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

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OVERHAUL Gudgeon pins - inspection
NOTE: Gudgeon pins are only supplied as
an assembly with replacement pistons.
1.Check gudgeon pins for signs of wear and
overheating.
2.Check clearance of gudgeon pin in piston:
Gudgeon pin to piston clearance = 0.006 to
0.015 mm (0.0002 to 0.0006 in)
3.Check overall dimensions of gudgeon pin:
Overall length = 72.67 to 72.79 mm (2.85 to
2.86 in)
Diameter - measured at each end and centre
of pin = 22.215 to 22.220 mm (0.87 to 0.871 in)Cylinder liner bore - inspection
1.Measure cylinder bore wear in two axis 40 to
50 mm (1.5 to 1.9 in) from top of bore:
Cylinder bore diameter - standard:
3.5 litre = 88.90 mm (3.5 in)
3.9 litre = 94.00 mm (3.7 in)
4.2 litre = 94.00 mm (3.7 in)
Maximum ovality = 0.013 mm (0.0005 in)
2.Compare cylinder bore diameter with piston
diameter and calculate piston to cylinder bore
clearance.
Piston to cylinder bore clearance = 0.002 to
0.045 mm (0.001 to 0.002 in)
NOTE: Pistons are available in service
standard size and 0.508 mm (0.02 in)
oversize. Service standard size pistons
are supplied 0.0254 mm (0.01 in) oversize. When
fitting new service standard size pistons, check
for correct piston to bore clearance, rebore or
hone bore if necessary.
CAUTION: The temperature of piston and
cylinder block must be the same to ensure
accurate measurement. When reboring
cylinder block, the crankshaft main bearing caps
must be fitted and bolts tightened to:
Initial torque - all bearing caps - 13 Nm (10 lbf.ft)
Numbers 1 to 4 bearing caps - 70 Nm (52 lbf.ft).
Rear bearing cap - 90 Nm (66 lbf.ft). 
						

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3.If only new piston rings are to be fitted, break
cylinder bore glazing using a fine grit, to
produce a 60°cross-hatch finish.
CAUTION: Ensure all traces of grit are
removed after above operation. If dipstick
tube has been removed, coat portion of
tube below collar with Loctite 572 prior to
refitting.Pistons - refit
CAUTION: On later 4.2L engines the piston
has a 0.5 mm (0.02 in) offset gudgeon pin
which can be identified by an arrow mark
on the piston crown. This arrow MUST always
point to the front of the engine.
1.4.2L engine only:Assemble pistons to
connecting rods with arrow on piston pointing
towards domed shaped boss on connecting
rod for RH bank of cylinders, and arrow
pointing away from dome shaped boss for LH
bank of cylinders. 
						

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OVERHAUL
2.Clamp hexagon body ofLRT-12-013in vice.
3.Slacken large nut and pull the centre screw 50
mm (1.9 in) out of hexagon body.
4.Locate piston adapterLRT-12-014with its long
spigot inside bore of hexagon body.
5.Fit parallel sleeve, grooved end last, up to
shoulder on centre screw.
6.Lubricate gudgeon pin and bores of connecting
rod and piston with graphited oil.
7.Locate connecting rod and piston to centre
screw with connecting rod entered on sleeve
up to groove.
8.Fit gudgeon pin on to centre screw and into
piston bore up to connecting rod.
9.Fit remover/replacer bush with flanged end
towards gudgeon pin.
10.Screw the stop nut on to centre screw and
position piston against face of adapter
LRT-12-014.
11.Lubricate centre screw threads and thrust race
with graphited oil, screw large nut up to thrust
race.
12.Lock the stop nut securely with lockscrew.
13.Set torque wrench to 16 Nm (12 lbf.ft), and
using a socket on large nut, pull gudgeon pin in
until flange of remover/replacer bush is
distanceAfrom face of piston.
DistanceA= 0.4 mm (0.02 in)
14.If correct torque figure is not achieved during
above operation, fit of gudgeon pin to
connecting rod is not acceptable and
necessitates renewal of components.
CAUTION: The centre screw and thrust
race must be kept well lubricated
throughout operation. Flange of
remover/replacer must not be allowed to contact
piston.15.Dismantle tool, remove piston, check no
damage has occurred during pressing and
piston moves freely on gudgeon pin.
16.Repeat above operation for remaining pistons. 
						

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Piston to cylinder bore clearance - checking
1.Starting with number 1 piston, invert piston and
with arrow on piston crown pointing towards
REAR of cylinder block, insert piston in cylinder
liner.
2.Position piston with bottom of skirt 30 mm (1.2
in) from top of cylinder block.
3.Using feeler gauges, measure and record
clearance between piston and left hand side of
cylinder block:
Piston to bore clearance = 0.02 to 0.045 mm
(0.001 to 0.002 in)
4.Repeat above procedures for remaining
pistons.Pistons and connecting rods - refit
1.Fit oil control ring rails and expander, ensuring
ends butt and not overlap.
2.Fit ring marked TOP with marking uppermost
into second groove.
3.Fit top compression ring into groove either way
round.
4.Position oil control expander ring joint and ring
rail gaps all at one side, between gudgeon pin
and away from left hand side of piston - viewed
from front of piston. Space gaps in ring rails
approximately 25 mm (1.0 in) each side of
expander ring joint.
5.Position compression rings with ring gaps on
opposite sides of piston between gudgeon pin
and right hand side of piston - viewed from
front of piston.
6.Thoroughly clean cylinder bores.
7.Lubricate piston rings and gudgeon pin with
engine oil.
8.Lubricate cylinder bores with engine oil. 
						

