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

							ENGINE
2
OVERHAUL Rocker shafts - dismantling
1.Remove and discard split pin from one end of
rocker shaft.
2.Remove plain washer, wave washer, rocker
arms, brackets and springs.Inspecting components
1.Thoroughly clean components.
2.Inspect each component for wear, in particular
rocker arms and shafts. Discard weak or
broken springs.
3.Inspect push rod seats in rocker arms.
4.Check push rods for straightness and inspect
ball ends for damage, replace as necessary. 
						

							ENGINE
OVERHAUL3
Rocker shafts - assembling
1.Assemble rocker shafts with identification
groove at one o’clock position with push rod
end of rocker arm to the right.
CAUTION: If rocker shafts are incorrectly
assembled and fitted to engine, oil supply
to rocker arms will be restricted.
2.Fit new split pin to one end of rocker shaft.
3.Fit plain washer and wave washer.
4.Lubricate rocker arm bushes with clean engine
oil.
5.Early type rocker arms are angled, and must
be fitted with the valve end of the rocker arms
angled away from each other as illustrated.
6.On later type rocker arms the valve end is
offset and must be fitted as illustrated.
NOTE: Early and late rocker arms are
interchangeable provided the complete set
is changed.7.Assemble rocker arms, brackets and springs to
rocker shaft.
8.Compress springs, fit wave washer, plain
washer and secure with new split pin. 
						

							ENGINE
4
OVERHAUL Rocker shafts - refit
1.Lubricate push rods with engine oil.
2.Fit push rods in removed order.
3.Fit each rocker shaft assembly, ensuring
identification groove is uppermost and towards
front of engine on RH side and towards rear of
engine on LH side.
CAUTION: Incorrect fitment will result in
an oil feed restriction.
4.Fit bolts and tighten to 38 Nm (28 lbf.ft).
5.Clean gasket surface in rocker cover and on
cylinder head, ensure bolt holes are clean and
dry.
6.Fit new gasket, dry, to rocker cover.
CAUTION: Replace cork gasket(s) with
modified gaskets which incorporate
compression limiters in the bolt holes.7.Fit rocker cover to cylinder head, fit new,
’patched’multi-hex bolts and tighten by
diagonal selection to:
Stage 1 - 3 Nm (2.5 lbf.ft)
Stage 2 - 8 Nm (6 lbf.ft)
CAUTION: The 2 short screws/bolts must
be fitted on side of cover nearest centre of
engine. Ensure that outer rim of gasket is
correctly positioned around periphery of rocker
cover.
8. LH rocker shaft only:Align dipstick tube to
rocker cover, fit and tighten screw. 
						

							ENGINE
OVERHAUL5
CYLINDER HEAD
Cylinder head - remove
1.Remove rocker shaft assembly.
2.Mark heads LH and RH for reassembly.
Engine numbers without suffix B
NOTE: RH cylinder head illustrated
3.Using sequence shown, remove 14 bolts
securing cylinder head to cylinder block.
Engine numbers with suffix B
Engines fitted with secondary air injection (SAI)
4.Using a suitable hexagonal drive bit, remove
and discard 2 secondary air injection adapters
from cylinder head.
NOTE: To release the adapter thread
locking agent and prevent damage to the
cylinder head, remove the adapters by
loosening then tightening slightly. Repeat this
procedure until the adapters are removed.
CAUTION: Do not use an air tool to
remove adapters.
NOTE: RH cylinder head illustrated
5.Using sequence shown, remove and discard
10 bolts securing cylinder head to cylinder
block.
NOTE: No bolts are fitted in the four lower
holes in each cylinder head.
All engines
6.Release cylinder head from 2 dowels and
remove cylinder head.
7.Remove and discard cylinder head gasket. 
						

							ENGINE
6
OVERHAUL Valves and springs - remove
1.Remove spark plugs.
2.Using valve spring compressorLRT-12-034or
a suitable alternative, compress valve spring.
3.Remove 2 collets.
4.Release spring compressor and remove valve,
valve spring cap and valve spring.
5.Repeat above operations for remaining valves.
CAUTION: Keep valves, springs, caps and
collets in fitted order.
6.Remove and discard valve stem oil seals.Cylinder head - inspection
1.Clean all traces of gasket material from
cylinder head using a plastic scraper.
2.Check core plugs for signs of leakage and
corrosion, replace as necessary. Apply sealant,
Part number STC 50552 to threads of threaded
core plugs.
3.Check gasket face of each cylinder head for
warping, across centre and from corner to
corner:
Maximum warp = 0.05 mm (0.002 in) 
						

							ENGINE
OVERHAUL7
4.Check cylinder head height at each end of
cylinder head:
Engine numbers without suffix B
A= 23.9 mm (0.94 in) - new
B= 63.5 mm (2.5 in) - new
Engine numbers with suffix B
A= 22.94 mm (0.903 in) - new
B= 62.56 mm (2.463 in) - new
5.Cylinder heads may be refaced:
Reface limit = 0.50 mm ( 0.02 in) from new
dimension.Valves, valve springs and guides - inspectionNOTE: Two types of exhaust valve may be
fitted - standard valves A in illustration or
carbon break valves - B in illustration.
Carbon break valves may be identified by the
machined profile C on the valve stem. To prevent
exhaust valves sticking, standard exhaust valves
should be replaced with carbon break valves
during engine overhaul.
NOTE: Modified inlet valves, carbon break
exhaust valves and valve guides are fitted
to later engines. The modified exhaust
valves may be identified by measuring the
distance A from the valve head face to the top of
the undercut on the valve stem. Additionally, the
exhaust valves have a black nitrided finish whilst
the inlet valves have a chrome finish. 
						

