Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 1997 Rover Manual
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INFORMATION 2 GENERAL DATA Oil pump - Engine numbers with suffix B Inner to outer rotor clearance - maximum 0.25 mm.........0.01 in Rotors to cover plate clearance - maximum 0.1 mm.......0.004 in Drive gear wear step depth - maximum 0.15 mm...........0.006 in Oil pressure relief valve - Engine numbers with suffix B Spring free length 60.0 mm........................... 2.4in Camshaft Maximum run-out 0.05 mm............................0.002 in End-float - Camshafts with thrust plate 0.05 to 0.35 mm...........0.002 to 0.014 in Piston rings Ring to groove clearance: Top compression 0.05 to 0.10 mm...........................0.002 to 0.004 in 2nd compression 0.05 to 0.10 mm...........................0.002 to 0.004 in Ring fitted gap: Top compression 0.44 to 0.57 mm...........................0.02 to 0.022 in 2nd compression 0.44 to 0.57 mm...........................0.02 to 0.022 in Oil control rails 0.38 to 1.40 mm.............................0.014 to 0.05 in Oil control ring width 3.00 mm.........................0.12 in - maximum Pistons Clearance in bore, measured at bottom of skirt at right angles to bore 0.02 to 0.045 mm....................0.001 to 0.002 in Gudgeon pins Length 72.67 to 72.79 mm....................................2.85 to 2.86 in Diameter 22.215 to 22.220 mm..................................0.87 to 0.871 in Clearance in piston 0.006 to 0.015 mm..........................0.0002 to 0.0006 in Connecting rods Length between centres 143.71 to 143.81 mm......................5.66 to 5.67 in Cylinder bore Cylinder bore diameter: 3.5 engine 88.90 mm................................ 3.5in 3.9 engine 94.00 mm................................ 3.7in 4.2 engine 94.00 mm................................ 3.7in Maximum ovality 0.013 mm............................0.0005 in Crankshaft Main journal diameter 58.409 to 58.422 mm........................2.29 to 2.30 in Maximum regrind diameter 57.900 to 57.914 mm...................2.28 to 2.281 in Maximum out of round 0.040 mm.......................0.002 in Big-end journal diameter 50.800 to 50.812 mm......................1.99 to 2.00 in Maximum regrind diameter 50.292 to 50.305 mm...................1.97 to 1.98 in Maximum out of round 0.040 mm.......................0.002 in End-float 0.10 to 0.20 mm..................................0.004 to 0.008 in Maximum run-out 0.08 mm............................0.003 in Spigot bearing inside diameter 19.177 + 0.025.................0.75 + 0.001 - 0.00 mm - 0.00 in
INFORMATION GENERAL DATA3 Main bearings Main bearing diametrical clearance 0.010 to 0.048 mm..............0.0004 to 0.002 in Undersizes 0.254, 0.508 mm................................0.01, 0.02 in Big-end bearings Big-end bearing diametrical clearance 0.015 to 0.055 mm...........0.0006 to 0.0021 in Undersizes 0.254, 0.508 mm................................0.01, 0.02 in Endfloat on journal 0.15 to 0.36 mm...........................0.006 to 0.01 in Flywheel Flywheel minimum thickness 39.93 mm................... 1.6in Drive plate Drive plate setting height 8.08 to 8.20 mm......................0.32 to 0.33 in
INFORMATION TORQUE WRENCH SETTINGS1 ENGINE Crankshaft pulley bolt 270 Nm........................ 200lbf.ft Timing cover to cylinder block bolts 22 Nm.............. 16lbf.ft Camshaft gear bolt 50 Nm.......................... 37lbf.ft Rocker cover bolts: + Stage 1 4 Nm.................................. 3lbf.ft Stage 2 8 Nm.................................. 6lbf.ft Stage 3 - Re-torque to 8 Nm....................... 6lbf.ft Rocker shaft to cylinder head bolts 38 Nm.............. 28lbf.ft Cylinder head bolts - Engine numbers without suffix B: + * Bolts 11 to 14 - Outer row 60 Nm.................... 44lbf.ft Bolts 2, 4, 6, 