Land Rover 4 0 4 6 V8 Engine Overhaul 4th Edition Rover Manual

							ENGINE
12
OVERHAUL
4.Using suitable piloted cutters, cut valve seats
to the following dimensions:
Valve seat:
WidthA:
Inlet = 36.83 mm (1.45 in)
Exhaust = 31.50 mm (1.24 in)
Seating widthB:
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)
AngleC=56°to 70°
AngleD:
Up to ’99 Model Year = 46°to 46°25’
’99 Model Year onwards = 45°to 45°30’
AngleE=20°Valves - lapping-in
1.Lap each valve to its seat using fine grinding
paste.
2.Clean valve and seat.
3.Coat valve seat with a small quantity of
engineer’s blue, insert valve and press it into
position several times without rotating. Remove
valve and check for even and central seating.
Seating position shown by engineer’s blue
should be in centre of valve face.
4.Check valve installed heightAif valve seats
have been recut or new valves or valve seat
inserts have been fitted.
5.Check valve installed heightA:
Standard and carbon break valves - Inlet and
exhaust - Early engines = 47.63 mm (1.9 in) -
maximum
Modified valves - Inlet and exhaust - Later
engines = 44.16 to 45.29 mm (1.741 to 1.802
in) - maximum
6.Thoroughly clean cylinder head, blow out
oilways and coolant passages. 
						

							ENGINE
OVERHAUL13
Engines fitted with secondary air injection (SAI)
1.Using a 5/8 in x 20 TPI (threads per inch) UNF
tap having a class 2A thread, remove deposits
from secondary air injection adapter tappings
in cylinder head.
CAUTION: Ensure that tap used has 20
TPI.Valves and springs - refit
1.Fit new valve stem oil seals, lubricate valve
stems, fit valves, valve springs and caps,
compress valve springs usingLRT-12-034
and fit collets.
2.Using a wooden dowel and mallet, lightly tap
each valve stem two or three times to seat
valve cap and collets.
3.Fit spark plugs and tighten to 20 Nm (15 lbf.ft). 
						

							ENGINE
14
OVERHAUL Cylinder head - refit
1.Clean cylinder block and cylinder head faces
using suitable gasket removal spray and a
plastic scraper.
2.Ensure that bolt holes in cylinder block are
clean and dry.
CAUTION: Do not use metal scraper or
machined surfaces may be damaged.
3.Fit cylinder head gasket with the word’TOP’
uppermost.
NOTE: Gasket must be fitted dry.
4.Carefully fit cylinder head and locate on
dowels.
5.Lightly oil threads of new cylinder head bolts.
NOTE: RH cylinder head illustrated.
6.Fit new cylinder head bolts:
Long bolts: 1, 3 and 5
Short bolts: 2, 4, 6, 7, 8, 9 and 10
7.Using sequence shown, tighten cylinder head
bolts to:
Stage 1 - 20 Nm (15 lbf.ft)
Stage 2 - 90 degrees
Stage 3 - Further 90 degrees
CAUTION: Do not tighten bolts 180°in one
operation.
Engines fitted with secondary air injection (SAI)
8.Fit new secondary air injection adapters and
using a suitable hexagonal drive bit, tighten to
33 Nm (24 lbf.ft).
CAUTION: Do not use air tools to tighten
adapters.
All engines
9.Fit rocker shaft assembly.
10.Repeat above procedures for remaining
cylinder head. 
						

							ENGINE
OVERHAUL15
TIMING CHAIN AND GEARS
Sump - remove
1.Remove dipstick.
NOTE: Sump fitted to early engines
illustrated
2.Remove 14 bolts and 3 nuts securing sump to
cylinder block and timing cover.
3.Taking care not to damage sealing faces,
carefully release sump from timing cover and
cylinder block.
4.Remove sump, remove and discard gasket - if
fitted.Timing cover - remove
NOTE: Timing cover, oil pump, oil
pressure by-pass valve and oil pressure
relief valve are only supplied as an
assembly.
1.Secure toolLRT-12-080to crankshaft pulley
with 2 bolts.
2.Restrain crankshaft pulley usingLRT-12-080,
remove crankshaft pulley retaining bolt, collect
spacer washer - if fitted.
3.Remove crankshaft pulley.
4.Remove sump.
5.Remove nut and washers securing oil pick-up
pipe to stud. 
						

							ENGINE
16
OVERHAUL
6.Remove 2 bolts securing oil pick-up pipe to oil
pump cover, withdraw pipe from cover; remove
and discard’O’ring.
7.Remove oil pick-up pipe, recover spacer from
stud.
8.Remove bolt securing camshaft sensor to
timing cover, withdraw sensor; remove and
discard’O’ring.
9.Release harness connector from mounting
bracket.
NOTE: New Range Rover timing cover
illustrated.
10.Noting their fitted position, remove 9 bolts
securing timing cover to cylinder block; remove
cover; collect camshaft sensor harness
mounting bracket.
NOTE: Timing cover is dowel located.
11.Remove oil pump drive gear.
12.Remove and discard gasket.
13.Remove and discard oil seal from timing cover. 
						

