Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 1997 Rover Manual
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ENGINE DESCRIPTION AND OPERATION3 CYLINDER BLOCK COMPONENTS 1.Cylinder block 2.Piston and gudgeon pin 3.Connecting rod 4.Core plugs 5.Camshaft 6.Dipstick 7.Camshaft key 8.Timing chain 9.Camshaft sprocket 10.Spacer 11.Distributor drive gear - if fitted 12.Distributor - if fitted 13.Oil pump gears * 14.Timing cover and gasket * 15.Timing cover oil seal * 16.Crankshaft pulley 17.Crankshaft sprocket 18.Woodruff key 19.Crankshaft20.Centre main bearing shell - upper 21.Crankshaft rear oil seal 22.Rear main bearing cap and side seals 23.Connecting rod cap 24.Main bearing caps 25.Oil pump cover * 26.Oil pressure relief valve assembly * 27.Oil pressure switch * 28.Oil pump suction pipe and strainer 29.Sump 30.Drain plug 31.Timing cover ** 32.Timing cover gasket ** 33.Timing cover oil seal ** 34.Oil filter ** 35.Oil pressure switch ** 36.Oil pressure relief valve assembly ** 37.Camshaft thrust plate - if fitted * Engine numbers without suffix B ** Engine numbers with suffix B
ENGINE 4 DESCRIPTION AND OPERATION CYLINDER HEAD COMPONENTS 1.Cylinder head 2.Rocker cover 3.PCV filter 4.Rocker shaft 5.Tappet 6.Pushrod 7.Rocker shaft bracket 8.Rocker arm 9.Rocker shaft spring 10.PCV air intake filter11.Engine oil filler cap 12.Inlet valve seal, spring, cap, and collets 13.Exhaust valve seal, spring, cap and collets 14.Inlet valve and seat 15.Exhaust valve and seat 16.Inlet manifold gasket and seals 17.Cylinder head gasket 18.Valve guide 19.Bolts - cylinder head
ENGINE DESCRIPTION AND OPERATION5 Engine without suffix B added to serial no. illustrated OPERATION The V8 engine is an eight cylinder, water cooled unit comprising of cast aluminium cylinder block and cylinder heads. The two banks of cast iron cylinder liners are shrink fitted and are located on stops in the cylinder block. The banks of cylinders are set at 90°to each other. The crankshaft is carried in five main bearings, end-float being controlled by the thrust faces of the upper centre main bearing shell.The centrally located camshaft is driven by the crankshaft via an inverted tooth chain. The valves are operated by rockers, pushrods and hydraulic tappets. The distributor - if fitted, is driven by a skew gear from the front of the camshaft. The aluminium alloy, pistons have two compression rings and an oil control ring and are secured to the connecting rods by semi-floating gudgeon pins. On later 4.2L engines the gudgeon pin is offset 0.5 mm (0.02 in), identified by an arrow mark on the piston crown, which must always point to the front of the engine. Plain, big-end bearing shells are fitted to each connecting rod.
ENGINE 6 DESCRIPTION AND OPERATION Lubrication - Engine numbers without suffix B 1.Oil strainer 2.Crankshaft main bearing oil feed 3.Oil pressure relief valve 4.Oil pump5.Main gallery AOil to cooler BOil from cooler
ENGINE DESCRIPTION AND OPERATION7 Lubrication - Engine numbers with suffix B 1.Oil strainer 2.Oil pump 3.Pressure relief valve 4.Oil pressure switch5.Main gallery AOil to cooler BOil from cooler Engine numbers without suffix B The full flow lubrication system uses an external gear pump which is driven by the distributor drive shaft. The oil pump gears are housed in the timing cover and the oil pressure relief valve and warning light switch are fitted to the oil pump cover. Engine numbers with suffix B The full flow lubrication system uses a gear type oil pump driven from the crankshaft. The assembly is integral with the timing cover which also carries the full flow oil filter, oil pressure switch and pressure relief valve.All engines Oil is drawn from the pressed steel sump through a strainer and into the oil pump, excess pressure being relieved by the pressure relief valve. The oil pressure warning light switch is screwed into the oil pump cover and registers the oil pressure in the main oil gallery on the outflow side of the filter. Pressurised oil passes through an oil cooler - if fitted to the full flow oil filter and through internal drillings to the crankshaft where it is directed to each main bearing and to the big end bearings via Nos. 1, 3 and 5 main bearings. An internal drilling in the cylinder block directs oil to the camshaft where it passes through further internal drillings to the hydraulic tappets, camshaft journals and rocker shaft. Lubrication to the thrust side of the cylinders is by oil grooves machined in each connecting rod big end joint face, which are timed to align with holes in the big end journals on the power and exhaust strokes.