8 and 10 - Centre row 90 Nm............. 66lbf.ft Bolts 1, 3, 5, 7 and 9 - Inner row 90 Nm............... 66lbf.ft Cylinder head bolts - Engine numbers with suffix B: + * Stage 1 20 Nm.................................. 15lbf.ft Stage 2 Then 90° .................................. Stage 3 Further 90° .................................. Lifting eye to cylinder head bolts 40 Nm................ 30lbf.ft Connecting rod nuts/bolts 50 Nm..................... 37lbf.ft Main bearing cap bolts +** Initial torque - all bolts: 14 Nm....................... 10lbf.ft Final torque: Numbers 1 to 4 main bearing cap bolts: 70 Nm......... 52lbf.ft Rear main bearing cap bolts: 90 Nm.................. 66lbf.ft Flywheel bolts 80 Nm.............................. 59lbf.ft Drive plate assembly bolts 45 Nm..................... 33lbf.ft Drive plate adapter Allen screws 85 Nm................ 63lbf.ft Oil sump drain plug 45 Nm.......................... 33lbf.ft Oil sump bolts + 23 Nm............................. 17lbf.ft Oil pressure relief valve plug - Engine numbers without suffix B 45 Nm............................. 33lbf.ft Oil pump cover to timing cover - Engine numbers without suffix B 12 Nm............................. 9lbf.ft Oil pump cover plate screws - Engine numbers with suffix B *** 4 Nm............................. 3lbf.ft Oil pump cover plate bolt - if fitted *** 8 Nm............ 6lbf.ft Oil pressure switch 15 Nm.......................... 11lbf.ft Oil strainer bolts 10 Nm............................. 7lbf.ft Distributor clamp nut 20 Nm......................... 15lbf.ft Spark plug 20 Nm................................. 15lbf.ft Coolant pump/timing cover to cylinder block 22 Nm....... 16lbf.ft Camshaft thrust plate bolts - if fitted 25 Nm............. 18lbf.ft + Tighten in sequence * Lightly oil threads prior to assembly. ** Coat threads with lubricant EXP16A (Marston Lubricants) prior to assembly. *** Coat threads with Loctite 222 prior to assembly.
INFORMATION 2 TORQUE WRENCH SETTINGS GENERAL For bolts and nuts not otherwise specified: METRIC M5 4 Nm...................................... 3lbf.ft M6 6 Nm...................................... 4lbf.ft M8 18 Nm...................................... 13lbf.ft M10 35 Nm..................................... 26lbf.ft M12 65 Nm..................................... 48lbf.ft M14 80 Nm..................................... 59lbf.ft M16 130 Nm..................................... 96lbf.ft UNC / UNF 1/4 9 Nm...................................... 7lbf.ft 5/16 25 Nm..................................... 18lbf.ft 3/8 40 Nm...................................... 30lbf.ft 7/16 75 Nm..................................... 55lbf.ft 1/2 90 Nm...................................... 66lbf.ft 5/8 135 Nm...................................... 100lbf.ft
INFORMATION SERVICE TOOLS1 SERVICE TOOLS Land Rover Number Rover Number Description LRT-12-010* 18G 1014* Protection sleeve - crankshaft rear oil seal LRT-12-013 18G 1150 Remover/replacer gudgeon pin LRT-12-014 18G 1150E Adapter remover/replacer gudgeon pin LRT-12-034 18G 1519 Valve spring compressor LRT-12-037 RO.274401 Drift remover - valve guide LRT-12-038 RO.600959 Drift replacer - valve guide LRT-12-055 Distance piece - valve guide LRT-12-089** Replacer - timing cover oil seal LRT-12-090** Retainer - oil pump gears LRT-12-091** Replace - crankshaft rear oil seal LRT-12-095** Protection sleeve - crankshaft rear oil seal LRT-12-501 MS76B Basic handle set - valve seat cutters LRT-12-503 MS150-8.5 Adjustable valve seat pilot LRT-12-515 RO.605774A Distance piece - valve guide LRT-12-517 - Adjustable valve seat cutter * Engine numbers without suffix B ** Engine numbers with suffix B Service tools must be obtained direct from the manufacturers: V.L. Churchill, P.O. Box No 3, London Road, Daventry, Northants, NN11 4NF. England.
