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

ENGINE
42
OVERHAUL FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
1.Restrain flywheel and remove 6 bolts securing
flywheel.
2.Remove flywheel.
NOTE: Dowel located. On early engines,
balance weights were on engine side of
flywheel; replacement flywheels will have
balance weights on clutch side.Flywheel and starter ring gear - inspection
1.Inspect flywheel face for cracks, scores and
overheating. The flywheel can be refaced
providing thickness does not go below
minimum.
Flywheel minimum thicknessA= 39.93...

ENGINE
OVERHAUL43
Starter ring gear - renew
1.Drill a 9.5 mm (0.375 in) diameter hole axially
at base of tooth and inner diameter of starter
ring, sufficiently deep enough to weaken ring
gear.
CAUTION: Do not allow drill to enter
flywheel.
2.Secure flywheel in soft jawed vice.
3.Split ring gear using a cold chisel.
WARNING: Wear safety goggles and take
precautions against flying fragments when
splitting ring gear.
4.Remove flywheel from vice, remove old ring
gear, and place flywheel, clutch side down,...

ENGINE
44
OVERHAUL Flywheel - refit
1.Ensure bolt holes in crankshaft are clean and
dry.
2.Fit flywheel and locate on 2 dowels.
3.Fit flywheel bolts.
4.Using assistance, restrain flywheel and tighten
flywheel bolts to 78 Nm (58 lbf.ft).DRIVE PLATE AND RING GEAR ASSEMBLY
Drive plate and ring gear assembly - remove
1.Suitably identify each component to its fitted
position.
2.Remove 4 bolts securing drive plate assembly.
3.Remove clamp ring and drive plate assembly.
NOTE: Dowel located.
4.Remove 6 Allen...

ENGINE
OVERHAUL45
Drive plate and ring gear - inspection
1.Inspect drive plate for cracks and distortion.
2.Renew drive plate if necessary.
3.Inspect ring gear for worn, chipped and broken
teeth.
4.Renew ring gear assembly if necessary.Drive plate and ring gear assembly - check
setting height
NOTE: The following procedures are only
applicable to shimmed drive plates, there
is no need to check setting height on drive
plates which are not shimmed.
1.Ensure bolt holes in crankshaft are clean and
dry. Fit...

ENGINE
46
OVERHAUL 5.Measure existing shim and, if necessary, select
appropriate shim to obtain specified setting
height.
Shims available:
1.20 - 1.25mm (0.048 to 0.050 in)
1.30 - 1.35mm (0.051 to 0.053 in)
1.40 - 1.45mm (0.055 to 0.057 in)
1.50 - 1.55mm (0.059 to 0.061 in)
1.60 - 1.65mm (0.063 to 0.065 in)
1.70 - 1.75mm (0.067 to 0.070 in)
1.80 - 1.85mm (0.071 to 0.073 in)
1.90 - 1.95mm (0.075 to 0.077 in)
2.00 - 2.05mm (0.079 to 0.081 in)
2.10 - 2.15mm (0.083 to 0.085 in)
6.Retain selected shimDrive...

ENGINE
OVERHAUL47
CRANKSHAFT, MAIN AND BIG-END BEARINGS
Big-end bearings - remove
1.Remove timing chain and gears.
NOTE: Oil strainer fitted to engines
without suffix B to the serial number
illustrated.
2.Remove 2 bolts or nut on engines with suffix B
to the serial number securing oil strainer.
3.Remove strainer, remove and discard gasket -
if fitted.
4.Suitably identify bearing caps to their
respective connecting rods.
5.Remove 2 nuts/bolts securing each bearing
cap.
6.Remove bearing cap, remove and...

ENGINE
48
OVERHAUL Big-end bearings - refit
1.Fit new bearing shells to each connecting rod.
NOTE: Big-end bearings are available in
0.254 and 0.508 mm (0.01 and 0.02 in)
oversizes.
2.Lubricate bearing shells and crankshaft
journals with engine oil.
3.Pull connecting rods on to crankshaft journals
and remove plastic tubing from bolts - if fitted.
4.Fit new bearing shells to each big-end bearing
cap.
NOTE: If crankshaft has been reground,
ensure appropriate oversize bearing shells
are fitted.
5.Lubricate...

ENGINE
OVERHAUL49
Crankshaft - remove
1.Remove flywheel or drive plate and ring gear
assembly.
2.Remove timing cover.
3.Remove timing gears.
4.Remove big-end bearings.
5.Make suitable reference marks between each
main bearing cap and cylinder block.
6.Starting at centre main bearing and working
outwards, progressively slacken then remove
10 main bearing cap bolts.
CAUTION: Keep bolts in their fitted order.
7.Remove 5 main bearing caps and bearing
shells, discard shells.
8.Lift out crankshaft and rear oil...

ENGINE
50
OVERHAUL
3.Measure each journal for overall wear and
ovality, make 3 checks at 120°intervals.
Main bearing journal diameter = 58.409 to
58.422 mm (2.29 to 2.30 in)
Maximum out of round = 0.040 mm (0.002 in)
Big-end bearing journal diameter = 50.800 to
50.812 mm (1.99 to 2.00 in)
Maximum out of round = 0.040 mm (0.002 in)
If measurements exceed permitted maximum,
regrind or fit new crankshaft.
NOTE: Crankshaft main bearings are
available in 0.254 and 0.508 mm (0.01 and
0.02 in) oversizes. When...

ENGINE
OVERHAUL51
Crankshaft spigot bearing - renew
1.Carefully extract old spigot bearing.
2.Clean bearing recess in crankshaft.
3.Fit new bearing flush with, or to a maximum of
1.6 mm (0.06 in) below end face of crankshaft.
4.Ream bearing to correct inside diameter.
Spigot bearing inside diameter = 19.177 +
0.025 - 0.000 mm (0.75 + 0.001 - 0.000 in)
5.Remove all traces of swarf.Crankshaft - refit
1.Clean main bearing caps, bearing shell
recesses and mating surfaces of cylinder
block.
CAUTION: Ensure...