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

							ENGINE
14
OVERHAUL
Engine numbers without suffix B
NOTE: RH cylinder head illustrated
5.Lightly oil threads of cylinder head bolts.
6.Fit cylinder head bolts:
Long bolts: 1, 3 and 5.
Medium bolts: 2, 4, 6, 7, 8, 9, and 10.
Short bolts: 11, 12, 13 and 14.
7.Using sequence shown, progressively tighten
cylinder head bolts to:
Bolts 11 to 14 - Outer row - 60 Nm (44 lbf.ft)
Bolts 2, 4, 6, 8 and 10 - Centre row - 90 Nm
(66 lbf.ft)
Bolts 1, 3, 5, 7 and 9 - Inner row - 90 Nm (66
lbf.ft)
Engine numbers with suffix B
NOTE: RH cylinder head illustrated
8.Lightly oil threads of new cylinder head bolts.
9.Fit cylinder head bolts:
Long bolts: 1, 3 and 5
Short bolts: 2, 4, 6, 7, 8, 9 and 10
NOTE: There are no bolts fitted in the four
lower holes in each cylinder head.
10.Using sequence shown, tighten cylinder head
bolts to:
Stage 1 - 20 Nm (15 lbf.ft)
Stage 2 - 90°
Stage 3 - Further 90°
CAUTION: Do not tighten bolts 180°in one
operation.
All engines
11.Fit rocker shaft assembly. 
						

							ENGINE
OVERHAUL15
TIMING CHAIN AND GEARS
Distributor - if fitted - remove
1.Remove distributor cap.
2.Rotate crankshaft until centre line of rotor arm
is aligned with No. 1 spark plug segment in
distributor cap and No. 1 piston is at TDC.
3.Scribe an alignment mark between distributor
body and clamp.
4.Remove nut securing distributor clamp.
5.Remove distributor.
6.Remove clamp.
7.Remove and discard O ring from distributor.Sump - remove
1.Remove dipstick.
2.Remove screw securing dipstick tube to LH
rocker cover.
NOTE: Sump fitted to engines without
suffix B engine numbers illustrated.
3.Remove 16 bolts securing sump to cylinder
block.
NOTE: Engine numbers with suffix B, 17
bolts are used to secure sump to cylinder
block.
4.Carefully release sump from cylinder block.
CAUTION: Take care not to damage
sealing faces of cylinder block and sump.
5.Remove sump. 
						

							ENGINE
16
OVERHAUL Timing cover - remove - Engine numbers without
suffix B
1.Remove crankshaft pulley bolt and collect
spacer washer.
2.Remove crankshaft pulley.
3.Remove bolts and nut securing timing cover to
cylinder block.
4.Release and remove timing cover.
5.Remove and discard gasket.
6.Remove and discard oil seal from timing cover.Timing cover - remove - Engine numbers with
suffix B
NOTE: Timing cover, oil pump and oil
pressure relief valve are only supplied as
an assembly.
1.Using assistance, restrain flywheel and remove
crankshaft pulley bolt; collect spacer washer.
2.Remove crankshaft pulley.
3.Noting their fitted position, remove bolts
securing timing cover to cylinder block; remove
cover.
NOTE: Dowel located.
4.Remove oil pump drive gear.
5.Remove and discard gasket.
6.Remove and discard oil seal from timing cover. 
						

							ENGINE
OVERHAUL17
Timing gears - remove
1.Restrain camshaft gear and remove bolt
securing gear, collect washer.
2.Remove distributor drive gear - if fitted and
spacer.
3.Remove timing chain and gears as an
assembly.
4.Collect Woodruff keys from camshaft and
crankshaft.Timing chain and gears - inspection
1.Thoroughly clean all components.
2.Inspect distributor drive gear - if fitted for wear.
3.Inspect timing chain links and pins for wear.
4.Inspect timing chain gears for wear. Renew
parts as necessary. 
						

							ENGINE
18
OVERHAUL Timing gears - refit
1.Clean gear locations on camshaft and
crankshaft, fit Woodruff keys.
2.Check camshaft Woodruff key is fully engaged
in keyway.
CAUTION: Space between Woodruff key
and keyway acts as an oil feed. It is
therefore most important that key is
properly seated and parallel to axis of camshaft.
Overall dimension A must not exceed 30.15 mm
(1.2 in).
3.Temporarily fit crankshaft gear, and if
necessary turn crankshaft to bring timing mark
on gear to the twelve oclock position, remove
gear.
4.Temporarily fit camshaft gear with marking F
facing forwards.
5.Turn camshaft until mark on camshaft gear is
at the six oclock position, remove gear without
moving camshaft.
6.Position timing gears on work surface with
timing marks upwards and aligned.
7.Fit timing chain around gears, keeping timing
marks aligned.
8.Fit gear and chain assembly.
NOTE: Timing marks and F mark on
camshaft gear must be facing forwards. 
						