ENGINE 8 DESCRIPTION AND OPERATION Distributor drive and timing chain lubrication 1.Bearing 2.Camshaft 3.Key 4.Camshaft timing chain sprocket 5.Spacer 6.Distributor drive gear The distributor drive and timing chain are lubricated from the camshaft front bearing. The feed to the timing chain is channelled along the camshaft sprocket, key and spacer.Hydraulic tappets1.Clip 2.Pushrod seat 3.Inner sleeve 4.Upper chamber 5.Non-return ball valve 6.Spring 7.Outer sleeve 8.Lower chamber - high pressure The purpose of the hydraulic tappet is to provide maintenance free and quiet operation of the inlet and exhaust valves. It achieves this by utilising engine oil pressure to eliminate the mechanical clearance between the rockers and the valve stems. During normal operation, engine oil pressure present in the upper chamber passes through the non-return ball valve and into the lower, high pressure, chamber. When the cam begins to lift the outer sleeve, the resistance of the valve spring felt through the push rod and seat causes the tappet inner sleeve to move downwards inside the outer sleeve. This downward movement of the inner sleeve closes the ball valve and increases the pressure in the lower, high pressure chamber, sufficiently to ensure that the push rod opens the valve fully. As the tappet moves off the peak of the cam the ball valve opens to equalise the pressure in both chambers which ensures the valve closes when the tappet is on the back of the cam.
ENGINE OVERHAUL1 ROCKER SHAFTS Rocker shafts - remove 1.LH rocker shaft only:Remove screw securing dipstick tube to rocker cover. 2.Remove 4 Allen screws securing rocker cover to cylinder head. NOTE: Note fitted position of 2 long screws. Later engines - multi-hex bolts are used. 3.Remove rocker cover. 4.Remove and discard gasket from rocker cover. 5.Mark each rocker shaft in relation to original cylinder head. CAUTION: Incorrect fitment of rocker shafts will lead to an oil feed restriction. 6.Progressively slacken and remove 4 bolts securing rocker shaft assembly to cylinder head. 7.Remove rocker shaft assembly. 8.Remove pushrods and store in fitted order. 9.Repeat above procedures for remaining rocker shaft.
ENGINE 2 OVERHAUL Rocker shafts - dismantling 1.Remove and discard split pin from one end of rocker shaft. 2.Remove plain washer, wave washer, rocker arms, brackets and springs.Inspecting components 1.Thoroughly clean components. 2.Inspect each component for wear, in particular rocker arms and shafts. Discard weak or broken springs. 3.Inspect push rod seats in rocker arms. 4.Check push rods for straightness and inspect ball ends for damage, replace as necessary.
ENGINE OVERHAUL3 Rocker shafts - assembling 1.Assemble rocker shafts with identification groove at one oclock position with push rod end of rocker arm to the right. CAUTION: If rocker shafts are incorrectly assembled and fitted to engine, oil supply to rocker arms will be restricted. 2.Fit new split pin to one end of rocker shaft. 3.Fit plain washer and wave washer. 4.Lubricate rocker arm bushes with clean engine oil. 5.Early type rocker arms are angled, and must be fitted with the valve end of the rocker arms angled away from each other as illustrated. 6.On later type rocker arms the valve end is offset and must be fitted as illustrated. NOTE: Early and late rocker arms are interchangeable provided the complete set is changed.7.Assemble rocker arms, brackets and springs to rocker shaft. 8.Compress springs, fit wave washer, plain washer and secure with new split pin.