ENGINE CONTENTS Page DESCRIPTION AND OPERATION CYLINDER BLOCK COMPONENTS 3.................................... CYLINDER HEAD COMPONENTS 4..................................... OPERATION 5...................................................... OVERHAUL ROCKER SHAFTS 1.................................................. Rocker shafts - remove 1.............................................. Rocker shafts - dismantling 2........................................... Inspecting components 2.............................................. Rocker shafts - assembling 3........................................... Rocker shafts - refit 4................................................. CYLINDER HEAD 5.................................................. Cylinder head - remove 5.............................................. Valves and springs - remove 6.......................................... Cylinder head - inspection 6............................................ Valves, valve springs and guides - inspection 7............................. Valve guides - renew 9................................................ Valve seat inserts - inspection 10........................................ Valve seat inserts - renew 10........................................... Valve seats and seat inserts - refacing 11.................................. Valves - lapping-in 12................................................. Valves and springs - refit 13............................................ Cylinder head - refit 13................................................ TIMING CHAIN AND GEARS 15......................................... Distributor - if fitted - remove 15......................................... Sump - remove 15.................................................... Timing cover - remove - engine numbers without suffix B 16................... Timing cover - remove - engine numbers with suffix B 16...................... Timing gears - remove 17.............................................. Timing chain and gears - inspection 17.................................... Timing gears - refit 18................................................. Timing cover - refit - engine numbers without suffix B 19...................... Timing cover - refit - engine numbers with suffix B 20......................... Sump - refit 21....................................................... Distributor - if fitted - refit 22............................................ OIL COOLER ADAPTER - ENGINE NUMBERS WITHOUT SUFFIX B 23......... Oil cooler adapter - remove 23.......................................... Oil cooler adapter - refit 23............................................. OIL PUMP - ENGINE NUMBERS WITHOUT SUFFIX B 24.................... Oil pump - remove 24................................................. Oil pump - inspection 24............................................... Oil pump - refit 25.................................................... OIL PUMP - ENGINE NUMBERS WITH SUFFIX B 25........................ Oil pump remove 25.................................................. Oil pressure relief valve - remove 26...................................... Oil pump - inspection 26............................................... Oil pressure relief valve - inspection 27.................................... Oil pump - refit 28.................................................... Oil pressure relief valve - refit 28......................................... CAMSHAFT AND TAPPETS 29......................................... Camshaft end-float - check 29..........................................
ENGINE CONTENTS Page Camshaft and tappets - remove 29....................................... Camshaft and tappets - inspection 30..................................... Camshaft and tappets - refit 31.......................................... PISTONS, CONNECTING RODS, PISTON RINGS AND CYLINDER BORES 31... Pistons and connecting rods - remove 31.................................. Piston rings - remove 32............................................... Piston rings - inspection 32............................................. Pistons - remove 33.................................................. Pistons and connecting rods - inspection 33................................ Gudgeon pins - inspection 34........................................... Cylinder liner bore - inspection 34........................................ Pistons - refit 35..................................................... Piston to cylinder bore clearance - checking 37............................. Pistons and connecting rods - refit 37..................................... FLYWHEEL AND STARTER RING GEAR 38............................... Flywheel - remove 38................................................. Flywheel and starter ring gear - inspection 39............................... Starter ring gear - renew 39............................................. Flywheel - refit 40.................................................... DRIVE PLATE AND RING GEAR ASSEMBLY 41........................... Drive plate and ring gear assembly - remove 41............................. Drive plate and ring gear - inspection 41................................... Drive plate and ring gear assembly - check setting height 42................... Drive plate and ring gear assembly - refit 43................................ CRANKSHAFT, MAIN AND BIG-END BEARINGS 43........................ Big-end bearings - remove 43........................................... Big-end bearings - refit 44.............................................. Crankshaft - remove 45................................................ Crankshaft - inspection 46.............................................. Crankshaft spigot bearing - renew 47..................................... Crankshaft - refit 48................................................... Crankshaft end - float - check 50.........................................
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