							ENGINE
OVERHAUL19
9.Fit spacer to camshaft with flange facing
forwards.
10.Fit distributor drive gear - if fitted to camshaft
with grooved face towards camshaft gear.
11.Fit camshaft gear bolt and washer, restrain
camshaft gear and tighten bolt to 50 Nm (37
lbf.ft).Timing cover - refit - Engine numbers without
suffix B
1.Clean sealant from threads of cover bolts.
2.Clean all traces of old gasket material from
timing cover and mating face of cylinder block.
CAUTION: Use a plastic scraper.
3.Use a lint free cloth and thoroughly clean oil
seal location in timing cover.
4.Lubricate new oil seal sealing surfaces with
engine oil.
5.Locate seal to timing cover and press seal in
squarely until flush with front face of timing
cover.
6.Position new gasket to cylinder block.
7.Coat threads of timing cover bolts with Loctite
242 sealant.
8.Fit timing cover, fit bolts and nut and tighten
progressively to 22 Nm (16 lbf.ft).
9.Fit crankshaft pulley.
10.Fit spacer washer to pulley bolt, fit bolt and
tighten to 270 Nm (200 lbf.ft). 
						

							ENGINE
20
OVERHAUL Timing cover - refit - Engine numbers with suffix
B
NOTE: Timing cover, oil pump and oil
pressure relief valve are only supplied as
an assembly.
1.Clean sealant from threads of timing cover
bolts.
2.Clean all traces of gasket material from mating
faces of timing cover and cylinder block.
CAUTION: Use a plastic scraper.
3.Clean oil seal location in timing cover.
4.Lubricate oil seal recess in timing cover with
engine oil.
5.Apply Hylosil jointing compound to new timing
cover gasket, position gasket to cylinder block.
6.Position oil pump drive gear in timing cover
with groove towards front of timing cover.
7.Locate toolLRT-12-090on timing cover and oil
pump drive gear.
8.Position timing cover to cylinder block and at
the same time, rotate toolLRT-12-090until
drive gear keyway is aligned with Woodruff
key.
9.Fit timing cover to cylinder block.
10.Smear threads of timing cover bolts with
Loctite 242 sealant, fit bolts and tighten
progressively to 22 Nm (16 lbf.ft).
NOTE: Do not fit coolant pump bolts at
this stage.
11.Remove toolLRT-12-090.
A- Early type seal
B- Later type seal - use as replacement for all
engines
12.Lubricate new timing cover oil seal with Shell
Retinax LX grease ensuring that space
between seal lips is filled with grease.
CAUTION: Do not use any other type of
grease.
13.Fit timing cover oil seal using toolLRT-12-089.
14.Fit crankshaft pulley, fit bolt and spacer
washer; tighten bolt to 270 Nm (200 lbf.ft). 
						

							ENGINE
OVERHAUL21
Sump - refit
1.Remove all traces of old sealant from mating
faces of cylinder block and sump.
NOTE: Sump fitted to engines with suffix B
engine numbers illustrated.
2.Clean mating faces with suitable solvent. Apply
a bead of Hylosil type 101 or 106 sealant to
sump joint face as shown:
Bead width - areas A, B, C and D = 12 mm (0.5
in)
Bead width - remaining areas = 5 mm (0.20 in)
Bead length - areas A and B = 32 mm (1.23 in)
Bead length - areas C and D = 19 mm (0.75 in)
CAUTION: Do not spread sealant bead.
3.Fit sump, taking care not to damage sealant
bead.
CAUTION: Sump must be fitted
immediately after applying sealant.
4.Fit sump bolts and using sequence shown,
tighten progressively to 23 Nm (17 lbf.ft).
NOTE: Engine numbers without suffix B -
use sequence numbers 1 to 8 and 10 to 16.
5.Fit and tighten screw securing dipstick tube to
LH rocker cover.
6.Fit dipstick. 
						

							ENGINE
22
OVERHAUL Distributor - if fitted - refit
1.Ensure timing pointer is aligned with 3°mark
on crankshaft pulley and No.1 piston is on the
compression stroke.
2.
Engine numbers without suffix B:Position oil
pump drive shaft tongue at the ten to four
position.
3.Lubricate a new O ring with engine oil and fit
to distributor.
4.Turn distributor drive until rotor arm is
approximately 30°anti-clockwise from No.1
spark plug segment in distributor cap.
5.Insert distributor into timing cover, engage
drive gear and push distributor down until O
ring enters bore; position distributor clamp on
stud.6.
Engine numbers without suffix B:Locate
slotted adapter to oil pump drive shaft tongue.
7.Check that centre line of rotor arm is aligned
with No.1 spark plug segment in distributor cap
and reference marks on distributor body and
clamp are aligned; reposition distributor if
necessary.
8.Remove rotor arm.
9.Rotate distributor to position pick-up opposite
nearest reluctor tooth.
10.Fit distributor clamp nut ensuring that
counterbored portion is towards clamp; tighten
nut to 20 Nm (15 lbf.ft).
11.Fit rotor arm.
CAUTION: This distributor setting is to
enable engine to be started. When engine
is refitted, ignition timing must be set
using electronic equipment. 
						

							ENGINE
OVERHAUL23
OIL COOLER ADAPTER - ENGINE NUMBERS
WITHOUT SUFFIX B
Oil cooler adapter - remove
1.Remove oil filter element.
2.Mark position of adapter in relation to oil pump
cover.
3.Remove centre screw and withdraw adapter.
4.Remove and discard sealing ring.Oil cooler adapter - refit
1.Thoroughly clean adapter.
2.Position new sealing ring, fit adapter, ensuring
marks previously made line up, fit and tighten
centre screw.
3.Lubricate sealing ring of oil filter with engine oil.
4.Screw filter on to filter head until it seats then
tighten a further half-turn.