter
LRT-12-515 RO.605774ADistancepiece-valve guide
* Engine numbers withoutsuffixB** Engine
numbers withsuffix B
Service toolsmust beobtained directfromthe
manufacturers:
V.L. Churchill,
P.O. BoxNo3,
London Road,
Daventry, Northants, NN114NF.
England.