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

							ENGINE
24
OVERHAUL OIL PUMP - ENGINE NUMBERS WITHOUT
SUFFIX B
Oil pump - remove
1.Remove sump.
2.Remove distributor.
3.Remove timing cover.
4.Remove oil cooler adapter - if fitted.
5.Remove oil pressure relief valve plug, discard
sealing washer.
6.Withdraw pressure relief valve spring and
valve.
7.Remove oil pressure switch, discard sealing
washer.
8.Remove bolts securing oil pump cover.
9.Remove cover, remove and discard gasket.
10.Withdraw oil pump gears.Oil pump - inspection
1.Throughly clean oil pump gear housing, cover
and gears.
2.Clean oil pressure relief valve bore in housing.
3.Clean relief valve filter screen.
4.Inspect pump gears for wear and scoring.
5.Fit pump gears into housing.
6.Place straight edge across gears.
7.Check clearance between straight edge and
cover face.
Gear to cover face minimum clearance = 0.05
mm (0.002 in).
If clearance is below minimum specified check
gear recess in housing for wear. Renew
housing if necessary.
8.Remove oil pump gears from housing.
9.Clean oil pressure relief valve and spring.
10.Inspect relief valve for wear and scoring.
11.Inspect relief valve spring for wear or signs of
collapse.
Relief spring free length = 81.28 mm (3.2 in)
12.Check relief valve slides freely in its bore with
no perceptible side movement. 
						

							ENGINE
OVERHAUL25
Oil pump - refit
1.Lubricate relief valve, spring, and bore in
housing with clean engine oil.
2.Fit relief valve and valve spring.
3.Fit new sealing washer to plug, fit plug and
tighten to 45 Nm (33 lbf.ft).
4.Pack oil pump housing with Petroleum Jelly.
CAUTION: Use only Petroleum Jelly, no
other grease is suitable.
5.Fit oil pump gears ensuring that Petroleum
Jelly is forced into every cavity between teeth
of gears.
CAUTION: Unless pump is fully packed
with Petroleum Jelly it may not prime itself
when the engine is started.
6.Fit new pump cover gasket.
7.Position cover, fit bolts and tighten
progressively to 12 Nm (9 lbf.ft).
8.Fit oil cooler adapter.
9.Fit timing cover.
10.Fit distributor.
11.Fit sump.OIL PUMP - ENGINE NUMBERS WITH SUFFIX B
CAUTION: Overhaul procedures for the oil
pump and oil pressure relief valve are
limited to carrying out dimensional
checks. In the event of wear or damage being
found, a replacement timing cover assembly
must be fitted.
Oil pump - remove
1.Remove timing cover.
2.Remove oil pump drive gear.
3.Remove screws and bolt - if fitted securing
cover plate, remove plate.
4.Make suitable alignment marks on inner and
outer rotors, remove rotors. 
						

							ENGINE
26
OVERHAUL Oil pressure relief valve - remove
1.Remove circlip.
2.Remove relief valve plug, remove and discard
O ring.
3.Remove relief valve spring and piston.Oil pump - inspection
1.Thoroughly clean oil pump drive gear, cover
plate, rotors and housing. Remove all traces of
Loctite from cover plate securing screws;
ensure tapped holes in timing cover are clean
and free from oil.
2.Check mating surfaces of cover plate, rotors
and housing for scoring.
3.Assemble rotors and oil pump drive gear in
housing ensuring that reference marks are
aligned.
4.Using feeler gauges, check clearance between
teeth of inner and outer rotors:
Maximum clearance = 0.25 mm (0.01 in)
5.Remove oil pump drive gear, check depth of
any wear steps on gear teeth:
Wear step maximum depth = 0.15 mm (0.006
in) 
						