							ENGINE
8
OVERHAUL
Early valves - dimension A = 29.5 to 30.5 mm
(1.16 to 1.20 in)
Later valves - dimension
A = 32.5 to 33.5 mm (1.28 to 1.32 in)
The modified valves may be fitted to early engines in
engine sets provided that the modified valve guides
are also fitted.Valve guides
NOTE: The modified valve guides fitted to
later engines are 5 mm (0.211 in) shorter
than the early type guides, the overall
length of the modified guide being 57 mm (2.24
in); the reduction in length being the distance
the guide protrudes into the combustion
chamber side of the cylinder head. The modified
guides may be fitted to early engines, both with
and without suffix B to the engine serial number
in engine sets provided that the modified inlet
and carbon break exhaust valves are also fitted.
1.Remove carbon deposits from valve guides
using an 8.70 mm (0.34 in) diameter reamer
inserted from combustion face side of cylinder
head.
2.Clean valve springs, cotters, caps and valves.
Clean inlet valve guide bores. Ensure all loose
particles of carbon are removed on completion.
3.Check existing valve stem to guide clearances,
valve head diameters and fitted height of
valves. 
						

							ENGINE
OVERHAUL9
4.Check valve head diameterA:
Inlet = 39.75 to 40.00 mm (1.56 to 1.57 in)
Exhaust = 34.226 to 34.48 mm (1.34 to 1.35 in)
5.Check valve stem diameterB:
Inlet = 8.660 to 8.680 mm (0.340 to 0.342 in)
Exhaust:
Standard and carbon break valves fitted to
early engines = 8.651 to 8.666 mm (0.340 to
0.341 in)
Modified carbon break valves fitted to later
engines = 8.641 to 8.656 mm (0.336 to 0.340
in)
6.Check installed height of each valveC:
Valve installed heightC:
Standard and carbon break valves fitted to
early engines = 47.63 mm (1.9 in)
Modified inlet and carbon break exhaust valves
fitted to later engines = 44.163 to 45.29 mm
(1.741 to 1.802 in)7.Check valve stem to guide clearanceDusing
the following procedures:
8.Insert each valve into its respective guide.
9.Extend valve head approximately 13 mm (0.6
in) out of valve seat and position a suitable dial
test indicator to rear of valve head.
10.Move valve towards front of cylinder head and
zero dial test indicator gauge ensuring that
stylus of gauge remains in contact with valve
head.
11.Move valve towards rear of cylinder head and
record gauge reading to give valve stem to
guide clearance:
Inlet valves - Early and later engines = 0.025 to
0.066 mm (0.001 to 0.002 in)
Exhaust valves:
Standard and carbon break exhaust valves
fitted to early engines = 0.038 to 0.078 mm
(0.0015 to 0.003 in)
Modified carbon break exhaust valves fitted to
later engines = 0.048 to 0.088 mm (0.0019 to
0.0035 in)
12.Repeat above procedures for each valve in
turn.
13.Renew valves, guides and valve seat inserts
as necessary.
CAUTION: If modified valves and guides
are to be fitted, they must be replaced in
engine sets.
14.Check condition of valve springs:
Free length = 48.30 mm (1.90 in)
Fitted length = 40.40 mm (1.60 in)
Load at fitted length = 339±10 N (76±2 lbf)
Load at valve open length = 736±22 N (165±
2 lbf)
CAUTION: Valve springs must be replaced
as a complete set. 
						

							ENGINE
10
OVERHAUL Valve guides - renew
1.Using valve guide remover,LRT-12-037press
valve guide out into combustion face side of
cylinder head.
NOTE: Service valve guides are 0.025mm
(0.001 in) oversize on outside diameter to
ensure interference fit.
2.Lubricate new valve guide with engine oil and
with tapered portion of guide leading, place in
position on valve spring side of cylinder head.
3.UsingLRT-12-039Apartially press guide into
cylinder head, remove tool.
4.FitLRT-12-208over valve guide and continue
to press guide into cylinder head until tool
LRT-12-039Acontacts toolLRT-12-208.
Remove tool.
5.Check valve guide installed heightA= 15.0
mm (0.590 in)6.Using piloted reamers, ream valve guides from
valve spring side of head in 2 stages, with the
final cut being 0.1 mm (0.004 in) to give a
finished internal diameter of 8.70 mm (0.34 in)
diameter.
7.Remove all traces of swarf on completion. 
						

							ENGINE
OVERHAUL11
Valve seat inserts - inspection
1.Check valve seat inserts for pitting, burning
and wear. Replace inserts as necessary.Valve seat inserts - renew
NOTE: Service valve seat inserts are
available 0.025 mm (0.001 in) oversize on
outside diameter to ensure interference fit.
1.Remove worn valve seats.
CAUTION: Take care not to damage
counterbore in cylinder head.
2.Heat cylinder head evenly to approximately
120°C (250°F).
WARNING: Handle hot cylinder head with
care.
3.Using a suitable mandrel, press new insert fully
into counterbore.
4.Allow cylinder head to air cool.