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

							ENGINE
32
OVERHAUL Oil pressure by-pass valve - refit
1.Lubricate new’O’ring with engine oil and fit to
by-pass valve plug.
2.Lubricate by-pass valve spring, plunger and
plunger bore with engine oil.
3.Assemble plunger to by-pass valve spring,
insert plunger and spring into bore.
4.Fit by-pass valve plug, depress plug and fit
circlip.
5.Ensure circlip is fully seated in groove.Oil pressure relief valve - refit
1.Lubricate new’O’ring with engine oil and fit to
relief valve plug.
2.Lubricate relief valve spring, piston and piston
bore with engine oil.
3.Assemble piston to relief valve spring, insert
piston and spring into piston bore.
4.Fit relief valve plug, depress plug and fit circlip.
5.Ensure circlip is fully seated in groove. 
						

							ENGINE
OVERHAUL33
CAMSHAFT AND TAPPETS
Camshaft end-float - check
NOTE: this check is only applicable to
camshafts fitted with thrust plate.
1.Remove rocker shaft assemblies.
2.Remove push rods and store in fitted order.
3.Remove timing chain and gears.
4.Temporarily fit camshaft gear bolt.
5.Attach a suitable DTI to front of cylinder block
with stylus of gauge contacting end of
camshaft.
6.Push camshaft rearwards and zero gauge.
7.Using camshaft gear bolt, pull camshaft
forwards and note end-float reading on gauge.
End-float = 0.05 to 0.35 mm (0.002 to 0.014 in)
8.if end-float is incorrect, fit a new thrust plate
and re-check. If end-float is still incorrect, a
new camshaft must be fitted.Camshaft and tappets - remove
1.Remove tappets and retain with their
respective push rods.
CAUTION: Store tappets upright to
prevent oil loss.
NOTE: If tappets cannot be removed due
to damaged camshaft contact area,
proceed as follows:
2.Lift tappets in pairs to the point where
damaged face is about to enter tappet bore
and fit rubber bands to retain tappets. Repeat
until all tappets are retained clear of camshaft
lobes. The tappets can then be withdrawn out
the bottom of their bores when the sump and
camshaft are removed. 
						

							ENGINE
34
OVERHAUL
3.Remove 2 bolts securing camshaft thrust plate
- if fitted to cylinder block, remove plate.
4.Withdraw camshaft, taking care not to damage
bearings in cylinder block.Camshaft and tappets - inspection
1.Throughly clean all components.
2.Inspect camshaft bearing journals and lobes
for signs of wear, pitting, scoring and
overheating.
3.Support camshaft front and rear bearings on
vee blocks, and using a DTI, measure
camshaft run-out on centre bearing.
Maximum permitted run-out = 0.05 mm (0.002
in).
4.Inspect camshaft thrust plate - if fitted, for
wear, replace plate if wear is evident.
5.Clean and inspect tappets. Check for an even,
circular wear pattern on the camshaft contact
area. If contact area is pitted or a square wear
pattern has developed, tappet must be
renewed.
6.Inspect tappet body for excessive wear or
scoring. Replace tappet if scoring or deep wear
patterns extend up to oil feed area. Clean and
inspect tappet bores in engine block.
7.Ensure that tappets rotate freely in their
respective bores.
8.Inspect push rod contact area of tappet,
replace tappet if surface is rough or pitted. 
						

							ENGINE
OVERHAUL35
Camshaft and tappets - refit
1.Lubricate camshaft journals with clean engine
oil and carefully insert camshaft into cylinder
block.
2.Fit camshaft thrust plate - if fitted, ensuring that
it is correctly located in camshaft groove. Fit
bolts and tighten to 25 Nm (18 lbf.ft).
NOTE: If camshaft or thrust plate has been
replaced, it will be necessary to re-check
camshaft end-float.
3.Immerse tappets in clean engine oil. Before
fitting, pump the inner sleeve of tappet several
times using a push rod, to prime tappet and
reduce tappet noise when engine is first
started.
4.Lubricate tappet bores with clean engine oil
and fit tappets in removed order.
NOTE: Some tappet noise may be evident
on initial start-up. If necessary, run the
engine at 2500 rev/min for a few minutes
until noise ceases.
5.Fit timing chain and gears.
6.Fit rocker shaft assemblies.PISTONS, CONNECTING RODS, PISTON RINGS
AND CYLINDER BORES
Pistons and connecting rods - remove
1.Remove cylinder head(s).
2.Remove big-end bearings.
3.Remove carbon ridge from top of each cylinder
bore.
4.Suitably identify each piston to its respective
cylinder bore.
5.Push connecting rod and piston assembly to
top of cylinder bore and withdraw assembly.
6.Repeat above procedure for remaining pistons.
CAUTION: Big-end bearing shells must be
replaced whenever they are removed. 
						

