Land Rover 4 0 4 6 V8 Engine Overhaul 4th 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 pushrod seats in rocker arms.
4.Check pushrods 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: Incorrect assembly of rocker
shafts will lead to an oil feed restriction.
2.Fit new split pin to one end of rocker shaft.
3.Fit plain washer and wave washer.
4.Lubricate rocker arm bushes with engine oil.
5.Fit rocker arms with offsets as illustrated.
6.Assemble rocker arms, brackets and springs to
rocker shaft.
7.Compress springs,...

ENGINE
4
OVERHAUL 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 gasket(s) which incorporate
compression limiters in the bolt holes.
7.Fit rocker cover to cylinder head, fit new
’patched’multi-hex bolts and tighten in
diagonal sequence to:
Stage 1 - 3 Nm (2.5 lbf.ft)
Stage 2 - 8 Nm (6 lbf.ft)
CAUTION: The 2 short bolts must be fitted
on side of cover nearest centre of...

ENGINE
OVERHAUL5
All engines
NOTE: RH cylinder head illustrated.
4.Using sequence shown, remove and discard
10 bolts securing cylinder head to cylinder
block.
5.Release cylinder head from 2 dowels and
remove cylinder head.
6.Remove and discard cylinder head gasket.
7.Repeat above procedures for remaining
cylinder head.Valves and springs - remove
1.Remove spark plugs.
2.Using valve spring compressorLRT-12-034or
a suitable alternative, compress valve spring.
3.Compress valve spring sufficiently to release...

ENGINE
6
OVERHAUL 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)
4.Check cylinder head height at each end of
cylinder head:
A= 22.94 mm (0.903 in) - New
B= 62.56 mm...

ENGINE
OVERHAUL7
Valves, valve springs and guides - inspection
Valves
NOTE: 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...

ENGINE
8
OVERHAUL
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 using the following procedures.
4.Check valve head diameterA:
Inlet = 39.75 to 40.00 mm (1.56 to 1.57 in)...

ENGINE
OVERHAUL9
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...

ENGINE
10
OVERHAUL
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 tools.
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).
7.Remove all traces of swarf...

ENGINE
OVERHAUL11
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.Valve seats and seat inserts - refacing...