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

							ENGINE
12
OVERHAUL Valve seats and seat inserts - refacing
CAUTION: Renew worn valve guides and
seat inserts before refacing valve seats.
1.Check condition of valve seats and valves that
are to be re-used.
2.Remove carbon from valve seats.
3.Reface valves as necessary. If a valve has to
be ground to a knife-edge to obtain a true seat,
replace valve.
Valve seating face angleA=45°
4.Using suitable piloted cutters cut valve seats to
the following dimensions:
Valve seat:
WidthA:
Inlet = 36.83 mm (1.45 in)
Exhaust = 31.50 mm (1.24 in)
Seating widthB:
Inlet = 0.89 to 1.4 mm (0.035 to 0.055 in)
Exhaust = 1.32 to 1.83 mm (0.052 to 0.072 in)
AngleC=56°to 70°
Angle D:
Up to’99 Model Year = 46°to 46°25’
’99 Model year onwards = 46°to 46°30’
AngleE=20°Valves - lapping-in
1.Lap each valve to its seat using fine grinding
paste.
2.Clean valve and seat.
3.Coat valve seat with a small quantity of
engineer’s blue, insert valve and press it into
position several times without rotating. Remove
valve and check for even and central seating.
Seating position shown by engineer’s blue
should be in centre of valve face.
4.Check valve installed heightAif valve seats
have been recut or new valves or valve seat
inserts have been fitted.
Valve installed heightA:
Standard and carbon break exhaust valves -
Inlet and exhaust - Early engines = 47.63 mm
(1.9 in) - maximum
Modified valves - Inlet and exhaust - Later
engines = 44.16 to 45.29 mm (1.741 to 1.802
in) - maximum
5.Thoroughly clean cylinder head, blow out
oilways and coolant passages. 
						

							ENGINE
OVERHAUL13
Engines fitted with secondary air injection (SAI)
1.Using a 5/8 in x 20 TPI (threads per inch) UNF
tap having a class 2A thread, remove deposits
from secondary air injection adapter tappings
in cylinder head.
CAUTION: Ensure that tap used has 20
TPI.Valves and springs - refit
1.Fit new valve stem oil seals, lubricate valve
stems, fit valves, valve springs and caps,
compress valve springs usingLRT-12-034and
fit collets.
2.Using a wooden dowel and mallet, lightly tap
each valve stem two or three times to seat
valve cap and collets.
3.Fit spark plugs and tighten to 20 Nm (15 lbf.ft) 
						

							ENGINE
14
OVERHAUL Cylinder head - refit
1.Clean cylinder block faces using a suitable
gasket removal spray and plastic scraper;
ensure that bolt holes in cylinder block are
clean and dry.
CAUTION: Do not use metal scraper or
machined surfaces may be damaged.
2.Engine numbers without suffix B:Thoroughly
clean threads of cylinder head bolts.
CAUTION: Cylinder head bolts fitted to
engines without suffix B added to serial
number are not interchangeable with
those fitted to engines with suffix B added to
serial number.
3.Fit cylinder head gasket with the word’TOP’
uppermost.
NOTE: Gasket must be fitted dry.
CAUTION: Engines without suffix B have a
steel gasket whilst engines with suffix B
have a composite gasket. The two types of
gasket are not interchangeable and it is essential
to ensure that the correct type of gasket is fitted.
4.Carefully fit cylinder head and locate on
dowels.Engine numbers without suffix B
NOTE: RH cylinder head illustrated
5.Lightly oil threads of cylinder head bolts.
6.Fit cylinder head bolts:
Long bolts: 1, 3 and 5.
Medium bolts: 2, 4, 6, 7, 8, 9, and 10.
Short bolts: 11, 12, 13 and 14.
7.Using sequence shown, progressively tighten
cylinder head bolts to:
Bolts 11 to 14 - Outer row - 60 Nm (44 lbf.ft)
Bolts 2, 4, 6, 8 and 10 - Centre row - 90 Nm
(66 lbf.ft)
Bolts 1, 3, 5, 7 and 9 - Inner row - 90 Nm (66
lbf.ft) 
						