							ENGINE
36
OVERHAUL Piston rings - remove
1.Using a suitable piston ring expander, remove
and discard piston rings.
2.Remove carbon from piston ring grooves.
NOTE: Use an old broken piston ring with
a squared off end.
CAUTION: Do not use a wire brush.Piston rings - inspection
1.Temporarily fit new compression rings to
piston.
NOTE: The ring marked’TOP’must be
fitted, with marking uppermost, into
second groove. The chrome ring fits into
top groove and can be fitted either way round.
2.Check compression ring to groove clearance:
Top compression ringA= 0.05 to 0.10 mm
(0.002 to 0.004 in)
2nd compression ringB= 0.05 to 0.10 mm
(0.002 to 0.004 in)
3.Insert piston ring into its relevant cylinder bore,
held square to bore with piston and check ring
gaps.
Top compression ring = 0.30 to 0.50 mm
(0.012 to 0.02 in)
2nd compression ring = 0.40 to 0.65 mm(0.016
to 0.26 in)
Oil control ring rails = 0.38 to 1.40 mm (0.14 to
0.05 in)
CAUTION: Ensure that on completion of
checking, piston rings are identified and
retained with the cylinder in which they
were checked. 
						

							ENGINE
OVERHAUL37
Pistons - remove
1.Clamp hexagon body ofLRT-12-013in vice.
2.Screw large nut back until flush with end of
centre screw.
3.Push centre screw forward until nut contacts
thrust race.
4.Locate remover/replacer adapter
LRT-12-126/2with its long spigot inside bore
of hexagon body.
5.Locate piston and connecting rod assembly on
centre screw and up to adapterLRT-12-126/2
ensuring that prongs of adapter are positioned
on piston either side of gudgeon pin.
6.Fit remover/replacer bushLRT-12-126/1on
centre screw with flanged end away from
gudgeon pin.
7.Screw stop nut on to centre screw.
CAUTION: Ensure that LRT-12-126/1 is
correctly located in gudgeon pin bore of
piston.
8.Lock the stop nut securely with the lockscrew.
9.Push connecting rod to right to locate end of
gudgeon pin in adapterLRT-12-126/2.
10.Ensure thatLRT-12-126/1is still located in
gudgeon pin bore of piston.
11.Screw large nut up toLRT-12-013.
12.Hold lockscrew and turn large nut until
gudgeon pin is withdrawn from piston.
CAUTION: Ensure that prongs of adapter
LRT-12-126/2 remain in contact with piston
and do not contact gudgeon pin.13.Dismantle toolLRT-12-013and remove piston,
connecting rod and gudgeon pin.
NOTE: Keep each piston and gudgeon pin
with their respective connecting rod.
14.Repeat above operations for remaining
pistons. 
						

							ENGINE
38
OVERHAUL Pistons and connecting rods - inspection
1.Clean carbon from pistons
2.Inspect pistons for distortion, cracks and
burning.
3.Measure and record piston diameter at 90°to
gudgeon pin axis and 10 mm (0.4 in) from
bottom of skirt.
4.Check gudgeon pin bore in piston for signs of
overheating.
NOTE: Pistons fitted on production are
graded A or B, the grade letter is stamped
on the piston crown. Grade B pistons are
supplied as service replacements. Worn cylinder
liners fitted with grade A pistons may be honed
to accept grade B pistons provided that
specified cylinder bore and ovality limits are
maintained.
CAUTION: DO NOT attempt to de-glaze
cylinder bores.
CAUTION: Ensure replacement pistons are
correct for the compression ratio of the
engine. The compression ratio will be
found on the cylinder block above the engine
serial number. Ensure that replacement
connecting rods are correct for engine being
overhauled.
5.Check connecting rods for alignment.Gudgeon pins - inspection
NOTE: Gudgeon pins are only supplied as
an assembly with replacement pistons.
1.Check gudgeon pins for signs of wear and
overheating.
2.Check clearance of gudgeon pin in piston:
Gudgeon pin to piston clearance = 0.006 to
0.015 mm (0.0002 to 0.0006 in)
3.Check overall dimensions of gudgeon pin:
Overall length = 72.67 to 72.79 mm (2.85 to
2.86 in)
Diameter - measured at each end and centre
of pin = 22.215 to 22.220 mm (0.87 to 0.871 in) 
						

