Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 1996 Rover Manual
Have a look at the manual Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 1996 Rover Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 364 Land Rover manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
ENGINE DESCRIPTION ANDOPERATION 3 CYLINDER BLOCKCOMPONENTS 1. Cylinder block 2. Piston andgudgeon pin 3. Connecting rod 4. Core plugs 5. Camshaft 6. Dipstick 7. Camshaft key 8. Timing chain 9. Camshaft sprocket 10. Spacer 11. Distributor drivegear 12. Distributor 13. Oilpump gears* 14. Timing coverandgasket * 15. Timing coveroilseal * 16. Crankshaft pulley 17. Crankshaft sprocket 18. Woodruff key 19. Crankshaft 20. Centre mainbearing shell-upper 21. Crankshaft rearoilseal 22. Rear mainbearing capand side seals 23. Connecting rodcap 24. Main bearing caps 25. Oilpump cover* 26. Oilpressure reliefvalve assembly * 27. Oilpressure switch* 28. Oilpump suction pipeandstrainer 29. Sump 30. Drain plug 31. Timing cover** 32. Timing covergasket ** 33. Timing coveroilseal ** 34. Oilfilter ** 35. Oilpressure switch** 36. Oilpressure reliefvalve assembly ** 37. Camshaft thrustplate-if fitted * Engine numbers withoutsuffixB ** Engine numbers withsuffix B
ENGINE 4DESCRIPTION ANDOPERATION CYLINDER HEADCOMPONENTS 1. Cylinder head 2. Rocker cover 3. PCV filter 4. Rocker shaft 5. Tappet 6. Pushrod 7. Rocker shaftbracket 8. Rocker arm 9. Rocker shaftspring 10. PCV airintake filter 11. Engine oilfiller cap 12. Inlet valve seal,spring, cap,andcollets 13. Exhaust valveseal,spring, capand collets 14. Inlet valve andseat 15. Exhaust valveandseat 16. Inlet manifold gasketandseals 17. Cylinder headgasket 18. Valve guide
ENGINE DESCRIPTION ANDOPERATION 5 Operation TheV8engine isan eight cylinder, watercooled unit comprising ofcast aluminium cylinderblockand cylinder heads. The twobanks ofsteel cylinder linerswhich are pressed downtostops inthe cylinder block,areset at 900 toeach other. Thecrankshaft iscarried infive main bearings, end-floatbeingcontrolled bythe thrust facesofthe upper centre mainbearing shell. The centrally locatedcamshaft isdriven bythe crankshaft viaaninverted toothchain. Thevalves are operated byrockers, pushrods andhydraulic tappets. Distributor driveisby skew gearfromthe front ofthe camshaft. The aluminium alloy,pistons havetwocompression rings andanoilcontrol ringand aresecured tothe connecting rodsbysemi-floating gudgeonpins.On later 4.2L engines thegudgeon pinisoffset 0.5mm, identified byan arrow markonthe piston crown, which mustalways pointtothe front ofthe engine. Plain, big-end bearingshellsarefitted toeach connecting rod.
ENGINE 6DESCRIPTION ANDOPERATION Lubrication -Engine numbers withoutsuffixB 1.Oil strainer 2. Crankshaft mainbearing oilfeed 3. Oil pressure reliefvalve 4. Oil pump 5. Main gallery A Oiltocooler B Oilfrom cooler
ENGINE DESCRIPTION ANDOPERATION 7 Lubrication -Engine numbers withsuffix B 1.Oil strainer 2. Oil pump 3. Pressure reliefvalve 4. Oil pressure switch 5. Main gallery A Oil tocooler B Oil from cooler Engine numbers withoutsuffixB The fullflow lubrication systemusesanexternal gear pump which isdriven bythe distributor drive shaft. Theoilpump gearsarehoused inthe timing cover andtheoilpressure reliefvalve andwarning light switch arefitted tothe oilpump cover. Engine numbers withsuffix B The fullflow lubrication systemusesagear typeoil pump driven fromthecrankshaft. Theassembly is integral withthetiming coverwhich alsocarries the full flow oilfilter, oilpressure switchandpressure relief valve. All engines Oil isdrawn fromthepressed steelsump through a strainer andintotheoilpump, excess pressure being relieved bythe pressure reliefvalve. Theoil pressure warninglightswitch isscrewed intotheoil pump coverandregisters theoilpressure inthe main oilgallery onthe outflow sideofthe filter. Pressurised oilpasses through anoilcooler -if fitted to the fullflow oilfilter andtointernal drillings inthe crankshaft whereitis directed toeach mainbearing and tothe bigend bearings viaNos. 1,3and 5main bearings. Aninternal drillinginthe cylinder block directs oiltothe camshaft whereitpasses through further internal drillings tothe hydraulic tappets, camshaft journalsandrocker shaft.Lubrication to the thrust sideofthe cylinders isby oilgrooves machined ineach connecting rodbigend joint face, which aretimed toalign withholes inthe bigend journals onthe power andexhaust strokes.
