Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 1996 Rover Manual

							ENGINEOVERHAUL 15
6.
Engine
numbers withoutsuffixB:Locate
slotted adaptor tooil pump driveshafttongue.
7. Check thatcentre lineofrotor armisaligned
with No.1 spark plugsegment indistributor cap
and reference marksondistributor bodyand
clamp arealigned; reposition distributor if
necessary.
8. Remove rotorarm.
9. Rotate distributor toposition pick-upopposite
nearest reluctortooth.
10.Fitdistributor clampnutensuring that
counterbored portionistowards clamp;tighten
nut.
11. Fitrotor arm.
CAUTION: Thisdistributor settingisto
enable engine tobe started. Whenengine
is refitted, ignitiontimingmustbeset
using electronic equipment. OIL
COOLER ADAPTER -ENGINE NUMBERS
WITHOUT SUFFIXB
Oil cooler adapter -remove
1. Remove oilfilter element.
2.Mark position ofadapter inrelation tooil pump
cover.
3. Remove centrescrewandwithdraw adapter.
4. Remove anddiscard sealingring.
Oil cooler adapter -refit
1. Thoroughly cleanadapter.
2. Position newsealing ring,fitadapter, ensuring
marks previously madelineup,fitand tighten
centre screw.
3. Lubricate sealingringofoil filter withengine oil.
4. Screw filterontofilter head untilitseats then
tighten afurther half-turn.    
						

							ENGINE 16OVERHAUL
OIL
PUMP -ENGINE NUMBERS WITHOUT
SUFFIX B
Oil pump -remove
1. Remove sump.
2. Remove distributor.
3. Remove timingcover.
4. Remove oilcooler adapter -if fitted.
5. Remove oilpressure reliefvalve plug,discard
sealing washer.
6. Withdraw pressurereliefvalve spring and
valve.
7. Remove oilpressure switch,discard sealing
washer.
8. Remove boltssecuring oilpump cover.
9. Remove cover,remove anddiscard gasket.
10. Withdraw oilpump gears. Oil
pump -inspection
1. Throughly cleanoilpump gearhousing, cover
and gears.
2. Clean oilpressure reliefvalve boreinhousing.
3. Clean reliefvalve filterscreen.
4. Inspect pumpgearsforwear andscoring.
5.Fitpump gearsintohousing.
6. Place straight edgeacross gears.
7. Check clearance betweenstraightedgeand
housing face.
Gear tohousing minimum clearance =
0.05mm. If clearance isbelow minimum specifiedcheck
gear recess inhousing forwear. Renew
housing ifnecessary.
8. Remove oilpump gearsfromhousing.
9. Clean oilpressure reliefvalve andspring.
10. Inspect reliefvalve forwear andscoring.
11. Inspect reliefvalve spring forwear orsigns of
collapse.Relief valvefreelength =81.28 mm.
12. Check reliefvalve slides freelyinits bore with
no perceptible sidemovement.    
						

							ENGINEOVERHAUL 17
Oil
pump -refit
1. Lubricate reliefvalve, spring, andbore in
housing withclean engine oil.
2. Fitrelief valve andvalve spring.
3. Fitnew sealing washer toplug, fitplug and
tighten tocorrect torque.
4. Pack oilpump housing withPetroleum Jelly.
CAUTION: Useonly Petroleum Jelly,no
other grease issuitable.
5. Fitoilpump gearsensuring thatPetroleum
Jelly isforced intoevery cavity between teeth
of gears.
CAUTION: Unlesspumpisfully packed
with Petroleum Jellyitmay notprime itself
when theengine isstarted.
6. Fitnew pump covergasket.
7. Position cover,fitbolts andtighten
progressively tocorrect torque.
8. Fitoilcooler adapter.
9. Fittiming cover.
10. Fitdistributor.
11. Fitsump. OIL
PUMP -ENGINE NUMBERS WITHSUFFIX B
CAUTION: Overhaulprocedures forthe oil
pump andoilpressure reliefvalve are
limited tocarrying outdimensional
checks. Inthe event ofwear ordamage being
found, areplacement timingcoverassembly
must befitted.
Oil pump -remove
1. Remove timingcover.
2.Remove oilpump drivegear.
3. Remove 9screws securing coverplate,
remove plate.
4.Make suitable alignment marksoninner and
outer rotors, remove rotors.    
						

