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

							INFORMATION
2
GENERAL DATA Oil pump - Engine numbers without suffix B
Gear to cover face minimum clearance 0.05 mm...........0.002 in
Oil pressure relief valve - Engine numbers
without suffix B
Spring free length 81.28 mm........................... 3.2in
Oil pump - Engine numbers with suffix B
Inner to outer rotor clearance - maximum 0.25 mm.........0.01 in
Rotors to cover plate clearance - maximum 0.1 mm.......0.004 in
Drive gear wear step depth - maximum 0.15 mm...........0.006 in
Oil pressure relief valve - Engine numbers
with suffix B
Spring free length 60.0 mm........................... 2.4in
Oil pressure by-pass valve - Engine numbers
with suffix B
Spring free length 60.0 mm........................... 2.4in
Camshaft
Maximum run-out 0.05 mm............................0.002 in
End-float - Camshafts with thrust plate 0.05 to 0.35 mm...........0.002 to 0.014 in
Piston rings
Ring to groove clearance:
Top compression 0.05 to 0.10 mm...........................0.002 to 0.004 in
2nd compression 0.05 to 0.10 mm...........................0.002 to 0.004 in
Ring fitted gap:
Top compression 0.30 to 0.50 mm...........................0.012 to 0.02 in
2nd compression 0.40 to 0.65 mm...........................0.016 to 0.026 in
Oil control rails 0.38 to 1.40 mm.............................0.014 to 0.05 in
Oil control ring width 3.00 mm.........................0.12 in - maximum
Pistons
Clearance in bore 0.015 to 0.045 mm...........................0.001 to 0.002 in
Gudgeon pins
Length 72.67 to 72.79 mm....................................2.85 to 2.86 in
Diameter 22.215 to 22.220 mm..................................0.87 to 0.871 in
Clearance in piston 0.006 to 0.015 mm..........................0.0002 to 0.0006 in
Connecting rods
Length between centres 143.71 to 143.81 mm......................5.66 to 5.67 in
End-float on crankshaft 0.15 to 0.36 mm.......................0.006 to 0.014 in
Cylinder bore
Cylinder bore diameter:
3.5 engine 88.86 to 88.90 mm................................3.498 to 3.500 in
3.9 engine 94.00 to 94.04 mm................................3.700 to 3.702 in
4.2 engine 94.00 to 94.04 mm................................3.700 to 3.702 in
Maximum ovality 0.013 mm............................0.0005 in 
						

							INFORMATION
GENERAL DATA3
Crankshaft
Main journal diameter 58.409 to 58.422 mm........................2.29 to 2.30 in
Maximum regrind diameter 57.900 to 57.914 mm...................2.28 to 2.281 in
Maximum out of round 0.040 mm.......................0.002 in
Big-end journal diameter 50.800 to 50.812 mm......................1.99 to 2.00 in
Maximum regrind diameter 50.292 to 50.305 mm...................1.97 to 1.98 in
Maximum out of round 0.040 mm.......................0.002 in
End-float 0.08 to 0.26 mm..................................0.003 to 0.010 in
Maximum run-out 0.08 mm............................0.003 in
Spigot bearing inside diameter 19.177 + 0.025.................0.75 + 0.001
- 0.00 mm - 0.00 in
Main bearings
Main bearing diametrical clearance 0.010 to 0.048 mm..............0.0004 to 0.002 in
Undersizes 0.254, 0.508 mm................................0.01, 0.02 in
Big-end bearings
Big-end bearing diametrical clearance 0.015 to 0.055 mm...........0.0006 to 0.0021 in
Undersizes 0.254, 0.508 mm................................0.01, 0.02 in
Endfloat on journal 0.15 to 0.36 mm...........................0.006 to 0.01 in
Flywheel
Flywheel minimum thickness 39.93 mm................... 1.6in
Drive plate
Drive plate setting height 8.08 to 8.20 mm......................0.32 to 0.33 in 
						

