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

							Overhaul Manual 
3.5/3.9 & 4.2 litre
V8 ENGINE 
						

							3.5, 3.9 & 4.2 LITRE
V8 ENGINE
OVERHAUL
MANUAL
These engines, with or without suffix B
added to the engine serial number are fitted
to the following models:
Discovery
Defender
Range Rover Classic
Publication Part No. LRL 0164ENG 2nd Edition
2003 Land Rover
All rights reserved. No part of this publication
may be reproduced, stored in a retrieval system
or transmitted in any form, electronic,
mechanical, recording or other means without
written permission from Land Rover. 
						

							INTRODUCTION
CONTENTS
Page
INFORMATION
INTRODUCTION 1......................................................................................................
REPAIRS AND REPLACEMENTS 2...........................................................................
SPECIFICATION 2...................................................................................................... 
						

							INTRODUCTION
INTRODUCTION1
INTRODUCTION
How to use this Manual
To assist in the use of this Manual the section title is
given at the top and the relevant sub-section is given
at the bottom of each page.
This manual contains procedures for overhaul of the
V8 engine on the bench with the gearbox, clutch,
inlet manifold, exhaust manifolds, coolant pump,
starter motor, alternator, and all other ancillary
equipment removed. For information regarding
General Information, Adjustments, removal of oil
seals, engine units and ancillary equipment, consult
the Repair Manual.
This manual is divided into 3 sections:
Data, Torque & Tools
Description and Operation and
Overhaul
To assist filing of revised information each
sub-section is numbered from page 1.
Individual items are to be overhauled in the
sequence in which they appear in this manual. Items
numbers in the illustrations are referred to in the text.
Overhaul operations include reference to Service
tool numbers and the associated illustration depicts
the tool. Where usage is not obvious the tool is
shown in use. Operations also include reference to
wear limits, relevant data, and specialist information
and useful assembly details.
WARNINGS, CAUTIONSandNOTEShave the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.References
With the engine and gearbox assembly removed,
the crankshaft pulley end of the engine is referred to
as the front. References to RH and LH banks of
cylinders are taken viewing from the flywheel end of
the engine.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle is carried out particularly where safety
related items are concerned.
Engine serial number
The engine serial number and conpression ratio will
be found stamped on a cast pad on the cylinder
block between numbers 3 and 5 cylinders. The
compression ratio is above the serial number.
Dimensions
The dimensions quoted are to design engineering
specification with Service Limits where applicable. 
						

							INTRODUCTION
2
INTRODUCTION REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only Land Rover recommended parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Torque wrench setting figures given in this Manual
must be used. Locking devices, where specified,
must be fitted. If the efficiency of a locking device is
impaired during removal it must be renewed.
The terms of the vehicle warranty may be
invalidated by the fitting of parts other than Land
Rover recommended parts. All Land Rover
recommended parts have the full backing of the
vehicle warranty.
Land Rover dealers are obliged to supply only Land
Rover recommended parts.SPECIFICATION
Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular component or vehicle. Land Rover
dealers are not agents of the Company and have no
authority to bind the manufacturer by any expressed
or implied undertaking or representation. 
						

							INFORMATION
CONTENTS
Page
GENERAL DATA
DATA1 ........................................................................................................................
TORQUE WRENCH SETTINGS
ENGINE1 ....................................................................................................................
GENERAL2 .................................................................................................................
SEALANTS 3...............................................................................................................
SERVICE TOOLS
SERVICE TOOLS 1..................................................................................................... 
						

							INFORMATION
GENERAL DATA1
DATA
Firing order1, 8, 4, 3, 6, 5, 7, 2 ...............................
Cylinders 1, 3, 5, 7 - LH side of engine
Cylinders 2, 4, 6, 8 - RH side of engine
Cylinder head
Maximum warp 0.05 mm.............................0.002 in
Reface limit from new 0.50 mm........................0.02 in
Valve springs
Free length 48.30 mm................................1.90 in
Fitted length 40.40 mm................................1.60 in
Load - valve closed 339±10 N .......................... 76±2 lbf
Load - valve open 736±10 N ........................... 165±2 lbf
Valves
Valve stem diameter:
Inlet - All engines 8.660 to 8.680 mm............................0.340 to 0.341 in
Exhaust:
Standard and carbon break valves - Early
engines 8.651 to 8.666 mm..................................0.340 to 0.341 in
Modified carbon break valves - Later engines 8.641 to 8.656 mm......0.336 to 0.340 in
Valve head diameter:
Inlet 39.75 to 40.00 mm.....................................1.56 to 1.57 in
Exhaust 34.226 to 34.480 mm..................................1.34 to 1.35 in
Valve installed height:
Standard and carbon break valves - Inlet and
exhaust - Early engines - maximum 47.63 mm............ 1.9in
Modified valves - Inlet and exhaust - Later
engines - Maximum 44.16 to 45.29 mm.........................1.741 to 1.802 in
Valve stem to guide clearance:
Inlet - All engines 0.025 to 0.066 mm...........................0.001 to 0.002 in
Exhaust:
Standard and carbon break valves - Early
engines 0.038 to 0.078 mm..................................0.0015 to 0.003 in
Modified carbon break valves - Early engines 0.048 to 0.088 mm.....0.0019 to 0.0035 in
Valve guides
Valve guide installed height 15.0 mm....................0.59 in
Inside diameter after reaming 8.7 mm..................0.34 in
Valve seats
Valve seat width:
Inlet 36.83 mm.....................................1.45 in
Exhaust 31.50 mm..................................1.24 in
Valve seat angle:
Engines built prior to ’99 MY 46°to 46°25’ ..................
Engines built from ’99 MY 45°to 45°30’ ....................
Valve seat diameter:
Inlet 36.83.....................................1.45 in
Exhaust 31.50 mm..................................1.24 in
Valve seating width:
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
Valve face angle 45° ............................