							ENGINE 18OVERHAUL
Oil
pressure reliefvalve -remove
1. Remove circlip.
2. Remove reliefvalve plug,remove anddiscard
O ring.
3. Remove reliefvalve spring andpiston. Oil
pump -inspection
1. Thoroughly cleanoilpump drivegear, cover
plate, rotors andhousing. Removealltraces of
Loctite fromcover platesecuring screws;
ensure tappedholesintiming coverareclean
and free from oil.
2. Check mating surfaces ofcover plate,rotors
and housing forscoring.
3. Assemble rotorsandoilpump drivegearin
housing ensuring thatreference marksare
aligned.
4. Using feelergauges, checkclearance between
teeth ofinner andouter rotors:
Maximum clearance =0.25 mm
5.Remove oilpump drivegear, check depthof
any wear steps ongear teeth:
Wear stepmaximum depth=0.15 mm    
						

							ENGINEOVERHAUL 19
6.Place astraight edgeacross housing.
7. Using feelergauges, checkclearance between
straight edgeandrotors:
Maximum clearance =0.1 mm
Oil pressure reliefvalve -inspection
1. Clean reliefvalve components andpiston bore
in timing cover.
2. Check pistonandbore forscoring andthat
piston slidesfreelyinbore withnoperceptible
side movement.
3. Check reliefvalve spring fordamage and
distortion; checkspring freelength:
Spring freelength =60.0 mm Oil
pump -refit
1. Lubricate rotors,oilpump drivegear, cover
plate andhousing withengine oil.
2. Assemble rotorsinhousing ensuring that
reference marksarealigned.
3. Position coverplatetohousing.
4. Apply Loctite 222tothreads ofcover plate
screws, fitbut donot fully tighten screws.
5. Position drivegearinoil pump, tighten cover
plate screws tocorrect torque.
6. Fittiming cover.
Oil pressure reliefvalve -refit
1. Lubricate newOring with engine oiland fitto
relief valve plug.
2. Lubricate reliefvalve spring, pistonandpiston
bore withengine oil.
3. Assemble pistontorelief valve spring, insert
piston andspring intopiston bore.
4. Fitrelief valve plug,depress plugandfitcirclip.
5. Ensure circlipisfully seated ingroove.   
						

							ENGINE 20OVERHAUL
CAMSHAFT
ANDTAPPETS
Camshaft andtappets -remove
1. Remove rockershaftassemblies.
2. Remove pushrods andstore infitted order.
3. Remove timingchainandgears.
4.Remove tappetsandretain withtheir
respective pushrods.
NOTE:Iftappets cannotberemoved due
to damaged camshaftcontactarea,
proceed asfollows:
5. Lift tappets inpairs tothe point where
damaged faceisabout toenter tappet bore
and fitrubber bandstoretain tappets. Repeat
until alltappets areretained clearofcamshaft
lobes. Thetappets canthen bewithdrawn out
the bottom oftheir bores whenthesump is
removed.
6. Withdraw camshaft, takingcarenottodamage
bearings incylinder block.
Camshaft andtappets -inspection
1. Throughly cleanallcomponents.
2. Inspect camshaft bearingjournals andlobes
for signs ofwear, pitting, scoring and
overheating.
3. Support camshaft frontandrear bearings on
vee blocks, andusing aDTI, measure
camshaft run-outoncentre bearing.
Maximum permittedrun-out=0.05 mm.
4. Clean andinspect tappets. Checkforaneven,
circular wearpattern onthe camshaft contact
area. Ifcontact areaispitted orasquare wear
pattern hasdeveloped, tappetmustbe
renewed.
5. Inspect tappetbodyforexcessive wearor
scoring. Replace tappetifscoring ordeep wear
patterns extenduptooil feed area. Clean and
inspect tappetboresinengine block.
6. Ensure thattappets rotatefreelyintheir
respective bores.
7. Inspect pushrod contactareaoftappet, replace
tappet ifsurface isrough orpitted.    
						

