Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 1997 Rover Manual

							ENGINE
4
OVERHAUL Rocker shafts - refit
1.Lubricate push rods with engine oil.
2.Fit push rods in removed order.
3.Fit each rocker shaft assembly, ensuring
identification groove is uppermost and towards
front of engine on RH side and towards rear of
engine on LH side.
CAUTION: Incorrect fitment will result in
an oil feed restriction.
4.Fit bolts and tighten to 38 Nm (28 lbf.ft).
5.Clean gasket surface in rocker cover using
Bostik cleaner 6001 or equivalent, and allow to
dry.6.Apply a thin coating of Bostik 1775 or
equivalent impact adhesive to mating surfaces
of rocker cover and gasket.
7.Allow adhesive to cure, then fit gasket to rocker
cover.
CAUTION: Gasket fits one way round only,
it must be fitted accurately as subsequent
movement will destroy bonding. Allow
cover to stand for 30 minutes before fitting.
8.Fit rocker cover to cylinder head, fit Allen
screws/multi-hex bolts and tighten by diagonal
selection to:
Stage 1 - 4 Nm (3 lbf.ft)
Stage 2 - 8 Nm (6 lbf.ft)
Stage 3 - Re-torque to 8 Nm (6 lbf.ft)
CAUTION: The 2 short screws/bolts must
be fitted on side of cover nearest centre of
engine.
9. LH rocker shaft only:Align dipstick tube to
rocker cover, fit and tighten screw. 
						

							ENGINE
OVERHAUL5
CYLINDER HEAD
Cylinder head - remove
1.Remove rocker shaft assembly.
2.Mark heads LH and RH for reassembly.
Engine numbers without suffix B
NOTE: RH cylinder head illustrated
3.Using sequence shown, remove 14 bolts
securing cylinder head to cylinder block.
Engine numbers with suffix B
NOTE: RH cylinder head illustrated
4.Using sequence shown, remove and discard
10 bolts securing cylinder head to cylinder
block.
NOTE: No bolts are fitted in the four lower
holes in each cylinder head.
All engines
5.Release cylinder head from 2 dowels and
remove cylinder head.
6.Remove and discard cylinder head gasket. 
						

							ENGINE
6
OVERHAUL Valves and springs - remove
1.Remove spark plugs.
2.Using valve spring compressorLRT-12-034or
a suitable alternative, compress valve spring.
3.Remove 2 collets.
4.Release spring compressor and remove valve,
valve spring cap and valve spring.
5.Repeat above operations for remaining valves.
CAUTION: Keep valves, springs, caps and
collets in fitted order.
6.Remove and discard valve stem oil seals.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 Loctite
572 to threads of screwed 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) 
						

							ENGINE
OVERHAUL7
4.Check cylinder head height at each end of
cylinder head:
Engine numbers without suffix B
A
= 23.9 mm (0.94 in) - new
B= 63.5 mm (2.5 in) - new
Engine numbers with suffix B
A
= 22.94 mm (0.903 in) - new
B= 62.56 mm (2.463 in) - new
5.Cylinder heads may be refaced:
Reface limit = 0.50 mm ( 0.02 in) from new
dimension.Valves, valve springs and guides - inspection
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. 
						

							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.
3.Clean inlet valve guide bores. Ensure all loose
particles of carbon are removed on completion.
4.Check existing valve stem and head diameters.
5.Check valve stem to guide clearance using
new valves.
6.Renew valves and guides as necessary.
Valve head diameterA:
Inlet = 39.75 to 40.00 mm (1.5 to 1.6 in)
Exhaust = 34.226 to 34.48 mm (1.3 to 1.4 in)
Valve stem diameterB:
Inlet = 8.664 to 8.679 mm (0.341 to 0.342 in)
Exhaust = 8.651 to 8.666 mm (0.340 to 0.341
in)
7.Check installed height of each valve.
Valve installed heightC= 47.63 mm (1.9 in )
8.Renew valve/valve seat insert as necessary. 
						

