Land Rover 3 5 3 9 4 2 V8 Engine Overhaul 2003 2nd Edition Rover Manual

ENGINE
2
OVERHAUL Rocker shafts - dismantling
1.Remove and discard split pin from one end of
rocker shaft.
2.Remove plain washer, wave washer, rocker
arms, brackets and springs.Inspecting components
1.Thoroughly clean components.
2.Inspect each component for wear, in particular
rocker arms and shafts. Discard weak or
broken springs.
3.Inspect push rod seats in rocker arms.
4.Check push rods for straightness and inspect
ball ends for damage, replace as necessary. 

ENGINE
OVERHAUL3
Rocker shafts - assembling
1.Assemble rocker shafts with identification
groove at one o’clock position with push rod
end of rocker arm to the right.
CAUTION: If rocker shafts are incorrectly
assembled and fitted to engine, oil supply
to rocker arms will be restricted.
2.Fit new split pin to one end of rocker shaft.
3.Fit plain washer and wave washer.
4.Lubricate rocker arm bushes with clean engine
oil.
5.Early type rocker arms are angled, and must
be fitted with the valve end of the...

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 and on
cylinder head, ensure bolt holes are clean and
dry.
6.Fit new gasket, dry, to...

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
Engines fitted with secondary air injection (SAI)
4.Using a suitable hexagonal drive bit, remove
and discard 2 secondary air injection adapters
from cylinder head.
NOTE: To release the adapter thread...

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...

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 - inspectionNOTE: Two types of exhaust valve may be
fitted - standard valves A in illustration or
carbon break valves - B in illustration....

ENGINE
8
OVERHAUL
Early valves - dimension A = 29.5 to 30.5 mm
(1.16 to 1.20 in)
Later valves - dimension
A = 32.5 to 33.5 mm (1.28 to 1.32 in)
The modified valves may be fitted to early engines in
engine sets provided that the modified valve guides
are also fitted.Valve guides
NOTE: The modified valve guides fitted to
later engines are 5 mm (0.211 in) shorter
than the early type guides, the overall
length of the modified guide being 57 mm (2.24
in); the reduction in length being the distance
the guide...

ENGINE
OVERHAUL9
4.Check valve head diameterA:
Inlet = 39.75 to 40.00 mm (1.56 to 1.57 in)
Exhaust = 34.226 to 34.48 mm (1.34 to 1.35 in)
5.Check valve stem diameterB:
Inlet = 8.660 to 8.680 mm (0.340 to 0.342 in)
Exhaust:
Standard and carbon break valves fitted to
early engines = 8.651 to 8.666 mm (0.340 to
0.341 in)
Modified carbon break valves fitted to later
engines = 8.641 to 8.656 mm (0.336 to 0.340
in)
6.Check installed height of each valveC:
Valve installed heightC:
Standard and carbon break...

ENGINE
10
OVERHAUL 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
with tapered portion of guide leading, place in
position on valve spring side of cylinder head.
3.UsingLRT-12-039Apartially press guide into
cylinder head, remove tool.
4.FitLRT-12-208over valve guide and...

ENGINE
OVERHAUL11
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...