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

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22
OVERHAUL
11.Fit timing cover bolts and using sequence
shown,tighten to 22 Nm (16 lbf.ft).
CAUTION: Ensure CMP sensor multiplug
bracket - if fitted is secured by bolt. Do not
fit coolant pump bolts at this stage.
12.Remove toolLRT-12-090.
13.Fit oil pick-up pipe bolts and tighten to 10 Nm
(8 lbf.ft).
A- Early type seal
B- Later type seal - use as replacement for all
engines
CAUTION: Replacement oil seal is
pre-greased, DO NOT use any additional
lubricant.
14.Fit timing cover oil seal using toolLRT-12-089.
15.Fit sump.
16.Fit crankshaft pulley, fit bolt and spacer
washer.
17.Using toolLRT-12-080to restrain crankshaft,
tighten bolt to 270 Nm (200 lbf.ft).
18.Remove toolLRT-12-080. 
						

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OVERHAUL23
Sump - refit
1.Remove all traces of old sealant from mating
faces of cylinder block and sump; ensure bolt
holes are clean and dry.
CAUTION: Use a plastic scraper.
NOTE: Sump fitted to engines with suffix B
engine numbers illustrated.
2.Clean mating faces with suitable solvent. Apply
a bead of sealant, Part number STC 50550 to
sump joint face as shown:
Bead width - areas A, B, C and D = 12 mm (0.5
in)
Bead width - remaining areas = 5 mm (0.20 in)
Bead length - areas A and B = 32 mm (1.23 in)
Bead length - areas C and D = 19 mm (0.75 in)
CAUTION: Do not spread sealant bead.
Sump must be fitted immediately after
applying sealant.
3.Fit sump, taking care not to damage sealant
bead.
4.Noting that the two parts of the tool are
’handed’, fit toolLRT-12-183to the engine
backplate using slave bolts.
5.Secure the tool to the sump using the bolts
which are part of the tool.
NOTE: The holes in the tool are larger than
the diameter of the bolts in order to allow
the sump to move as the sump bolts are
tightened.
6.Fit sump bolts and using sequence shown,
tighten progressively to 23 Nm (17 lbf.ft).
NOTE: Engine numbers without suffix B -
use sequence numbers 1 to 8 and 10 to 16. 
						

							ENGINE
24
OVERHAUL 7.Remove toolLRT-12-183.
8.Fit and tighten screw securing dipstick tube to
LH rocker cover.
9.Fit dipstick.Distributor - if fitted - refit
1.Ensure timing pointer is aligned with 3°mark
on crankshaft pulley and No.1 piston is on the
compression stroke.
2.Engine numbers without suffix B:Position oil
pump drive shaft tongue at the ten to four
position.
3.Lubricate a new’O’ring with engine oil and fit
to distributor.
4.Turn distributor drive until rotor arm is
approximately 30°anti-clockwise from No.1
spark plug segment in distributor cap.
5.Insert distributor into timing cover, engage
drive gear and push distributor down until’O’
ring enters bore; position distributor clamp on
stud. 
						

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OVERHAUL25
6.Engine numbers without suffix B:Locate
slotted adapter to oil pump drive shaft tongue.
7.Check that centre line of rotor arm is aligned
with No.1 spark plug segment in distributor cap
and reference marks on distributor body and
clamp are aligned; reposition distributor if
necessary.
8.Remove rotor arm.
9.Rotate distributor to position pick-up opposite
nearest reluctor tooth.
10.Fit distributor clamp nut ensuring that
counterbored portion is towards clamp; tighten
nut to 20 Nm (15 lbf.ft).
11.Fit rotor arm.
CAUTION: This distributor setting is to
enable engine to be started. When engine
is refitted, ignition timing must be set
using electronic equipment.OIL COOLER ADAPTER - ENGINE NUMBERS
WITHOUT SUFFIX B
Oil cooler adapter - remove
1.Remove oil filter element.
2.Mark position of adapter in relation to oil pump
cover.
3.Remove centre screw and withdraw adapter.
4.Remove and discard sealing ring. 
						

							ENGINE
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OVERHAUL Oil cooler adapter - refit
1.Thoroughly clean adapter.
2.Lubricate a new sealing ring with engine oil, fit
adapter, ensuring marks previously made line
up, fit and tighten centre screw.
3.Lubricate sealing ring of oil filter with engine oil.
4.Screw filter on to filter head until it seats then
tighten a further half-turn.OIL PUMP - ENGINE NUMBERS WITHOUT
SUFFIX B
Oil pump - remove
1.Remove sump.
2.Remove distributor.
3.Remove timing cover.
4.Remove oil cooler adapter - if fitted.
5.Remove oil pressure relief valve plug, discard
sealing washer.
6.Withdraw pressure relief valve spring and
valve.
7.Remove oil pressure switch, discard sealing
washer.
8.Remove bolts securing oil pump cover.
9.Remove cover, remove and discard gasket.
10.Withdraw oil pump gears. 
						