							ENGINE
OVERHAUL9
9.Check valve stem to guide clearance.
Valve stem to guide clearanceD:
Inlet = 0.025 to 0.066 mm (0.001 to 0.002 in)
Exhaust = 0.038 to 0.078 mm (0.0015 to 0.003
in)
10.Check condition of valve springs:
Free length = 48.30 mm (1.90 in)
Fitted length = 40.40 mm (1.60 in)
Load at fitted length = 339±10 N (76±2 lbf)
Load at valve open length = 736±22 N (165±
2 lbf)
CAUTION: Valve springs must be replaced
as a complete set.Valve guides - renew
1.Using valve guide remover,LRT-12-037press
valve guide out into combustion face side of
cylinder head.
NOTE: Service valve guides are 0.025mm
(0.001 in) oversize on outside diameter to
ensure interference fit.
2.Lubricate new valve guide with engine oil and
place in position.
3.UsingLRT-12-038partially press guide into
cylinder head, remove tool.
4.FitLRT-12-515over valve guide and continue
to press guide into cylinder head until tool
LRT-12-038contacts toolLRT-12-515.
Remove tool.
Valve guide installed heightA= 15.0 mm
(0.590 in)
5.Ream valve guides to 8.70 mm (0.34 in)
diameter. Remove all traces of swarf on
completion. 
						

							ENGINE
10
OVERHAUL Valve seat inserts - inspection
1.Check valve seat inserts for pitting, burning
and wear. Replace inserts as necessary.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. 
						

							ENGINE
OVERHAUL11
Valve seats and seat inserts - refacing
CAUTION: Renew worn valve guides and
seat inserts before refacing valve seats.
1.Check condition of valve seats and valves that
are to be re-used.
2.Remove carbon from valve seats.
3.Reface valves as necessary. If a valve has to
be ground to a knife-edge to obtain a true seat,
replace valve.
Valve seating face angle = 45°
4.Cut valve seats usingLRT-12-501with
LRT-12-503andLRT-12-517.
Valve seat:
WidthA:
Inlet = 36.83 mm (1.45 in)
Exhaust = 31.50 mm (1.24 in)
Seating widthB:
Inlet = 0.89 to 1.4 mm (0.035 to 0.055 in)
Exhaust = 1.32 to 1.83 mm (0.052 to 0.072 in)
AngleC=56°to 57°
AngleD=46°to 46°25
AngleE=20° 
						

							ENGINE
12
OVERHAUL
5.Ensure cutter blades are correctly fitted to
cutter head with angled end of blade
downwards, facing work as illustrated. Check
that cutter blades are adjusted so that middle
of blade contacts area of metal to be cut. Use
light pressure and remove minimum amount of
material necessary.
6.Remove all traces of swarf on completion.Valves - lapping-in
1.Lap each valve to its seat using fine grinding
paste.
2.Clean valve and seat.
3.Coat valve seat with a small quantity of
engineers blue, insert valve and press it into
position several times without rotating. Remove
valve and check for even and central seating.
Seating position shown by engineers blue
should be in centre of valve face.
4.Check valve installed height if valve seats have
been recut or new valves or valve seat inserts
have been fitted.
Valve installed heightA= 47.63 mm (1.9 in) -
maximum
5.Thoroughly clean cylinder head, blow out
oilways and coolant passages. 
						

							ENGINE
OVERHAUL13
Valves and springs - refit
1.Fit new valve stem oil seals, lubricate valve
stems, fit valves, valve springs and caps,
compress valve springs usingLRT-12-034and
fit collets.
2.Using a wooden dowel and mallet, lightly tap
each valve stem two or three times to seat
valve cap and collets.
3.Fit spark plugs and tighten to 20 Nm (15 lbf.ft)Cylinder head - refit
1.Clean cylinder block faces using a suitable
gasket removal spray and plastic scraper;
ensure that bolt holes in cylinder block are
clean and dry.
CAUTION: Do not use metal scraper or
machined surfaces may be damaged.
2.
Engine numbers without suffix B:Thoroughly
clean threads of cylinder head bolts.
CAUTION: Cylinder head bolts fitted to
engines without suffix B added to serial
number are not interchangeable with
those fitted to engines with suffix B added to
serial number.
3.Fit cylinder head gasket with the word TOP
uppermost.
NOTE: Gasket must be fitted dry.
CAUTION: Engines without suffix B have a
steel gasket whilst engines with suffix B
have a composite gasket. The two types of
gasket are not interchangeable and it is essential
to ensure that the correct type of gasket is fitted.
4.Carefully fit cylinder head and locate on
dowels.