Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 2003 2nd Edition Rover Manual

ENGINE
12
OVERHAUL Valve seats and seat inserts - refacing
CAUTION: Renew worn valve guides and
seat inserts before refacing valve seats.
1.Check condition of valve seats and valves that
are to be re-used.
2.Remove carbon from valve seats.
3.Reface valves as necessary. If a valve has to
be ground to a knife-edge to obtain a true seat,
replace valve.
Valve seating face angleA=45°
4.Using suitable piloted cutters cut valve seats to
the following dimensions:
Valve seat:
WidthA:
Inlet = 36.83 mm (1.45 in)...

ENGINE
OVERHAUL13
Engines fitted with secondary air injection (SAI)
1.Using a 5/8 in x 20 TPI (threads per inch) UNF
tap having a class 2A thread, remove deposits
from secondary air injection adapter tappings
in cylinder head.
CAUTION: Ensure that tap used has 20
TPI.Valves and springs - refit
1.Fit new valve stem oil seals, lubricate valve
stems, fit valves, valve springs and caps,
compress valve springs usingLRT-12-034and
fit collets.
2.Using a wooden dowel and mallet, lightly tap
each valve stem two...

ENGINE
14
OVERHAUL Cylinder head - refit
1.Clean cylinder block faces using a suitable
gasket removal spray and plastic scraper;
ensure that bolt holes in cylinder block are
clean and dry.
CAUTION: Do not use metal scraper or
machined surfaces may be damaged.
2.Engine numbers without suffix B:Thoroughly
clean threads of cylinder head bolts.
CAUTION: Cylinder head bolts fitted to
engines without suffix B added to serial
number are not interchangeable with
those fitted to engines with suffix B added to...

ENGINE
OVERHAUL15
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.
Engines fitted with secondary air...

ENGINE
16
OVERHAUL 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.Timing cover - remove - Engine numbers without...

ENGINE
OVERHAUL17
Timing cover - remove - Engine numbers with
suffix B
NOTE: Timing cover, oil pump, oil
pressure by-pass valve and oil pressure
relief valve are only supplied as an
assembly.
1.Secure toolLRT-12-080to crankshaft pulley
with 2 bolts.
2.Restrain crankshaft pulley usingLRT-121-080
remove crankshaft pulley bolt and collect
spacer washer; remove crankshaft pulley.
3.Remove sump.4.Remove 2 bolts securing oil pick-up pipe to
timing cover.
5.Noting their fitted position, progressively
slacken...

ENGINE
18
OVERHAUL
8.Remove oil pump drive gear.
9.Remove and discard gasket.
10.Remove and discard oil seal from timing cover.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. 

ENGINE
OVERHAUL19
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.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...

ENGINE
20
OVERHAUL
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.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). 

ENGINE
OVERHAUL21
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,
ensure that bolt holes are clean and dry.
CAUTION: Use a plastic scraper.
3.Use a lint free cloth and thoroughly clean oil
seal location in timing cover.
4.Position new gasket, fitted dry, to cylinder
block.
5.Coat threads of timing cover bolts with sealant,
Part number STC 50552.
6.Fit timing...