							ENGINE
OVERHAUL27
6.Place a straight edge across housing.
7.Using feeler gauges, check clearance between
straight edge and rotors:
Maximum clearance = 0.1 mm (0.004 in)Oil pressure relief valve - inspection
1.Clean relief valve components and piston bore
in timing cover.
2.Check piston and bore for scoring and that
piston slides freely in bore with no perceptible
side movement.
3.Check relief valve spring for damage and
distortion; check spring free length:
Spring free length = 60.0 mm (2.4 in) 
						

							ENGINE
28
OVERHAUL Oil pump - refit
1.Lubricate rotors, oil pump drive gear, cover
plate and housing with engine oil.
2.Assemble rotors in housing ensuring that
reference marks are aligned.
3.Position cover plate to housing.
4.Apply Loctite 222 to threads of cover plate
screws and bolt - if fitted, fit but do not fully
tighten screws and bolt.
5.Position drive gear in oil pump, tighten cover
plate screws and bolt - if fitted to:
Screws - 4 Nm (3 lbf.ft).
Bolt - 8 Nm (6 lbf.ft)
6.Fit timing cover.Oil pressure relief valve - refit
1.Lubricate new O ring with engine oil and fit to
relief valve plug.
2.Lubricate relief valve spring, piston and piston
bore with engine oil.
3.Assemble piston to relief valve spring, insert
piston and spring into piston bore.
4.Fit relief valve plug, depress plug and fit circlip.
5.Ensure circlip is fully seated in groove. 
						

							ENGINE
OVERHAUL29
CAMSHAFT AND TAPPETS
Camshaft end-float - check
NOTE: this check is only applicable to
camshafts fitted with thrust plate.
1.Remove rocker shaft assemblies.
2.Remove push rods and store in fitted order.
3.Remove timing chain and gears.
4.Temporarily fit camshaft gear bolt.
5.Attach a suitable DTI to front of cylinder block
with stylus of gauge contacting end of
camshaft.
6.Push camshaft rearwards and zero gauge.
7.Using camshaft gear bolt, pull camshaft
forwards and note end-float reading on gauge.
End-float = 0.05 to 0.35 mm (0.002 to 0.014 in)
8.if end-float is incorrect, fit a new thrust plate
and re-check. If end-float is still incorrect, a
new camshaft must be fitted.Camshaft and tappets - remove
1.Remove tappets and retain with their
respective push rods.
NOTE: If tappets cannot be removed due
to damaged camshaft contact area,
proceed as follows:
2.Lift tappets in pairs to the point where
damaged face is about to enter tappet bore
and fit rubber bands to retain tappets. Repeat
until all tappets are retained clear of camshaft
lobes. The tappets can then be withdrawn out
the bottom of their bores when the sump and
camshaft are removed. 
						

							ENGINE
30
OVERHAUL
3.Remove 2 bolts securing camshaft thrust plate
- if fitted to cylinder block, remove plate.
4.Withdraw camshaft, taking care not to damage
bearings in cylinder block.Camshaft and tappets - inspection
1.Throughly clean all components.
2.Inspect camshaft bearing journals and lobes
for signs of wear, pitting, scoring and
overheating.
3.Support camshaft front and rear bearings on
vee blocks, and using a DTI, measure
camshaft run-out on centre bearing.
Maximum permitted run-out = 0.05 mm (0.002
in).
4.Inspect camshaft thrust plate - if fitted, for
wear, replace plate if wear is evident.
5.Clean and inspect tappets. Check for an even,
circular wear pattern on the camshaft contact
area. If contact area is pitted or a square wear
pattern has developed, tappet must be
renewed.
6.Inspect tappet body for excessive wear or
scoring. Replace tappet if scoring or deep wear
patterns extend up to oil feed area. Clean and
inspect tappet bores in engine block.
7.Ensure that tappets rotate freely in their
respective bores.
8.Inspect push rod contact area of tappet,
replace tappet if surface is rough or pitted. 
						

