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

ENGINE
32
OVERHAUL Oil pressure by-pass valve - refit
1.Lubricate new’O’ring with engine oil and fit to
by-pass valve plug.
2.Lubricate by-pass valve spring, plunger and
plunger bore with engine oil.
3.Assemble plunger to by-pass valve spring,
insert plunger and spring into bore.
4.Fit by-pass valve plug, depress plug and fit
circlip.
5.Ensure circlip is fully seated in groove.Oil pressure relief valve - refit
1.Lubricate new’O’ring with engine oil and fit to
relief valve plug.
2.Lubricate relief valve...

ENGINE
OVERHAUL33
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...

ENGINE
34
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...

ENGINE
OVERHAUL35
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...

ENGINE
36
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...

ENGINE
OVERHAUL37
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 remover/replacer adapter
LRT-12-126/2with its long spigot inside bore
of hexagon body.
5.Locate piston and connecting rod assembly on
centre screw and up to adapterLRT-12-126/2
ensuring that prongs of adapter are positioned
on piston either side of gudgeon pin.
6.Fit remover/replacer...

ENGINE
38
OVERHAUL Pistons and connecting rods - inspection
1.Clean carbon from pistons
2.Inspect pistons for distortion, cracks and
burning.
3.Measure and record piston diameter at 90°to
gudgeon pin axis and 10 mm (0.4 in) from
bottom of skirt.
4.Check gudgeon pin bore in piston for signs of
overheating.
NOTE: Pistons fitted on production are
graded A or B, the grade letter is stamped
on the piston crown. Grade B pistons are
supplied as service replacements. Worn cylinder
liners fitted with grade A...

ENGINE
OVERHAUL39
Cylinder liner bore - inspection
1.Measure cylinder bore wear in two axis 40 to
50 mm (1.5 to 1.9 in) from top of bore:
Cylinder bore diameter - standard:
3.5 litre = 88.86 to 88.90 mm (3.498 to 3.50 in)
3.9 litre = 94.00 to 94.04 mm (3.700 to 3.702
in)
4.2 litre = 94.00 to 94.04 mm (3.700 to 3.702
in)
Maximum ovality = 0.013 mm (0.0005 in)
2.Compare cylinder bore diameter with piston
diameter and calculate piston to cylinder bore
clearance.
Piston to cylinder bore clearance = 0.015 to...

ENGINE
40
OVERHAUL 7.Locate connecting rod and piston to centre
screw with connecting rod entered on parallel
sleeve up to the machined groove on the
sleeve.
CAUTION: Ensure that the parallel sleeve
used is the same diameter as the gudgeon
pin.
8.Fit gudgeon pin on to centre screw and into
piston bore up to connecting rod.
9.Fit remover/replacer bushLRT-12-126/1with
flanged end towards gudgeon pin.
10.Screw the stop nut on to the centre screw and
position piston against remover/replacer...

ENGINE
OVERHAUL41
Pistons and connecting rods - refit
1.Fit oil control ring rails and expander, ensuring
ends butt and not overlap.
2.Fit ring marked’TOP’with marking uppermost
into second groove.
3.Fit top compression ring into groove either way
round.
4.Position oil control expander ring joint and ring
rail gaps all at one side, between gudgeon pin
and away from left hand side of piston - viewed
from front of piston. Space gaps in ring rails
approximately 25 mm (1.0 in) each side of
expander ring...