Land Rover 4 0 4 6 V8 Engine Overhaul 4th Edition Rover Manual

							ENGINE
22
OVERHAUL 9.Fit sump drain plug and tighten to 45 Nm (33
lbf.ft).
10.Fit dipstick.Later engines fitted with cast alloy sump
1.Remove all traces of gasket and sealant from
the sump and cylinder block using a plastic
scraper. Ensure bolt holes in cylinder block are
clean and dry.
2.Apply a 5 mm (0.2 in) wide bead of sealant,
Part number STC 50550 across the cylinder
block to front cover joint and cylinder block to
rear main bearing cap joints. Apply a globule of
the sealant to the ends of the cruciform seals.
3.Position a new gasket, fitted dry, to the sump
ensure that the locating tags are correctly
positioned.
4.Fit sump taking care not to damage sealant
beads. 
						

							ENGINE
OVERHAUL23
5.Noting that the two parts of the tool are
’handed’, fit toolLRT-12-183to the engine
backplate using slave bolts.
6.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.
7.Fit sump bolts and using the sequence shown
tighten to 22 Nm (16 lbf.ft).
8.Remove toolLRT-12-183.9.Fit sump drain plug and sealing washer, tighten
drain plug to 24 Nm (18 lbf.ft).
10.Fit dipstick. 
						

							ENGINE
24
OVERHAUL OIL PUMP
NOTE: Overhaul procedures for the oil
pump, oil pressure by-pass and relief
valves are limited to carrying out
dimensional checks. In the event of wear or
damage being found, a replacement timing cover
and oil pump assembly must be fitted.
Oil pump - remove
1.Remove timing cover.
CAUTION: Do not attempt to remove oil
pump drive gear from inner rotor at this
stage.
2.Remove 7 screws and bolt securing oil pump
cover plate, remove plate.
3.Make suitable alignment marks on inner and
outer rotors, remove rotors and oil pump drive
gear as an assembly. 
						

							ENGINE
OVERHAUL25
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.Oil pressure relief valve - if fitted - 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. 
						

							ENGINE
26
OVERHAUL Oil pump - inspection
1.Thoroughly clean oil pump drive gear, cover
plate, rotors and housing. Remove all traces of
sealant from threads of cover plate securing
screws and bolt; ensure tapped holes in timing
cover are clean and free from oil.
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)
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). 
						

							ENGINE
OVERHAUL27
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).Oil pressure relief valve - if fitted - 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). 
						

							ENGINE
28
OVERHAUL Oil pump - refit
1.Lubricate rotors, oil pump drive gear, cover
plate and housing with engine oil.
2.Assemble rotors and drive gear 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.
5.Fit cover plate screws and bolt and tighten to:-
Screws - 4 Nm (3 lbf.ft)
Bolt - 8 Nm (6 lbf.ft)
6.Fit timing cover.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. 
						

							ENGINE
OVERHAUL29
Oil pressure relief valve if fitted - 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.CAMSHAFT AND TAPPETS
Camshaft end-float - check
1.Remove rocker shaft assemblies.
2.Remove pushrods and store in their fitted
order.
3.Remove timing chain and gears.
4.Temporarily fit camshaft gear and gear bolt.
5.Attach a suitable DTI to front of cylinder block
with stylus of gauge contacting camshaft gear.
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 0.25 mm (0.002 to 0.010 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. 
						

							ENGINE
30
OVERHAUL Camshaft and tappets - remove
1.Remove tappets and retain with their
respective pushrods.
CAUTION: Store tappets upright to
prevent oil loss.
2.When tappets prove difficult to remove due to
damaged camshaft contact area, proceed as
follows. 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.
3.Remove camshaft gear and bolt.
4.Remove 2 bolts securing camshaft thrust plate
to cylinder block, remove plate.
5.Withdraw camshaft, taking care not to damage
bearings in cylinder block.
NOTE: Camshafts fitted to 4.0 litre engines
are colour coded ORANGE whilst those
fitted to 4.6 litre engines are colour coded
RED. 
						

							ENGINE
OVERHAUL31
Camshaft and tappets - inspection
1.Thoroughly 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 thrust plate 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 cylinder block.
7.Ensure that tappets rotate freely in their
respective bores.
8.Inspect pushrod contact area of tappet, replace
tappet if surface is rough or pitted.Camshaft and tappets - refit
NOTE: If a replacement camshaft is to be
fitted, ensure colour coding is correct.
Camshafts fitted to 4.0 litre engines are
colour coded ORANGE whilst those fitted to 4.6
litre engines are colour coded RED.
1.Lubricate camshaft journals with engine oil and
carefully insert camshaft into cylinder block.
2.Fit camshaft thrust plate, 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 engine oil. Before fitting,
pump the inner sleeve of tappet several times
using a pushrod to prime tappet; this will
reduce tappet noise when engine is first
started.
4.Lubricate tappet bores with engine oil and fit
tappets in removed order.
NOTE: Some tappet noise may still 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.