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

							ENGINE
CONTENTS
Page
Oil pressure by-pass valve - refit 32......................................
Oil pressure relief valve - refit 32.........................................
CAMSHAFT AND TAPPETS 33.........................................
Camshaft end-float - check 33...........................................
Camshaft and tappets - remove 33.......................................
Camshaft and tappets - inspection 34.....................................
Camshaft and tappets - refit 35..........................................
PISTONS, CONNECTING RODS, PISTON RINGS AND CYLINDER BORES 35...
Pistons and connecting rods - remove 35..................................
Piston rings - remove 36...............................................
Piston rings - inspection 36.............................................
Pistons - remove 37..................................................
Pistons and connecting rods - inspection 38................................
Gudgeon pins - inspection 38...........................................
Cylinder liner bore - inspection 39........................................
Pistons - refit 39.....................................................
Piston to cylinder bore clearance - checking 40.............................
Pistons and connecting rods - refit 41.....................................
FLYWHEEL AND STARTER RING GEAR 42...............................
Flywheel - remove 42.................................................
Flywheel and starter ring gear - inspection 42...............................
Starter ring gear - renew 43.............................................
Flywheel - refit 44....................................................
DRIVE PLATE AND RING GEAR ASSEMBLY 44...........................
Drive plate and ring gear assembly - remove 44.............................
Drive plate and ring gear - inspection 45...................................
Drive plate and ring gear assembly - check setting height 45...................
Drive plate and ring gear assembly - refit 46................................
CRANKSHAFT, MAIN AND BIG-END BEARINGS 47........................
Big-end bearings - remove 47...........................................
Big-end bearings - refit 48..............................................
Crankshaft - remove 49................................................
Crankshaft - inspection 49..............................................
Crankshaft spigot bearing - renew 51.....................................
Crankshaft - refit 51...................................................
Crankshaft end - float - check 53......................................... 
						

							ENGINE
DESCRIPTION AND OPERATION1
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							ENGINE
2
DESCRIPTION AND OPERATION 
						

							ENGINE
DESCRIPTION AND OPERATION3
CYLINDER BLOCK COMPONENTS
1.Cylinder block
2.Piston and gudgeon pin
3.Connecting rod
4.Core plugs
5.Camshaft
6.Dipstick
7.Camshaft key
8.Timing chain
9.Camshaft sprocket
10.Spacer
11.Distributor drive gear - if fitted
12.Distributor - if fitted
13.Oil pump gears *
14.Timing cover and gasket *
15.Timing cover oil seal *
16.Crankshaft pulley
17.Crankshaft sprocket
18.Woodruff key
19.Crankshaft
20.Centre main bearing shell - upper21.Crankshaft rear oil seal
22.Rear main bearing cap and side seals
23.Connecting rod cap
24.Main bearing caps
25.Oil pump cover *
26.Oil pressure relief valve assembly *
27.Oil pressure switch *
28.Oil pump suction pipe and strainer
29.Sump
30.Drain plug
31.Timing cover **
32.Timing cover gasket **
33.Timing cover oil seal **
34.Oil filter **
35.Oil pressure switch **
36.Oil pressure by-pass valve assembly **
37.Oil pressure relief valve assembly **
38.Camshaft thrust plate - if fitted
39.Crankshaft pulley bolt and washer
40.Mud flinger
* Engine numbers without suffix B
** Engine numbers with suffix B 
						

							ENGINE
4
DESCRIPTION AND OPERATION
CYLINDER HEAD COMPONENTS
1.Cylinder head
2.Rocker cover
3.PCV filter
4.Rocker shaft
5.Tappet
6.Pushrod
7.Rocker shaft bracket
8.Rocker arm
9.Rocker shaft spring
10.PCV air intake filter11.Engine oil filler cap
12.Inlet valve seal, spring, cap, and collets
13.Exhaust valve seal, spring, cap and collets
14.Inlet valve and seat
15.Exhaust valve and seat
16.Inlet manifold gasket and seals
17.Cylinder head gasket
18.Valve guide
19.Bolts - cylinder head
20.Spark plug
21.Secondary air injection adapter - if fitted 
						

							ENGINE
DESCRIPTION AND OPERATION5
Engine without suffix B added to serial no. illustrated
OPERATION
The V8 engine is an eight cylinder, water cooled unit
comprising of cast aluminium cylinder block and
cylinder heads.
The two banks of cast iron cylinder liners are shrink
fitted and are located on stops in the cylinder block.
The banks of cylinders are set at 90°to each other.
The crankshaft is carried in five main bearings,
end-float being controlled by the thrust faces of the
upper centre main bearing shell.The centrally located camshaft is driven by the
crankshaft via an inverted tooth chain. The valves
are operated by rockers, pushrods and hydraulic
tappets. The distributor - if fitted, is driven by a skew
gear from the front of the camshaft.
The aluminium alloy, pistons have two compression
rings and an oil control ring and are secured to the
connecting rods by semi-floating gudgeon pins. On
later 4.2L engines the gudgeon pin is offset 0.5 mm
(0.02 in), identified by an arrow mark on the piston
crown, which must always point to the front of the
engine. Plain, big-end bearing shells are fitted to
each connecting rod. 
						