							ENGINE
OVERHAUL15
Engine numbers with suffix B
NOTE: RH cylinder head illustrated
8.Lightly oil threads of NEW cylinder head bolts.
9.Fit cylinder head bolts:
Long bolts: 1, 3 and 5
Short bolts: 2, 4, 6, 7, 8, 9 and 10
NOTE: There are no bolts fitted in the four
lower holes in each cylinder head.
10.Using sequence shown, tighten cylinder head
bolts to:
Stage 1 - 20 Nm (15 lbf.ft)
Stage 2 - 90°
Stage 3 - Further 90°
CAUTION: Do not tighten bolts 180°in one
operation.
Engines fitted with secondary air injection (SAI)
11.Fit new secondary air injection adapters and
using a suitable hexagonal drive bit, tighten to
33 Nm (24 lbf.ft).
CAUTION: Do not use air tools to tighten
adapters.
All engines
12.Fit rocker shaft assembly.TIMING CHAIN AND GEARS
Distributor - if fitted - remove
1.Remove distributor cap.
2.Rotate crankshaft until centre line of rotor arm
is aligned with No. 1 spark plug segment in
distributor cap and No. 1 piston is at TDC.
3.Scribe an alignment mark between distributor
body and clamp.
4.Remove nut securing distributor clamp.
5.Remove distributor.
6.Remove clamp.
7.Remove and discard’O’ring from distributor. 
						

							ENGINE
16
OVERHAUL Sump - remove
1.Remove dipstick.
2.Remove screw securing dipstick tube to LH
rocker cover.
NOTE: Sump fitted to engines without
suffix B engine numbers illustrated.
3.Remove 16 bolts securing sump to cylinder
block.
NOTE: Engine numbers with suffix B, 17
bolts are used to secure sump to cylinder
block.
4.Carefully release sump from cylinder block.
CAUTION: Take care not to damage
sealing faces of cylinder block and sump.
5.Remove sump.Timing cover - remove - Engine numbers without
suffix B
1.Secure toolLRT-12-080to crankshaft pulley
with 2 bolts.
2.Restrain crankshaft pulley usingLRT-12-080
remove crankshaft pulley bolt and collect
spacer washer, remove crankshaft pulley.
3.Remove bolts and nut securing timing cover to
cylinder block.
4.Release and remove timing cover.
5.Remove and discard gasket.
6.Remove and discard oil seal from timing cover. 
						

							ENGINE
OVERHAUL17
Timing cover - remove - Engine numbers with
suffix B
NOTE: Timing cover, oil pump, oil
pressure by-pass valve and oil pressure
relief valve are only supplied as an
assembly.
1.Secure toolLRT-12-080to crankshaft pulley
with 2 bolts.
2.Restrain crankshaft pulley usingLRT-121-080
remove crankshaft pulley bolt and collect
spacer washer; remove crankshaft pulley.
3.Remove sump.4.Remove 2 bolts securing oil pick-up pipe to
timing cover.
5.Noting their fitted position, progressively
slacken then remove bolts securing timing
cover to cylinder block.
CAUTION: Do not attempt to remove oil
pump drive gear at this stage.
6.Release timing cover from oil pick-up pipe,
remove cover.
NOTE: Dowel located.
7.Remove and discard’O’ring from oil pick-up
pipe. 
						

							ENGINE
18
OVERHAUL
8.Remove oil pump drive gear.
9.Remove and discard gasket.
10.Remove and discard oil seal from timing cover.Timing gears - remove
1.Restrain camshaft gear and remove bolt
securing gear, collect washer.
2.Remove distributor drive gear - if fitted and
spacer.
3.Remove timing chain and gears as an
assembly.
4.Collect Woodruff keys from camshaft and
crankshaft. 
						