ENGINE 8DESCRIPTION ANDOPERATION Distributor driveandtiming chainlubrication 1.Bearing 2. Camshaft 3. Key 4. Camshaft timingchainsprocket 5. Spacer 6. Distributor drivegear The distributor driveandtiming chainarelubricated from thecamshaft frontbearing. Thefeed tothe timing chainischannelled alongthecamshaft sprocket, keyand spacer. Hydraulic tappets1.Clip 2. Pushrod seat 3. Inner sleeve 4. Upper chamber 5. Non-return ballvalve 6. Spring 7. Outer sleeve 8. Lower chamber -high pressure The purpose ofthe hydraulic tappetisto provide maintenance freeandquiet operation ofthe inlet and exhaust valves.Itachieves thisbyutilising engine oilpressure toeliminate themechanical clearance betweentherockers andthevalve stems. During normal operation, engineoilpressure present in the upper chamber passesthrough thenon-return ball valve andintothelower, highpressure, chamber. When thecam begins tolift the outer sleeve, the resistance ofthe valve spring feltthrough thepush rod and seat causes thetappet innersleeve tomove downwards insidetheouter sleeve. Thisdownward movement ofthe inner sleeve closestheball valve and increases thepressure inthe lower, high pressure chamber, sufficiently toensure thatthe push rodopens thevalve fully. As the tappet moves offthe peak ofthe cam theball valve opens toequalise thepressure inboth chambers whichensures thevalve closes whenthe tappet ison the back ofthe cam.
ENGINEOVERHAUL 1 ROCKER SHAFTS Rocker shaft-remove 1. LH rocker shaftonly:Remove screwsecuring dipstick tubetorocker cover. 2.Remove 4screws securing rockercoverto cylinder head. NOTE:Markposition of2longer screws. 3. Remove rockercover. 4. Remove anddiscard gasketfromrocker cover. 5. Mark eachrocker shaftinrelation tooriginal cylinder head. CAUTION: Incorrectfitmentofrocker shafts willlead toan oilfeed restriction. 6.Progressively slackenandremove 4bolts securing rockershaftassembly tocylinder head. 7. Remove rockershaftassembly. 8. Remove pushrods andstore infitted order.
ENGINE 2OVERHAUL Dismantle 1. Remove splitpinfrom oneendofrocker shaft. 2. Remove plainwasher, wavewasher, rocker arms, brackets andsprings. Inspect 1. Thoroughly cleancomponents. 2. Inspect eachcomponent forwear, inparticular rocker armsandshafts. Discard weakor broken springs. 3. Inspect pushrod seatsinrocker arms. 4. Check pushrods forstraightness andinspect ball ends fordamage, replaceasnecessary. Assembly 1. Assemble rockershaftswithidentification groove atone oclock position withpush rod end ofrocker armtothe right. CAUTION: Ifrocker shaftsareincorrectly assembled andfitted toengine, oilsupply to rocker armswillberestricted. 2.Fitnew splitpintoone endofrocker shaft. 3. Fitplain washer andwave washer. 4. Lubricate rockerarmbushes withclean engine oil. 5. Early typerocker armsareangled, andmust be fitted withthevalve endofthe rocker arms angled awayfromeach other asillustrated. 6. On later typerocker armsthevalve endis offset andmust befitted asillustrated. NOTE: Earlyandlaterocker armsare interchangeable providedthecomplete set is changed. 7. Assemble rockerarms,brackets andsprings to rocker shaft. 8. Compress springs,fitwave washer, plain washer andsecure withnew splitpin.
ENGINEOVERHAUL 3 Rocker shaft-refit 1. Lubricate pushrods withengine oil. 2. Fitpushrods inremoved order. 3.Fiteach rocker shaftassembly, ensuring identification grooveisuppermost andtowards front ofengine onRH side andtowards rearof engine onLH side. CAUTION: Incorrectfitmentwillresult in an oilfeed restriction. 4. Fitbolts andtighten tocorrect torque. 5. Clean gasket surface inrocker coverusing Bostik cleaner 6001orequivalent, andallow to dry. 6. Apply athin coating ofBostik 1775or equivalent impactadhesive tomating surfaces of rocker coverandgasket. 7. Allow adhesive tocure, thenfitgasket torocker cover. CAUTION: Gasketfitsone way round only, it must befitted accurately assubsequent movement willdestroy bonding. 8. Fitrocker covertocylinder head,fitscrews and tighten tocorrect torque. CAUTION: The2short screws mustbe fitted onside ofcover nearest centreof engine. 9. LH rocker shaftonly: Aligndipstick tubeto rocker cover,fitand tighten screw.
ENGINE 4OVERHAUL CYLINDER HEAD Cylinder head-remove 1. Remove rockershaftassembly. 2. Mark heads LHand RHforreassembly. Engine numbers withoutsuffixB NOTE: RHcylinder headillustrated 3. Using sequence shown,remove 14bolts securing cylinderheadtocylinder block. Enginenumbers withsuffix B NOTE: RHcylinder headillustrated 4. Using sequence shown,remove anddiscard 10 bolts securing cylinderheadtocylinder block. NOTE: Nobolts arefitted inthe four lower holes ineach cylinder head. Allengines 5.Release cylinderheadfrom2dowels and remove cylinder head. 6. Remove anddiscard cylinder headgasket. Valves andsprings -remove 1. Remove sparkplugs. 2.Using valvespring compressor LRT-12-034 or a suitable alternative, compressvalvespring. 3. Remove 2collets. 4. Release springcompressor andremove valve, valve spring capand valve spring. 5. Repeat aboveoperations forremaining valves. CAUTION: Keepvalves, springs, capsand collets infitted order. 6. Remove anddiscard valvestemoilseals.