							ENGINE
6
DESCRIPTION AND OPERATION Lubrication - Engine numbers without suffix B
1.Oil strainer
2.Crankshaft main bearing oil feed
3.Oil pressure relief valve
4.Oil pump5.Main galleries
AOil to cooler
BOil from cooler 
						

							ENGINE
DESCRIPTION AND OPERATION7
Lubrication - Engine numbers with suffix B
1.Oil strainer
2.Oil pump
3.Pressure by-pass valve
4.Oil pressure switch5.Oil pressure relief valve
AOil to cooler
BOil from cooler
Engine numbers without suffix B
The full flow lubrication system uses an external
gear pump which is driven by the distributor drive
shaft. The oil pump gears are housed in the timing
cover and the oil pressure relief valve and warning
light switch are fitted to the oil pump cover.
Engine numbers with suffix B
The full flow lubrication system uses a gear type oil
pump driven from the crankshaft. The assembly is
integral with the timing cover which also carries the
full flow oil filter, oil pressure switch and pressure
relief valve.All engines
Oil is drawn from the pressed steel sump through a
strainer and into the oil pump, excess pressure
being relieved by the pressure relief valve. The oil
pressure warning light switch is screwed into the oil
pump cover and registers the oil pressure in the
main oil gallery on the outflow side of the filter.
Pressurised oil passes through an oil cooler - if fitted
to the full flow oil filter and through internal drillings
to the crankshaft where it is directed to each main
bearing and to the big end bearings via Nos. 1, 3
and 5 main bearings. An internal drilling in the
cylinder block directs oil to the camshaft where it
passes through further internal drillings to the
hydraulic tappets, camshaft journals and rocker
shaft. Lubrication to the thrust side of the cylinders is
by oil grooves machined in each connecting rod big
end joint face, which are timed to align with holes in
the big end journals on the power and exhaust
strokes. 
						

							ENGINE
8
DESCRIPTION AND OPERATION Distributor drive and timing chain lubrication
1.Bearing
2.Camshaft
3.Key
4.Camshaft timing chain sprocket
5.Spacer
6.Distributor drive gear
The distributor drive and timing chain are lubricated
from the camshaft front bearing. The feed to the
timing chain is channelled along the camshaft
sprocket, key and spacer.Hydraulic tappets1.Clip
2.Pushrod seat
3.Inner sleeve
4.Upper chamber
5.Non-return ball valve
6.Spring
7.Outer sleeve
8.Lower chamber - high pressure
The purpose of the hydraulic tappet is to provide
maintenance free and quiet operation of the inlet
and exhaust valves. It achieves this by utilising
engine oil pressure to eliminate the mechanical
clearance between the rockers and the valve stems.
During normal operation, engine oil pressure present
in the upper chamber passes through the non-return
ball valve and into the lower, high pressure,
chamber.
When the cam begins to lift the outer sleeve, the
resistance of the valve spring felt through the push
rod and seat causes the tappet inner sleeve to move
downwards inside the outer sleeve. This downward
movement of the inner sleeve closes the ball valve
and increases the pressure in the lower, high
pressure chamber, sufficiently to ensure that the
push rod opens the valve fully.
As the tappet moves off the peak of the cam the ball
valve opens to equalise the pressure in both
chambers which ensures the valve closes when the
tappet is on the back of the cam. 
						

							ENGINE
OVERHAUL1
ROCKER SHAFTS
Rocker shafts - remove
1.LH rocker shaft only:Remove screw securing
dipstick tube to rocker cover.
2.Noting fitted position of 2 longer screws or
multi-hex bolts, remove and discard
screws/bolts securing rocker cover to cylinder
head.
3.Remove rocker cover.
4.Remove and discard gasket from rocker cover.
NOTE: Gaskets fitted to early engines
were cork; these must be replaced with
later type gaskets which incorporate
compression limiters in the bolt holes.
5.Mark each rocker shaft in relation to original
cylinder head.
CAUTION: Incorrect fitment of rocker
shafts will lead to an oil feed restriction.
6.Progressively slacken and remove 4 bolts
securing rocker shaft assembly to cylinder
head.
7.Remove rocker shaft assembly.
8.Remove pushrods and store in fitted order.
9.Repeat above procedures for remaining rocker
shaft.