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

							ENGINE
44
OVERHAUL 7.
Bolts fitted in connecting rods:Fit a length of
plastic tubing over each connecting rod bolt.
8.Push each piston up its respective bore,
remove and discard shells from connecting
rods.
NOTE: Big-end bearing shells must be
replaced whenever they are removed.Big-end bearings - refit
1.Fit new bearing shells to each connecting rod.
NOTE: Big-end bearings are available in
0.254 and 0.508 mm (0.01 and 0.02 in)
oversizes.
2.Lubricate bearing shells and crankshaft
journals with engine oil.
3.Pull connecting rods on to crankshaft journals
and remove plastic tubing from bolts - if fitted.
4.Fit new bearing shells to each big-end bearing
cap.
NOTE: If crankshaft has been reground,
ensure appropriate oversize bearing shells
are fitted.
5.Lubricate bearing shells and fit bearing caps
ensuring reference marks on connecting rods
and bearing caps are aligned.
NOTE: Rib on edge of bearing cap must
face towards front of engine on RH bank
of cylinders and towards rear on LH bank
of cylinders.
6.Fit bearing cap nuts/bolts and tighten to 50 Nm
(37 lbf.ft).
7.Check connecting rods move freely sideways
on crankshaft. Tightness indicates insufficient
bearing clearance or misaligned connecting
rod. 
						

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OVERHAUL45
8.Check clearance between connecting rods on
each crankshaft journal.
Connecting rod clearance = 0.15 to 0.37 mm
(0.006 to 0.01 in).
9.Clean oil strainer.
10.Clean gasket mating faces on strainer and
cylinder block.
11.Fit gasket to strainer, position strainer, fit bolts
and tighten to 10 Nm (7 lbf.ft).
12.Fit sump.Crankshaft - remove
1.Remove flywheel or drive plate and ring gear
assembly.
2.Remove timing cover.
3.Remove timing gears.
4.Remove big-end bearings.
5.Make suitable reference marks between each
main bearing cap and cylinder block.
6.Starting at centre main bearing and working
outwards, progressively slacken then remove
10 main bearing cap bolts.
CAUTION: Keep bolts in their fitted order.
7.Remove 5 main bearing caps and bearing
shells, discard shells.
8.Lift out crankshaft and rear oil seal. Remove
and discard oil seal.
9.Remove and discard 5 bearing shells from
cylinder block.
NOTE: Main bearing shells must be
replaced whenever they are removed.
10.Remove and discard side seals from rear main
bearing cap.
11.Remove Woodruff key from crankshaft. 
						

							ENGINE
46
OVERHAUL Crankshaft - inspection
1.Clean crankshaft and blow out oil passages.
2.Support crankshaft front and rear bearing
journals on vee blocks, and using a DTI,
measure run-out on centre main bearing.
Maximum permitted run-out = 0.08 mm (0.003
in)
If run-out exceeds permitted maximum,
crankshaft is unsuitable for regrinding and
should be replaced.3.Measure each journal for overall wear and
ovality, make 3 checks at 120°intervals.
Main bearing journal diameter = 58.409 to
58.422 mm (2.29 to 2.30 in)
Maximum out of round = 0.040 mm (0.002 in)
Big-end bearing journal diameter = 50.800 to
50.812 mm (1.99 to 2.00 in)
Maximum out of round = 0.040 mm (0.002 in)
If measurements exceed permitted maximum,
regrind or fit new crankshaft.
NOTE: Crankshaft main bearings are
available in 0.254 and 0.508 mm (0.01 and
0.02 in) oversizes. When fitting 0.508 mm
(0.02 in) oversize bearings, centre main bearing,
which controls crankshaft end-float, has thrust
faces increased in thickness by 0.254 mm (0.01
in). Therefore if 0.508 mm (0.02 in) oversize
bearings are to be fitted, 0.127 mm (0.005 in)
must be machined off each thrust face of centre
main bearing shell to achieve correct end-float.
Ensure an equal amount of material is removed
from each thrust face. 
						