							ENGINE
OVERHAUL39
Cylinder liner bore - inspection
1.Measure cylinder bore wear in two axis 40 to
50 mm (1.5 to 1.9 in) from top of bore:
Cylinder bore diameter - standard:
3.5 litre = 88.86 to 88.90 mm (3.498 to 3.50 in)
3.9 litre = 94.00 to 94.04 mm (3.700 to 3.702
in)
4.2 litre = 94.00 to 94.04 mm (3.700 to 3.702
in)
Maximum ovality = 0.013 mm (0.0005 in)
2.Compare cylinder bore diameter with piston
diameter and calculate piston to cylinder bore
clearance.
Piston to cylinder bore clearance = 0.015 to
0.045 mm (0.001 to 0.002 in)
CAUTION: The temperature of piston and
cylinder block must be the same to ensure
accurate measurement.
CAUTION: DO NOT attempt to de-glaze
cylinder bores.Pistons - refit
CAUTION: On later 4.2L engines the piston
has a 0.5 mm (0.02 in) offset gudgeon pin
which can be identified by an arrow mark
on the piston crown. This arrow MUST always
point to the front of the engine.
1.4.2L engine only:Assemble pistons to
connecting rods with arrow on piston pointing
towards domed shaped bosses on connecting
rod for RH bank of cylinders, and arrow
pointing away from dome shaped bosses for
LH bank of cylinders.
2.Clamp hexagon body ofLRT-12-013in vice.
3.Screw large nut back until flush with end of
centre screw.
4.Locate remover/replacer adapter
LRT-12-126/2with its long spigot inside bore
of hexagon body.
5.Fit parallel sleeve, part of toolLRT-12-013with
grooved end towards open end ofLRT-12-013
up to shoulder of centre screw.
6.Lubricate gudgeon pin and bores of connecting
rod and piston with graphited oil. 
						

							ENGINE
40
OVERHAUL 7.Locate connecting rod and piston to centre
screw with connecting rod entered on parallel
sleeve up to the machined groove on the
sleeve.
CAUTION: Ensure that the parallel sleeve
used is the same diameter as the gudgeon
pin.
8.Fit gudgeon pin on to centre screw and into
piston bore up to connecting rod.
9.Fit remover/replacer bushLRT-12-126/1with
flanged end towards gudgeon pin.
10.Screw the stop nut on to the centre screw and
position piston against remover/replacer
adapterLRT-12-126/2.
CAUTION: Ensure that prongs of
LRT-12-126/2 remain in contact with piston
and do not contact the gudgeon pin.
11.Lock the stop nut securely with the lockscrew.
12.Lubricate centre screw threads and thrust race
with graphited oil, screw large nut up to
LRT-12-013.
13.Set torque wrench to 16 Nm (12 lbf.ft), and
using socket on large nut, pull gudgeon pin in
until flange ofLRT-12-126/1is distance’A’
from face of piston.
Distance’A’= 0.4 mm (0.016 in).
CAUTION: If torque wrench’breaks’
during above operation, fit of gudgeon pin
to connecting rod is not acceptable and
components must be replaced. The centre screw
and thrust race must be kept well lubricated
throughout operation.
14.Dismantle toolLRT-12-013, remove piston,
check no damage has occurred during
pressing and piston moves freely on gudgeon
pin.
15.Repeat above operations for remaining
pistons.Piston to cylinder bore clearance - checking
1.Starting with number 1 piston, invert piston and
with arrow on piston crown pointing towards
REAR of cylinder block, insert piston in cylinder
liner.
2.Position piston with bottom of skirt 30 mm (1.2
in) from top of cylinder block.
3.Using feeler gauges, measure and record
clearance between piston and left hand side of
cylinder block:
Piston to bore clearance = 0.15 to 0.045 mm
(0.001 to 0.002 in)
4.Repeat above procedures for remaining
pistons. 
						

							ENGINE
OVERHAUL41
Pistons and connecting rods - refit
1.Fit oil control ring rails and expander, ensuring
ends butt and not overlap.
2.Fit ring marked’TOP’with marking uppermost
into second groove.
3.Fit top compression ring into groove either way
round.
4.Position oil control expander ring joint and ring
rail gaps all at one side, between gudgeon pin
and away from left hand side of piston - viewed
from front of piston. Space gaps in ring rails
approximately 25 mm (1.0 in) each side of
expander ring joint.
5.Position compression rings with ring gaps on
opposite sides of piston between gudgeon pin
and right hand side of piston - viewed from
front of piston.
6.Thoroughly clean cylinder bores.
7.Lubricate piston rings and gudgeon pin with
engine oil.
8.Lubricate cylinder bores with engine oil.
9.Fit ring clamp to piston and compress piston
rings.
10.Insert connecting rod and piston assembly into
respective cylinder bore ensuring domed
shaped boss on connecting rod faces towards
front of engine on RH bank of cylinders, and
towards rear on LH bank of cylinders.
11.Fit big-end bearing caps and bearing shells.
NOTE: When both connecting rods are
fitted to each journal, bosses will face
towards each other.
12.Fit cylinder head(s).