							INFORMATION
TORQUE WRENCH SETTINGS1
ENGINE
Crankshaft pulley bolt 270 Nm........................ 200lbf.ft
Timing cover to cylinder block bolts ** 22 Nm............ 16lbf.ft
Camshaft gear bolt 50 Nm.......................... 37lbf.ft
Rocker cover bolts: + ****
Stage 1 3 Nm.................................. 2.5lbf.ft
Stage 2 8 Nm.................................. 6lbf.ft
Rocker shaft to cylinder head bolts 38 Nm.............. 28lbf.ft
Cylinder head bolts - Engine numbers without
suffix B: + *
Bolts 11 to 14 - Outer row 60 Nm.................... 44lbf.ft
Bolts 2, 4, 6, 8 and 10 - Centre row 90 Nm............. 66lbf.ft
Bolts 1, 3, 5, 7 and 9 - Inner row 90 Nm............... 66lbf.ft
Cylinder head bolts - Engine numbers with suffix
B: + */****
Stage 1 20 Nm.................................. 15lbf.ft
Stage 2 Further 90° ..................................
Stage 3 Further 90° ..................................
Lifting eye to cylinder head bolts 40 Nm................ 30lbf.ft
Connecting rod nuts/bolts:
Nuts: 50 Nm.................................... 37lbf.ft
Bolts
Stage 1 20 Nm.................................. 15lbf.ft
Stage 2 Further 80° ..................................
Main bearing cap bolts + *
Initial torque - all bolts: 14 Nm....................... 10lbf.ft
Final torque:
Numbers 1 to 4 main bearing cap bolts: 70 Nm......... 52lbf.ft
Rear main bearing cap bolts: 90 Nm.................. 66lbf.ft
Flywheel bolts 78 Nm.............................. 58lbf.ft
Drive plate and clamp ring bolts 45 Nm................ 33lbf.ft
Drive plate hub aligner Allen bolts 85 Nm............... 63lbf.ft
Oil sump drain plug 45 Nm.......................... 33lbf.ft
Oil sump bolts + 23 Nm............................. 17lbf.ft
Oil pick-up pipe bolts 10 Nm......................... 8lbf.ft
Oil strainer nut - Engine numbers with suffix B 22 Nm..... 16lbf.ft
Oil pressure relief valve plug - Engine numbers
without suffix B 45 Nm............................. 33lbf.ft
Oil pump cover to timing cover - Engine numbers
without suffix B 12 Nm............................. 9lbf.ft
Oil pump cover plate screws - Engine numbers
with suffix B ** 4 Nm.............................. 3lbf.ft
Oil pump cover plate bolt - if fitted ** 8 Nm............. 6lbf.ft
Oil pressure switch 15 Nm.......................... 11lbf.ft
Oil strainer bolts 10 Nm............................. 7lbf.ft
Distributor clamp nut 20 Nm......................... 15lbf.ft
Spark plug 20 Nm................................. 15lbf.ft
Coolant pump/timing cover to cylinder block 22 Nm....... 16lbf.ft
Camshaft thrust plate bolts - If fitted 25 Nm............. 18lbf.ft
Secondary air injection adapters - If fitted *** 33 Nm...... 24lbf.ft
+ Tighten in sequence
* Lightly oil threads prior to assembly.
** Coat threads with sealant Part number STC 50552 prior
to assembly.
*** New adapters must be fitted
**** New bolts must be fitted 
						

							INFORMATION
2
TORQUE WRENCH SETTINGS GENERAL
For bolts and nuts not otherwise specified:
METRIC
M5 4 Nm...................................... 3lbf.ft
M6 6 Nm...................................... 4lbf.ft
M8 18 Nm...................................... 13lbf.ft
M10 35 Nm..................................... 26lbf.ft
M12 65 Nm..................................... 48lbf.ft
M14 80 Nm..................................... 59lbf.ft
M16 130 Nm..................................... 96lbf.ft
UNC / UNF
1/4 9 Nm...................................... 7lbf.ft
5/16 25 Nm..................................... 18lbf.ft
3/8 40 Nm...................................... 30lbf.ft
7/16 75 Nm..................................... 55lbf.ft
1/2 90 Nm...................................... 66lbf.ft
5/8 135 Nm...................................... 100lbf.ft 
						

							INFORMATION
TORQUE WRENCH SETTINGS3
SEALANTS
A range of sealants is used when overhauling the engine, the sealant applications, together with the appropriate
part number is listed below.
Timing cover bolts STC 50552...........................
Sump to cylinder block STC 50550.......................
Oil pump cover plate screws and bolt - Engine
numbers with suffix B STC 50552........................
Cylinder head threaded core plugs STC 50552..............
Rear main bearing cap to cylinder block mating
faces STC 50550..................................... 
						

