Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 1997 Rover Manual

ENGINE
34
OVERHAUL Gudgeon pins - inspection
NOTE: Gudgeon pins are only supplied as
an assembly with replacement pistons.
1.Check gudgeon pins for signs of wear and
overheating.
2.Check clearance of gudgeon pin in piston:
Gudgeon pin to piston clearance = 0.006 to
0.015 mm (0.0002 to 0.0006 in)
3.Check overall dimensions of gudgeon pin:
Overall length = 72.67 to 72.79 mm (2.85 to
2.86 in)
Diameter - measured at each end and centre
of pin = 22.215 to 22.220 mm (0.87 to 0.871 in)Cylinder liner bore -...

ENGINE
OVERHAUL35
3.If only new piston rings are to be fitted, break
cylinder bore glazing using a fine grit, to
produce a 60°cross-hatch finish.
CAUTION: Ensure all traces of grit are
removed after above operation. If dipstick
tube has been removed, coat portion of
tube below collar with Loctite 572 prior to
refitting.Pistons - refit
CAUTION: On later 4.2L engines the piston
has a 0.5 mm (0.02 in) offset gudgeon pin
which can be identified by an arrow mark
on the piston crown. This arrow MUST always...

ENGINE
36
OVERHAUL
2.Clamp hexagon body ofLRT-12-013in vice.
3.Slacken large nut and pull the centre screw 50
mm (1.9 in) out of hexagon body.
4.Locate piston adapterLRT-12-014with its long
spigot inside bore of hexagon body.
5.Fit parallel sleeve, grooved end last, up to
shoulder on centre screw.
6.Lubricate gudgeon pin and bores of connecting
rod and piston with graphited oil.
7.Locate connecting rod and piston to centre
screw with connecting rod entered on sleeve
up to groove.
8.Fit gudgeon pin on to...

ENGINE
OVERHAUL37
Piston to cylinder bore clearance - checking
1.Starting with number 1 piston, invert piston and
with arrow on piston crown pointing towards
REAR of cylinder block, insert piston in cylinder
liner.
2.Position piston with bottom of skirt 30 mm (1.2
in) from top of cylinder block.
3.Using feeler gauges, measure and record
clearance between piston and left hand side of
cylinder block:
Piston to bore clearance = 0.02 to 0.045 mm
(0.001 to 0.002 in)
4.Repeat above procedures for remaining...

ENGINE
38
OVERHAUL
9.Fit ring clamp to piston and compress piston
rings.
10.Insert connecting rod and piston assembly into
respective cylinder bore ensuring domed
shaped boss on connecting rod faces towards
front of engine on RH bank of cylinders, and
towards rear on LH bank of cylinders.
NOTE: When both connecting rods are
fitted to each journal, bosses will face
towards each other.
11.Fit big-end bearing caps and bearing shells.
12.Fit cylinder head(s).FLYWHEEL AND STARTER RING GEAR
Flywheel - remove...

ENGINE
OVERHAUL39
Flywheel and starter ring gear - inspection
1.Inspect flywheel face for cracks, scores and
overheating. The flywheel can be refaced
providing thickness does not go below
minimum.
Flywheel minimum thicknessA= 39.93 mm
(1.6 in)
2.Inspect ring gear for worn, chipped and broken
teeth.
CAUTION: Do not attempt to remove
reluctor ring - if fitted.
3.Renew ring gear if necessary.Starter ring gear - renew
1.Drill a 9.5 mm (0.375 in) diameter hole axially
at base of tooth and inner diameter of...

ENGINE
40
OVERHAUL
5.Heat new ring gear uniformly to between 170°
and 175°C (340°and 350°F).
CAUTION: Do not exceed this
temperature.
WARNING: Handle hot ring gear with care.
.
6.Locate ring gear on flywheel with chamfered
inner diameter towards flywheel flange.
NOTE: If ring gear is chamfered on both
sides, it can be fitted either way round.
7.Press ring gear on to flywheel until it butts
against flywheel flange.
8.Allow flywheel to air cool.Flywheel - refit
1.Fit flywheel and locate on 2 dowels.
2.Fit...

ENGINE
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DRIVE PLATE AND RING GEAR ASSEMBLY
Drive plate and ring gear assembly - remove
1.Suitably identify each component to its fitted
position.
NOTE: Shimmed drive plate assembly
illustrated.
2.Remove 4 bolts securing drive plate assembly.
3.Remove buttress ring and drive plate
assembly.
NOTE: Dowel located.
4.Remove 6 socket head Allen screws securing
hub aligner to crankshaft, remove hub aligner.
5.Remove selective shim - if fitted; retain shim.Drive plate and ring gear - inspection...

ENGINE
42
OVERHAUL Drive plate and ring gear assembly - check
setting height
NOTE: The following procedures are only
applicable to shimmed drive plates, there
is no need to check setting height on drive
plates which are not shimmed.
1.Fit original selective shim and hub aligner, fit
socket head Allen screws and tighten to 80 Nm
(63 lbf.ft).
2.Fit drive plate assembly and buttress ring
ensuring that reference marks are aligned; fit
bolts and tighten to 45 Nm (33 lbf.ft).
CAUTION: If a new drive plate...

ENGINE
OVERHAUL43
Drive plate and ring gear assembly - refit
1.Position selected shim - if fitted to crankshaft.
2.Fit hub aligner, fit Allen screws and tighten to
85 Nm (63 lbf.ft).
3.Fit drive plate assembly and buttress ring
ensuring that reference marks are aligned or
that paint mark is towards torque converter.
4.Fit bolts and tighten to 45 Nm (33 lbf.ft).CRANKSHAFT, MAIN AND BIG-END BEARINGS
Big-end bearings - remove
1.Remove sump.
2.Remove 2 bolts securing oil strainer.
3.Remove strainer, remove...