							ENGINEOVERHAUL 21
Camshaft
andtappets -refit
1. Lubricate camshaftjournalswithclean engine
oil and carefully insertcamshaft intocylinder
block.
2. Immerse tappetsinclean engine oil.Before
fitting, pumptheinner sleeve oftappet several
times using apushrod, toprime tappet and
reduce tappetnoisewhenengine isfirst
started.
3. Lubricate tappetboreswithclean engine oil
and fittappets inremoved order.
NOTE:Sometappet noisemaybeevident
on initial start-up. Ifnecessary, runthe
engine at2500 rev/min forafew minutes
until noise ceases.
4. Fittiming chainandgears.
5. Fitrocker shaftassemblies.
PISTONS, CONNECTING RODS,PISTON RINGS
AND CYLINDER BORES
Pistons andconnecting rods-remove
1. Remove cylinderhead(s).
2. Remove big-endbearings.
3. Remove carbonridgefromtopofeach cylinder
bore.
4. Suitably identifyeachpiston toits respective
cylinder bore.
5. Push connecting rodand piston assembly to
top ofcylinder boreandwithdraw assembly.
6. Remove plastictubingfromconnecting rod
bolts.
7. Repeat aboveprocedure forremaining pistons.
Piston rings-remove
1. Using asuitable pistonringexpander, remove
piston rings.
2. Remove carbonfrompiston ringgrooves.
NOTE: Useanold broken pistonringwith
a squared offend.
CAUTION: Donot use awire brush. Piston
rings-inspection
1. Temporarily fitnew compression ringsto
piston.
NOTE: Thering marked TOPmustbe
fitted, withmarking uppermost, into
second groove. Thechrome ringfitsinto
top groove andcanbefitted either wayround.
2.Check compression ringtogroove clearance:
Top compression ringA=0.05 to0.10 mm.
2nd compression ringB=0.05 to0.10 mm.
3.Insert newpiston ringintorelevant cylinder,
held square tobore withpiston, andcheck ring
gaps. Top compression ring=0.44 to0.57 mm.
2nd compression ring=0.44 to0.57 mm.
Oil control ringrails =0.38 to1.40 mm.
4. Use afine-cut flatfiletoincrease gapif
required. Selectanew piston ringifgap
exceeds limit.    
						

							ENGINE 22OVERHAUL
Pistons
-remove
1. Clamp hexagon bodyofLRT-12-013 invice.
2. Screw largenutback untilflush withendof
centre screw.
3. Push centre screwforward untilnutcontacts
thrust race.
4. Locate pistonadapter LRT-12-014 withitslong
spigot insideboreofhexagon body.
5. Fitparallel sleeve,grooved endfirst, onto
centre screwandsmear outside diameter with
engine oil.
6. Locate pistonandconnecting rodassembly on
centre screwanduptoadapter LRT-12-014.
7. Fitremover/replacer bushofLRT-12-014 on
centre screwwithflanged endaway from
gudgeon pin.
8. Screw stopnutonto centre screwleaving
clearance A,between nutand
remover/replacer bush.
Clearance A=3mm.
9. Lock thestop nutsecurely withlockscrew.
10. Push connecting rodtoright tolocate endof
gudgeon pininadapter LRT-12-014.
11. Ensure remover/replacer islocated ingudgeon
pin bore ofpiston.
12. Screw largenutuptothrust race.
13. Hold lockscrew andturn large nutuntil
gudgeon piniswithdrawn frompiston.
14. Dismantle tooland remove piston,connecting
rod and gudgeon pin.
15. Repeat aboveoperation forremaining pistons. Pistons
-inspection
1. Clean carbon frompistons
2. Inspect pistonsfordistortion andcracks.
3.Measure pistondiameter at90 °to gudgeon pin
axis and8m m from bottom ofskirt. Thepiston
must be0.018 mmto0.033 mmsmaller than
cylinder bore.   
						