							ENGINE
OVERHAUL31
Camshaft and tappets - refit
1.Lubricate camshaft journals with clean engine
oil and carefully insert camshaft into cylinder
block.
2.Fit camshaft thrust plate - if fitted, ensuring that
it is correctly located in camshaft groove. Fit
bolts and tighten to 25 Nm (18 lbf.ft)
NOTE: If camshaft or thrust plate has been
replaced, it will be necessary to re-check
camshaft end-float.
3.Immerse tappets in clean engine oil. Before
fitting, pump the inner sleeve of tappet several
times using a push rod, to prime tappet and
reduce tappet noise when engine is first
started.
4.Lubricate tappet bores with clean engine oil
and fit tappets in removed order.
NOTE: Some tappet noise may be evident
on initial start-up. If necessary, run the
engine at 2500 rev/min for a few minutes
until noise ceases.
5.Fit timing chain and gears.
6.Fit rocker shaft assemblies.PISTONS, CONNECTING RODS, PISTON RINGS
AND CYLINDER BORES
Pistons and connecting rods - remove
1.Remove cylinder head(s).
2.Remove big-end bearings.
3.Remove carbon ridge from top of each cylinder
bore.
4.Suitably identify each piston to its respective
cylinder bore.
5.Push connecting rod and piston assembly to
top of cylinder bore and withdraw assembly.
6.Repeat above procedure for remaining pistons.
CAUTION: Big-end bearing shells must be
replaced whenever they are removed. 
						

							ENGINE
32
OVERHAUL Piston rings - remove
1.Using a suitable piston ring expander, remove
and discard piston rings.
2.Remove carbon from piston ring grooves.
NOTE: Use an old broken piston ring with
a squared off end.
CAUTION: Do not use a wire brush.Piston rings - inspection
1.Temporarily fit new compression rings to
piston.
NOTE: The ring marked TOP must be
fitted, with marking uppermost, into
second groove. The chrome ring fits into
top groove and can be fitted either way round.
2.Check compression ring to groove clearance:
Top compression ringA= 0.05 to 0.10 mm
(0.002 to 0.004 in)
2nd compression ringB= 0.05 to 0.10 mm
(0.002 to 0.004 in)
3.Insert piston ring into its relevant cylinder bore,
held square to bore with piston and check ring
gaps.
Top compression ring = 0.44 to 0.57 mm (0.02
to 0.22 in)
2nd compression ring = 0.44 to 0.57 mm(0.02
to 0.22 in)
Oil control ring rails = 0.38 to 1.40 mm (0.14 to
0.05 in) 
						

							ENGINE
OVERHAUL33
Pistons - remove
1.Clamp hexagon body ofLRT-12-013in vice.
2.Screw large nut back until flush with end of
centre screw.
3.Push centre screw forward until nut contacts
thrust race.
4.Locate piston adapterLRT-12-014with its long
spigot inside bore of hexagon body.
5.Locate piston and connecting rod assembly on
centre screw and up to adapterLRT-12-014.
6.Fit remover/replacer bush ofLRT-12-014on
centre screw with flanged end away from
gudgeon pin.
7.Screw stop nut on to centre screw.
8.Lock the stop nut securely with lockscrew.
9.Push connecting rod to right to locate end of
gudgeon pin in adapterLRT-12-014.
10.Ensure remover/replacer is located in gudgeon
pin bore of piston.
11.Screw large nut up toLRT-12-013.
12.Hold lockscrew and turn large nut until
gudgeon pin is withdrawn from piston.
13.Dismantle tool and remove piston, connecting
rod and gudgeon pin.
NOTE: Keep each piston and gudgeon pin
with their respective connecting rod.
14.Repeat above operation for remaining pistons.Pistons and connecting rods - inspection
1.Clean carbon from pistons
2.Inspect pistons for distortion and cracks.
3.Measure piston diameter at 90°to gudgeon pin
axis and 10 mm (0.4 in) from bottom of skirt.
The piston must be 0.02 mm to 0.045 mm
(0.001 to 0.002 in) smaller than cylinder bore.
4.Check gudgeon pin bore in piston for signs of
overheating.
5.Check connecting rods for alignment.