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OVERHAUL
9.Fit ring clamp to piston and compress piston
rings.
10.Insert connecting rod and piston assembly into
respective cylinder bore ensuring domed
shaped boss on connecting rod faces towards
front of engine on RH bank of cylinders, and
towards rear on LH bank of cylinders.
NOTE: When both connecting rods are
fitted to each journal, bosses will face
towards each other.
11.Fit big-end bearing caps and bearing shells.
12.Fit cylinder head(s).FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
1.Restrain crankshaft and remove 6 bolts
securing flywheel.
2.Remove flywheel.
NOTE: Dowel located. 
						

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Flywheel and starter ring gear - inspection
1.Inspect flywheel face for cracks, scores and
overheating. The flywheel can be refaced
providing thickness does not go below
minimum.
Flywheel minimum thicknessA= 39.93 mm
(1.6 in)
2.Inspect ring gear for worn, chipped and broken
teeth.
CAUTION: Do not attempt to remove
reluctor ring - if fitted.
3.Renew ring gear if necessary.Starter ring gear - renew
1.Drill a 9.5 mm (0.375 in) diameter hole axially
at base of tooth and inner diameter of starter
ring, sufficiently deep enough to weaken ring
gear.
CAUTION: Do not allow drill to enter
flywheel.
2.Secure flywheel in soft jawed vice.
3.Split ring gear using a cold chisel.
WARNING: Wear safety goggles and take
precautions against flying fragments when
splitting ring gear.
4.Remove flywheel from vice, remove old ring
gear, and place flywheel, clutch side down, on
a flat surface. 
						

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OVERHAUL
5.Heat new ring gear uniformly to between 170°
and 175°C (340°and 350°F).
CAUTION: Do not exceed this
temperature.
WARNING: Handle hot ring gear with care.
.
6.Locate ring gear on flywheel with chamfered
inner diameter towards flywheel flange.
NOTE: If ring gear is chamfered on both
sides, it can be fitted either way round.
7.Press ring gear on to flywheel until it butts
against flywheel flange.
8.Allow flywheel to air cool.Flywheel - refit
1.Fit flywheel and locate on 2 dowels.
2.Fit flywheel bolts.
3.Using assistance, restrain crankshaft and
tighten flywheel bolts to 80 Nm (59 lbf.ft). 
						

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DRIVE PLATE AND RING GEAR ASSEMBLY
Drive plate and ring gear assembly - remove
1.Suitably identify each component to its fitted
position.
NOTE: Shimmed drive plate assembly
illustrated.
2.Remove 4 bolts securing drive plate assembly.
3.Remove buttress ring and drive plate
assembly.
NOTE: Dowel located.
4.Remove 6 socket head Allen screws securing
hub aligner to crankshaft, remove hub aligner.
5.Remove selective shim - if fitted; retain shim.Drive plate and ring gear - inspection
1.Inspect drive plate for cracks and distortion.
2.Renew drive plate if necessary.
3.Inspect ring gear for worn, chipped and broken
teeth.
4.Renew ring gear assembly if necessary. 
						

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42
OVERHAUL Drive plate and ring gear assembly - check
setting height
NOTE: The following procedures are only
applicable to shimmed drive plates, there
is no need to check setting height on drive
plates which are not shimmed.
1.Fit original selective shim and hub aligner, fit
socket head Allen screws and tighten to 80 Nm
(63 lbf.ft).
2.Fit drive plate assembly and buttress ring
ensuring that reference marks are aligned; fit
bolts and tighten to 45 Nm (33 lbf.ft).
CAUTION: If a new drive plate assembly is
being fitted, paint mark on plate must face
towards torque converter.
3.Check the setting height:
Drive plate setting heightA= 8.08 to 8.20 mm
(0.32 to 0.33 in)
4.If setting height is not as specified, remove
buttress ring, drive plate assembly, hub aligner
and selective shim.5.Measure existing shim and, if necessary, select
appropriate shim to obtain specified setting
height.
Shims available:
1.20 - 1.25mm (0.048 to 0.050 in)
1.30 - 1.35mm (0.051 to 0.053 in)
1.40 - 1.45mm (0.055 to 0.057 in)
1.50 - 1.55mm (0.059 to 0.061 in)
1.60 - 1.65mm (0.063 to 0.065 in)
1.70 - 1.75mm (0.067 to 0.070 in)
1.80 - 1.85mm (0.071 to 0.073 in)
1.90 - 1.95mm (0.075 to 0.077 in)
2.00 - 2.05mm (0.079 to 0.081 in)
2.10 - 2.15mm (0.083 to 0.085 in)
6.Retain selected shim 
						

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Drive plate and ring gear assembly - refit
1.Position selected shim - if fitted to crankshaft.
2.Fit hub aligner, fit Allen screws and tighten to
85 Nm (63 lbf.ft).
3.Fit drive plate assembly and buttress ring
ensuring that reference marks are aligned or
that paint mark is towards torque converter.
4.Fit bolts and tighten to 45 Nm (33 lbf.ft).CRANKSHAFT, MAIN AND BIG-END BEARINGS
Big-end bearings - remove
1.Remove sump.
2.Remove 2 bolts securing oil strainer.
3.Remove strainer, remove and discard gasket.
4.Suitably identify bearing caps to their
respective connecting rods.
5.Remove 2 nuts/bolts securing each bearing
cap.
6.Remove bearing cap, remove and discard
bearing shell.
CAUTION: Keep bearing caps and
nuts/bolts in their fitted order.