							ENGINE
OVERHAUL27
Oil pump - inspection
1.Throughly clean oil pump gear housing, cover
and gears.
2.Clean oil pressure relief valve bore in housing.
3.Clean relief valve filter screen.
4.Inspect pump gears for wear and scoring.
5.Fit pump gears into housing.
6.Place straight edge across gears.
7.Check clearance between straight edge and
cover face.
Gear to cover face minimum clearance = 0.05
mm (0.002 in).
If clearance is below minimum specified check
gear recess in housing for wear. Renew
housing if necessary.
8.Remove oil pump gears from housing.
9.Clean oil pressure relief valve and spring.
10.Inspect relief valve for wear and scoring.
11.Inspect relief valve spring for wear or signs of
collapse.
Relief spring free length = 81.28 mm (3.2 in)
12.Check relief valve slides freely in its bore with
no perceptible side movement.Oil pump - refit
1.Lubricate relief valve, spring, and bore in
housing with clean engine oil.
2.Fit relief valve and valve spring.
3.Fit new sealing washer to plug, fit plug and
tighten to 45 Nm (33 lbf.ft).
4.Pack oil pump housing with Petroleum Jelly.
CAUTION: Use only Petroleum Jelly, no
other grease is suitable.
5.Fit oil pump gears ensuring that Petroleum
Jelly is forced into every cavity between teeth
of gears.
CAUTION: Unless pump is fully packed
with Petroleum Jelly it may not prime itself
when the engine is started.
6.Fit new pump cover gasket, dry.
7.Position cover, fit bolts and tighten
progressively to 12 Nm (9 lbf.ft).
8.Fit oil cooler adapter.
9.Fit timing cover.
10.Fit distributor.
11.Fit sump. 
						

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OVERHAUL OIL PUMP - ENGINE NUMBERS WITH SUFFIX B
CAUTION: Overhaul procedures for the oil
pump, oil pressure by-pass valve and oil
pressure relief valve are limited to carrying
out dimensional checks. In the event of wear or
damage being found, a replacement timing cover
assembly must be fitted.
Oil pump - remove
1.Remove timing cover.
2.Remove oil pump drive gear.
3.Remove screws and bolt - if fitted securing
cover plate, remove plate.
4.Make suitable alignment marks on inner and
outer rotors, remove rotors.Oil pressure by-pass valve - remove
1.Remove circlip.
2.Remove by-pass valve plug.
3.Remove and discard’O’ring from plug.
4.Remove by-pass valve spring and plunger.
5.Check plunger and bore of by-pass valve in oil
pump body for scoring and corrosion.
NOTE: Light corrosion may be removed
using grade 600 emery cloth soaked in oil. 
						

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OVERHAUL29
Oil pressure relief valve - remove
1.Remove circlip.
2.Remove relief valve plug.
3.Remove and discard’O’ring from plug.
4.Remove relief valve spring and piston.
5.Check piston and bore of relief valve in oil
pump body for scoring and corrosion.
NOTE: Light corrosion may be removed
using grade 600 emery cloth soaked in oil.Oil pump - inspection
1.Thoroughly clean oil pump drive gear, cover
plate, rotors and housing. Remove all traces of
sealant from cover plate securing screws and
bolt - if fitted; ensure tapped holes in timing
cover are clean and dry.
2.Check mating surfaces of cover plate, rotors
and housing for scoring.
3.Assemble rotors and oil pump drive gear in
housing ensuring that reference marks are
aligned.
4.Using feeler gauges, check clearance between
teeth of inner and outer rotors:
Maximum clearance = 0.25 mm (0.01 in)
5.Remove oil pump drive gear, check depth of
any wear steps on gear teeth:
Wear step maximum depth = 0.15 mm (0.006
in) 
						

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OVERHAUL
6.Place a straight edge across housing.
7.Using feeler gauges, check clearance between
straight edge and rotors:
Maximum clearance = 0.1 mm (0.004 in)Oil pressure by-pass valve - inspection
1.Clean by-pass valve components and plunger
bore in timing cover.
2.Check plunger and bore for scoring and that
plunger slides freely in bore with no perceptible
side movement.
3.Check by-pass valve spring for damage and
distortion; check spring free length:
Spring free length = 60.0 mm (2.4 in). 
						

							ENGINE
OVERHAUL31
Oil pressure relief valve - inspection
1.Clean relief valve components and piston bore
in timing cover.
2.Check piston and bore for scoring and that
piston slides freely in bore with no perceptible
side movement.
3.Check relief valve spring for damage and
distortion; check spring free length:
Spring free length = 60.0 mm (2.4 in).Oil pump - refit
1.Lubricate rotors, oil pump drive gear, cover
plate and housing with engine oil.
2.Assemble rotors in housing ensuring that
reference marks are aligned.
3.Position cover plate to housing.
4.Apply sealant, Part number STC 50552 to
threads of cover plate screws and bolt - if fitted,
fit but do not fully tighten screws and bolt.
5.Position drive gear in oil pump, tighten cover
plate screws and bolt - if fitted to:
Screws - 4 Nm (3 lbf.ft).
Bolt - 8 Nm (6 lbf.ft)
6.Fit timing cover.