							INFORMATION
SERVICE TOOLS1
SERVICE TOOLS
Land Rover Number Description
LRT-12-010* Protection sleeve - crankshaft rear oil seal...............................
LRT-12-013 Remover/replacer - gudgeon pin................................
LRT-12-014 Adapter remover/replacer - gudgeon pin................................
LRT-12-034 Valve spring compressor................................
LRT-12-037 Drift - remover - valve guide................................
LRT-12-039A Drift - replacer - valve guide...............................
LRT-12-080 Crankshaft pulley retaining tool................................
LRT-12-089 Replacer - timing cover oil seal................................
LRT-12-090** Retainer - oil pump gears...............................
LRT-12-091** Replacer - crankshaft rear oil seal...............................
LRT-12-095** Protection sleeve - crankshaft rear oil seal...............................
LRT-12-126/1 Bush - remover/replacer - gudgeon pin..............................
LRT-12-126/2 Adapter - remover/replacer - gudgeon pin..............................
LRT-12-183 Sump alignment tool - 2 off................................
LRT-12-208 Distance piece - valve guide................................
LRT-99-003 Driver handle................................
* Engine numbers without suffix B
** Engine numbers with suffix B
The use of approved special service tools is important. They are essential if service operations are to be carried out
efficiently and safely. Where special tools are specified,only these tools should be used to avoid the possibility
of personal injury or damage to the components.Also, the amount of time they save can be considerable.
Special tools bulletins will be issued periodically giving details of new tools as they are introduced.
All orders and enquiries from the United Kingdom and European countries except Germany, Austria, Switzerland
and Spain and countries not in the following list should be sent direct to:
SPX UK Ltd.,
Genoa House,
Everdon Park,
Daventry,
Northants,
England, NN11 5YJ
Telephone: 00 44 (0) 132 7303467/303455
Fax: 00 44 (0) 1327 706632
e-mail: [email protected]
Overseas orders for the following countries should be placed with the local XPS distributor.
Germany, Austria and Switzerland
SPX Europe GMBH,
Porschestrasse 4,
63512 Hainburg,
Germany,
Telephone: 0049 61829590
Fax: 0049 6182959299 
						

							INFORMATION
2
SERVICE TOOLS Spain
SPX Iberica SA,
C/Francisco Aritio
158 nave 72 (Nudo Oeste),
19004 Guadalajara,
Spain
Telephone: 0034 949208381
Fax: 0034 949208327
North America
SPX Corporation,
665, Eisenhower Drive,
Owatonna,
MN 55060,
USA
Telephone: 0018 772979110
Fax: 0018 005787375
SPX Australia,
28, Clayton Road,
Notting Hill,
Victoria 3168,
Australia,
Telephone: 00 (61) 00395446222
Fax: 00 (61) 0395445222
e-mail: [email protected]
Japan and East Asia
Jatek Ltd.,
5 - 53, Minawacho 2-chome,
Kohoku-ku,
Yokohama,
Kanagawa 223-0051,
Japan
Telephone: 0081 455627700
Fax: 0081 455627800 
						

							ENGINE
CONTENTS
Page
DESCRIPTION AND OPERATION
CYLINDER BLOCK COMPONENTS 3....................................
CYLINDER HEAD COMPONENTS 4.....................................
OPERATION 5......................................................
OVERHAUL
ROCKER SHAFTS 1..................................................
Rocker shafts - remove 1..............................................
Rocker shafts - dismantling 2...........................................
Inspecting components 2..............................................
Rocker shafts - assembling 3...........................................
Rocker shafts - refit 4.................................................
CYLINDER HEAD 5..................................................
Cylinder head - remove 5..............................................
Valves and springs - remove 6..........................................
Cylinder head - inspection 6............................................
Valves, valve springs and guides - inspection 7.............................
Valve guides - renew 10...............................................
Valve seat inserts - inspection 11........................................
Valve seat inserts - renew 11...........................................
Valve seats and seat inserts - refacing 12..................................
Valves - lapping-in 12.................................................
Engines fitted with secondary air injection (SAI) 13..........................
Valves and springs - refit 13............................................
Cylinder head - refit 14................................................
TIMING CHAIN AND GEARS 15.........................................
Distributor - if fitted - remove 15.........................................
Sump - remove 16....................................................
Timing cover - remove - engine numbers without suffix B 16...................
Timing cover - remove - engine numbers with suffix B 17......................
Timing gears - remove 18..............................................
Timing chain and gears - inspection 19....................................
Timing gears - refit 19.................................................
Timing cover - refit - engine numbers without suffix B 21......................
Timing cover - refit - engine numbers with suffix B 21.........................
Sump - refit 23.......................................................
Distributor - if fitted - refit 24............................................
OIL COOLER ADAPTER - ENGINE NUMBERS WITHOUT SUFFIX B 25.........
Oil cooler adapter - remove 25..........................................
Oil cooler adapter - refit 26.............................................
OIL PUMP - ENGINE NUMBERS WITHOUT SUFFIX B 26....................
Oil pump - remove 26.................................................
Oil pump - inspection 27...............................................
Oil pump - refit 27....................................................
OIL PUMP - ENGINE NUMBERS WITH SUFFIX B 28........................
Oil pump - remove 28.................................................
Oil pressure by-pass valve - remove 28...................................
Oil pressure relief valve - remove 29......................................
Oil pump - inspection 29...............................................
Oil pressure by-pass valve - inspection 30.................................
Oil pressure relief valve - inspection 31....................................
Oil pump - refit 31....................................................