							ENGINE
OVERHAUL17
Timing gears - remove
1.Restrain camshaft gear and remove bolt
securing gear.
2.Remove timing chain and gears as an
assembly.
3.Collect Woodruff key from crankshaft.Timing chain and gears - inspection
1.Thoroughly clean all components.
2.Inspect timing chain links and pins for wear.
3.Inspect timing chain gears for wear. Replace
components as necessary. 
						

							ENGINE
18
OVERHAUL Timing gears - refit
1.Clean gear locations on camshaft and
crankshaft, fit Woodruff key to crankshaft.
2.Temporarily fit crankshaft gear and if
necessary, turn crankshaft to bring timing mark
on gear to the twelve o’clock position, remove
gear.
3.Temporarily fit camshaft gear.
4.Turn camshaft until mark on camshaft sprocket
is at the six o’clock position, remove gear
without moving camshaft.
5.Position timing gears on work surface with
timing marks aligned.
6.Fit timing chain around gears, keeping timing
marks aligned.
7.Fit gear and chain assembly.
NOTE: Timing marks must be facing
forwards.
8.Fit camshaft gear bolt, restrain camshaft gear
and tighten bolt to 50 Nm (37 lbf.ft). 
						

							ENGINE
OVERHAUL19
Timing cover - refit
NOTE: Timing cover, oil pump, oil
pressure by-pass valve and oil pressure
relief valve are only supplied as an
assembly.
1.Clean sealant from threads of timing cover
bolts.
2.Clean all traces of gasket material from mating
faces of timing cover and cylinder block,
ensure bolt holes are clean and dry.
CAUTION: Use a plastic scraper.
3.Clean oil seal location in timing cover.
4.Position new gasket, fitted dry, to timing cover
locating dowels.
5.Position oil pump drive gear in timing cover
with groove facing towards front of timing
cover.
6.Locate toolLRT-12-090on timing cover and
oil pump drive gear.
7.Position timing cover to cylinder block and at
the same time, rotate toolLRT-12-090until
drive gear keyway is aligned with Woodruff
key.
8.Fit timing cover to cylinder block.
NOTE: New Range Rover timing cover
illustrated.
9.Position camshaft sensor harness mounting
bracket to timing cover ensuring that bracket is
positioned parallel to crankshaft centre line.
10.Smear threads of timing cover bolts with
sealant, Part number STC 50552, fit bolts and
tighten in sequence shown to 22 Nm (16 lbf.ft).
CAUTION: Do not fit coolant pump bolts at
this stage.
11.Remove toolLRT-12-090. 
						

							ENGINE
20
OVERHAUL
A- Early type seal
B- Later type seal - use as replacement on all
engines
CAUTION: Replacement oil seal is
pre-greased, do not use any additional
lubricant.
12.Fit timing cover oil seal using toolLRT-12-089.
13.Smear a new’O’ring with engine oil and fit to
oil pick-up pipe.
14.Position oil pick-up pipe spacer on number 4
main bearing cap stud.
15.Fit oil pick-up pipe ensuring that end of pipe is
correctly inserted in oil pump body.
16.Fit oil pick-up pipe to oil pump body bolts and
tighten to 8 Nm (6 lbf.ft).
17.Fit washers and nut securing oil pick-up pipe to
stud, tighten nut to 24 Nm (18 lbf.ft).
18.Smear a new’O’ring with engine oil and fit to
camshaft sensor.
19.Insert camshaft sensor into timing cover, fit bolt
and tighten to 8 Nm (6 lbf.ft).
20.Position camshaft sensor harness connector
on mounting bracket.
21.Fit sump.
22.Fit crankshaft pulley, fit bolt and spacer washer
- if fitted.
23.Restrain crankshaft pulley using tool
LRT-12-080and tighten bolt to 270 Nm (200
lbf.ft).
NOTE: Crankshaft pulleys which
incorporate a mud flinger can be fitted to
all engines.
24.Remove toolLRT-12-080. 
						

							ENGINE
OVERHAUL21
Sump - refit
Early engines fitted with pressed steel sump
1.Remove all traces of old sealant from mating
faces of cylinder block and sump, ensure bolt
holes are clean and dry.
2.Apply a bead of sealant, Part number STC
50550 to sump joint face as shown:
Bead width - areas A, B, C and D = 12 mm (0.5
in)
Bead width - remaining areas = 5 mm (0.20 in)
Bead length - areas A and B = 32 mm (1.23 in)
Bead length - areas C and D = 19 mm (0.75 in)
CAUTION: Do not spread sealant bead.
Sump must be fitted immediately after
applying sealant.
3.Apply a globule of the sealant to cover the
ends of the cruciform seals.
4.Noting that the two parts of the tool are
’handed’, fit toolLRT-12-183to the engine
backplate using slave bolts.
5.Secure the tool to the sump using the bolts
which are part of the tool.
NOTE: The holes in the tool are larger than
the diameter of the bolts in order to allow
the sump to move as the sump bolts are
tightened.
6.Fit sump, taking care not to damage sealant
bead.
7.Fit sump bolts and nuts and working in
sequence shown, tighten to 23 Nm (17 lbf.ft).
8.Remove toolLRT-12-183.