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

							ENGINE
42
OVERHAUL FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
1.Restrain flywheel and remove 6 bolts securing
flywheel.
2.Remove flywheel.
NOTE: Dowel located. On early engines,
balance weights were on engine side of
flywheel; replacement flywheels will have
balance weights on clutch side.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
3.Renew ring gear if necessary. 
						

							ENGINE
OVERHAUL43
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.
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. 
						

							ENGINE
44
OVERHAUL Flywheel - refit
1.Ensure bolt holes in crankshaft are clean and
dry.
2.Fit flywheel and locate on 2 dowels.
3.Fit flywheel bolts.
4.Using assistance, restrain flywheel and tighten
flywheel bolts to 78 Nm (58 lbf.ft).DRIVE PLATE AND RING GEAR ASSEMBLY
Drive plate and ring gear assembly - remove
1.Suitably identify each component to its fitted
position.
2.Remove 4 bolts securing drive plate assembly.
3.Remove clamp ring and drive plate assembly.
NOTE: Dowel located.
4.Remove 6 Allen bolts securing hub aligner to
crankshaft, remove hub aligner.
5.Remove and retain selective shim - if fitted. 
						

							ENGINE
OVERHAUL45
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.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.Ensure bolt holes in crankshaft are clean and
dry. Fit original selective shim and hub aligner,
fit Allen bolts and tighten to 85 Nm (63 lbf.ft).
2.Fit drive plate assembly and clamp 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
clamp ring, drive plate assembly, hub aligner
and selective shim. 
						

							ENGINE
46
OVERHAUL 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 shimDrive plate and ring gear assembly - refit
1.Position selected shim - if fitted to crankshaft.
2.Fit hub aligner, fit Allen bolts and tighten to 85
Nm (63 lbf.ft).
3.Fit drive plate assembly and clamp 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). 
						

							ENGINE
OVERHAUL47
CRANKSHAFT, MAIN AND BIG-END BEARINGS
Big-end bearings - remove
1.Remove timing chain and gears.
NOTE: Oil strainer fitted to engines
without suffix B to the serial number
illustrated.
2.Remove 2 bolts or nut on engines with suffix B
to the serial number securing oil strainer.
3.Remove strainer, remove and discard gasket -
if fitted.
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.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. 
						

							ENGINE
48
OVERHAUL 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:
Nuts - 50 Nm (37 lbf.ft).
Bolts:
Stage 1 - 20 Nm (15 lbf.ft)
Stage 2 - Further 80°
7.Check connecting rods move freely sideways
on crankshaft. Tightness indicates insufficient
bearing clearance or misaligned connecting
rod.
8.Check clearance between connecting rods on
each crankshaft journal.
Connecting rod clearance = 0.15 to 0.36 mm
(0.006 to 0.014 in).
9.Clean oil strainer.
Engines numbers without suffix B
10.Clean mating faces of strainer and cylinder
block.
11.Fit new gasket, dry.
12.Position oil strainer to stud.
13.Fit oil strainer, fit nut but do not tighten at this
stage.
NOTE: This will allow for correct
positioning of oil strainer when timing
cover is fitted.
CAUTION: Ensure nut is tightened to 22
Nm (16 lbf.ft) when oil pick-up pipe is fitted
to timing cover.
Engines numbers with suffix B
14.Clean mating faces on strainer and cylinder
block.
15.Fit new gasket to strainer, position strainer, fit
bolts and tighten to 10 Nm (7 lbf.ft).
16.Fit timing chain and gears. 
						

							ENGINE
OVERHAUL49
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 cruciform seals from rear
main bearing cap.
11.Remove Woodruff key from crankshaft.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. 
						

							ENGINE
50
OVERHAUL
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.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) 
						

							ENGINE
OVERHAUL51
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.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.