							ENGINEOVERHAUL 23
Cylinder
bore-inspection
1. Measure cylinderborewear intwo axis 40to
50 mm from topofbore.
Piston tocylinder boreclearance =0.018 to
0.033 mm.
NOTE: Pistons areavailable inservice
standard sizeand0.508 mmoversize.
Service standard sizepistons aresupplied
0.0254 mmoversize. Whenfitting newservice
standard sizepistons, checkforcorrect pistonto
bore clearance, honeboreifnecessary.
CAUTION: Thetemperature ofpiston and
cylinder blockmustbethe same toensure
accurate measurement. Whenreboring
cylinder block,thecrankshaft mainbearing caps
must befitted andbolts tighten tocorrect
torque.
2. Ifonly newpiston ringsaretobe fitted, break
cylinder boreglazing usingafine grit, to
produce a60 ° cross-hatch finish.
CAUTION:Ensurealltraces ofgrit are
removed afterabove operation.
Connecting rod-inspection
1. Check alignment ofconnecting rod. Pistons
-refit
CAUTION: Onlater 4.2Lengines thepiston
has a0.5 mm offset gudgeon pinwhich
can beidentified byanarrow markonthe
piston crown. Thisarrow MUST always pointto
the front ofthe engine.
1.4.2L engine only:Assemble pistonsto
connecting rodswitharrow onpiston pointing
towards domedshaped bossonconnecting
rod forRH bank ofcylinders, andarrow
pointing awayfromdome shaped bossforLH
bank ofcylinders.
2. Clamp hexagon bodyofLRT-12-013 invice.
3. Remove largenutand pullthecentre screw50
mm outofhexagon body.
4. Locate pistonadapter LRT-12-014 withitslong
spigot insideboreofhexagon body.
5. Fitparallel sleeve,grooved endlast, upto
shoulder oncentre screw.
6. Lubricate gudgeonpinand bores ofconnecting
rod and piston withgraphited oil.
7. Locate connecting rodand piston tocentre
screw withconnecting rodentered onsleeve
up togroove.     
						

							ENGINE 24OVERHAUL
8.
Fitgudgeon pinonto centre screwandinto
piston boreuptoconnecting rod.
9. Fitremover/replacer bushwithflanged end
towards gudgeon pin.
10. Screw thestop nutonto centre screwand
position pistonagainst faceofadaptor
LRT-12-014.
11. Lubricate centrescrewthreads andthrust race
with graphited oil,fit,and screw largenutupto
thrust race.
12. Adjust stopnutleaving clearance B,between
nut and remover/replacer bush.
Clearance B=0.8 mm.
13. Lock thestop nutsecurely withlockscrew.
14. Settorque wrench to16 Nm, andusing socket
on large nut,pullgudgeon pininuntil flange of
remover/replacer bushisdistance Cfrom face
of piston.
Distance C=4mm.
CAUTION: Flangeofremover/replacer
must notbeallowed tocontact piston.If
torque figureisnot achieved duringabove
operation, fitof gudgeon pintoconnecting rodis
not acceptable andnecessitates renewalof
components. Thecentre screwandthrust race
must bekept welllubricated throughout
operation.
15. Dismantle tool,remove piston,checkno
damage hasoccurred duringpressing and
piston moves freelyongudgeon pin.
16. Repeat aboveoperation forremaining pistons. Pistons
andconnecting rods-refit
1. Fitoilcontrol ringrails andexpander, ensuring
ends buttand notoverlap.
2.Fitring marked TOPwithmarking uppermost
into second groove.
3. Fittop compression ringintogroove eitherway
round.
4. Position oilcontrol expander ringjoint andring
rail gaps allatone side, between gudgeon pin
and piston thrustface.Space gapsinring rails
approximately 25mm each sideofexpander
ring joint.
5. Position compression ringswithringgaps on
opposite sidesofpiston between gudgeon pin
and piston thrustface.
6. Fitbig-end bearingshelltoconnecting rod.
7. Lubricate big-endbearingshell,piston rings
and gudgeon pinwith engine oil.
8. Lubricate cylinderboresandcrankshaft
big-end journals withengine oil.