							ENGINE
OVERHAUL47
Crankshaft dimensions:
Bearing journal radius - all journals except rear main
journalA= 1.90 to 2.28 mm (0.075 to 0.09 in).
Rear main bearing journal radiusB= 3.04 mm
(0.012 in)
Bearing journal diameterC:
Standard = 58.409 to 58.422mm (2.29 to 2.3 in).
0.254 mm (0.01 in) undersize = 58.154 to 58.168
mm (2.290 to 2.300 in)
0.508 mm (0.02 in)undersize = 57.900 to 57.914 mm
(2.280 to 2.281 in)
Bearing journal widthD= 26.975 to 27.026 mm
(1.062 to 1.064 in).
Bearing journal diameterE:
Standard = 50.800 to 50.812 mm (1.99 to 2.00 in).
0.254 mm (0.01 in) undersize = 50.546 to 50.558
mm (1.98 to 1.99 in)
0.508 mm (0.02 in) undersize = 50.292 to 50.305
mm (1.97 to 1.98 in)
1.Check crankshaft spigot bearing for wear,
replace if necessary:
Spigot bearing inside diameter = 19.177 +
0.025 - 0.000 mm (0.75 + 0.001 - 0.000 in)Crankshaft spigot bearing - renew
1.Carefully extract old spigot bearing.
2.Clean bearing recess in crankshaft.
3.Fit new bearing flush with, or to a maximum of
1.6 mm (0.06 in) below end face of crankshaft.
4.Ream bearing to correct inside diameter.
Spigot bearing inside diameter = 19.177 +
0.025 - 0.000 mm (0.75 + 0.001 - 0.000 in)
5.Remove all traces of swarf. 
						

							ENGINE
48
OVERHAUL Crankshaft - refit
1.Clean main bearing caps, bearing shell
recesses and mating surfaces of cylinder
block.
CAUTION: Ensure main bearing cap bolt
holes in cylinder block are clean and dry.
2.Fit new upper main bearing shells, with oil
holes and grooves, in cylinder block, ensuring
flanged shell is fitted in centre position.
3.Lubricate main bearing shells with engine oil
and position crankshaft in cylinder block.
4.Fit new main bearing shells to bearing caps
and lubricate with engine oil.
5.Lubricate main bearing shells and fit numbers
1 to 4 bearing caps ensuring reference marks
made during dismantling are aligned.
6.Fit numbers 1 to 4 main bearing cap bolts and
tighten to 13 Nm (10 lbf.ft).
CAUTION: Do not tighten bolts further at
this stage.
7.Fit side seals to rear main bearing cap.
CAUTION: Seals must protrude
approximately 1.5 mm (0.05 in) above
bearing cap face.
8.Apply a 3 mm (0.12 in) wide bead of Hylomar
PL32 jointing compound to bearing cap rear
mating face on cylinder block.
CAUTION: Ensure sealant does not enter
bolt holes.
9.Lubricate rear main bearing shell and side
seals with engine oil, fit bearing cap assembly.
10.Fit rear main bearing cap bolts and tighten to
13 Nm (10 lbf.ft).
CAUTION: Do not tighten bolts further at
this stage. 
						

							ENGINE
OVERHAUL49
11.Clean seal location and running surface on
crankshaft.
12.
Engine numbers without suffix B:Clean seal
protectorLRT-12-010and lubricate with engine
oil.
13.
Engine numbers with suffix B:Clean seal
protectorLRT-12-095and lubricate with engine
oil.
14.Lubricate oil seal lip with engine oil.
NOTE: Seal protector LRT-12-095
illustrated.
15.Position seal protector to crankshaft.
16.
Engine numbers without suffix B:Fit oil seal
squarely using hand pressure only until fully
seated in recess.
17.
Engine numbers with suffix B:Fit seal using
toolLRT-12-091.
18.Using sequence shown, tighten main bearing
cap bolts to:
Numbers 1 to 4 bearing caps - 70 Nm (52 lbf.ft)
Rear bearing cap -90 Nm (66 lbf.ft)
19.Fit Woodruff key to crankshaft.
20.Check crankshaft end-float.
NOTE: If 0.508 mm (0.02 in) oversize main
bearings have been fitted, it may be
necessary to machine thrust faces of
centre main bearing to achieve correct end-float.
Ensure an equal amount of material is removed
from each thrust face.
21.Fit big-end bearings.
22.Fit timing cover and gears.
23.Fit flywheel or drive plate and ring gear
assembly. 
						

							ENGINE
50
OVERHAUL Crankshaft end - float - check
1.Set-up DTI to measure end float.
2.Move crankshaft forwards and zero gauge.
3.Move crankshaft rearwards, record end-float
reading obtained.
Crankshaft end-float = 0.10 to 0.20mm (0.004
to 0.008 in).
4.Remove DTI.
NOTE: Crankshaft end-float is controlled
by thrust faces on upper half of centre
main bearing shell.