							ENGINE
OVERHAUL19
Timing chain and gears - inspection
1.Thoroughly clean all components.
2.Inspect distributor drive gear - if fitted for wear.
3.Inspect timing chain links and pins for wear.
4.Inspect timing chain gears for wear. Renew
parts as necessary.Timing gears - refit
1.Clean gear locations on camshaft and
crankshaft, fit Woodruff keys.
2.Check camshaft Woodruff key is fully engaged
in keyway.
CAUTION: Space between Woodruff key
and keyway acts as an oil feed. It is
therefore most important that key is
properly seated and parallel to axis of camshaft.
Overall dimension’A’must not exceed 30.15 mm
(1.2 in).
3.Temporarily fit crankshaft gear, and if
necessary turn crankshaft to bring timing mark
on gear to the twelve o’clock position, remove
gear.
4.Temporarily fit camshaft gear with marking’F’
facing forwards.
5.Turn camshaft until mark on camshaft gear is
at the six o’clock position, remove gear without
moving camshaft. 
						

							ENGINE
20
OVERHAUL
6.Position timing gears on work surface with
timing marks upwards and aligned.
7.Fit timing chain around gears, keeping timing
marks aligned.
8.Fit gear and chain assembly.
NOTE: Timing marks and’F’mark on
camshaft gear must be facing forwards.9.Fit spacer to camshaft with flange facing
forwards.
10.Fit distributor drive gear - if fitted to camshaft
with grooved face towards camshaft gear.
11.Fit camshaft gear bolt and washer, restrain
camshaft gear and tighten bolt to 50 Nm (37
lbf.ft). 
						

							ENGINE
OVERHAUL21
Timing cover - refit - Engine numbers without
suffix B
1.Clean sealant from threads of cover bolts.
2.Clean all traces of old gasket material from
timing cover and mating face of cylinder block,
ensure that bolt holes are clean and dry.
CAUTION: Use a plastic scraper.
3.Use a lint free cloth and thoroughly clean oil
seal location in timing cover.
4.Position new gasket, fitted dry, to cylinder
block.
5.Coat threads of timing cover bolts with sealant,
Part number STC 50552.
6.Fit timing cover, fit bolts and nut and tighten
progressively, by diagonal selection to 22 Nm
(16 lbf.ft).
7. Unwaxed oil seal only:Lubricate new oil seal
sealing surfaces with engine oil.
CAUTION: If replacement oil seal has a
waxed coating, it must be fitted dry DO
NOT lubricate oil seal or recess in timing
cover.
8.Locate seal to timing cover and press seal in
squarely until flush with front face of timing
cover.
9.Fit crankshaft pulley.
10.Fit spacer washer to pulley bolt.
11.Fit bolt and using toolLRT-12-080restrain
crankshaft pulley and tighten bolt to 270 Nm
(200 lbf.ft).
12.Remove toolLRT-12-080.Timing cover - refit - Engine numbers with suffix
B
NOTE: Timing cover, oil pump, oil
pressure by-pass valve and oil pressure
relief valve are only supplied as an
assembly.
1.Clean sealant from threads of timing cover
bolts.
2.Clean all traces of gasket material from mating
faces of timing cover and cylinder block,
ensure that bolt holes are clean and dry.
CAUTION: Use a plastic scraper.
3.Clean oil seal location in timing cover.
4.Position a new gasket, fitted dry, to timing
cover locating dowels.
5.Position oil pump drive gear in timing cover
with groove towards front of timing cover.
6.Lubricate a new’O’ring with engine oil and fit
to oil pick-up pipe.
7.Locate toolLRT-12-090on timing cover and oil
pump drive gear.
8.Position timing cover to cylinder block and oil
pick-up pipe and at the same time, rotate tool
LRT-12-090until drive gear keyway is aligned
with Woodruff key.
9.Fit timing cover.
10.Smear threads of timing cover bolts with
sealant, Part number STC 50552.