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Land Rover v8 35 39 42 Overhaul Manual
Land Rover v8 35 39 42 Overhaul Manual
ENGINE
OVERHAUL
MANUAL
This overhaul manual is applicable to 3.5,
3.9 and 4.2 Litre V8 engines with or without
suffix B added to the engine serial number.
INTRODUCTION
INTRODUCTION
References
Dimensions
Each major section starts with a contents page,
listing the information contained in the relevant
sub-sections. To assist filing of revised information
each sub-section is numbered from page 1.
INTRODUCTION
INTRODUCTION
REPAIRS AND REPLACEMENTS
SPECIFICATION
INTRODUCTION
INFORMATION
DATA
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 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
Valve springs
Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.30 mm
Fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.40 mm
Load at fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . 339 10 N
Valves
Valve stem diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve installed height - maximum . . . . . . . . . . . . . . .
Valve stem to guide clearance:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.664 to 8.679 mm
8.651 to 8.666 mm
39.75 to 40.00 mm
34.226 to 34.480 mm
47.63 mm
0.025 to 0.066 mm
0.038 to 0.078 mm
Valve guides
Valve guide installed height . . . . . . . . . . . . . . . . . . . . 24.13 mm
Valve seats
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 15
Valve seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.0 mm
Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil pump
Gear to body minimum clearance . . . . . . . . . . . . . . . 0.05 mm
Oil pressure relief valve
Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.28 mm
Oil pump - Engine Nos with suffix B
Inner to outer rotor clearance - maximum . . . . . . . . . 0.25 mm
Rotors to cover plate clearance - maximum . . . . . . . 0.1 mm
Drive gear wear step depth - maximum . . . . . . . . . . . 0.15 mm
Oil pressure relief valve - Engine Nos with
suffix B
Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.0 mm
Camshaft
Maximum run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm
GENERAL DATA
INFORMATION
Piston rings
Ring to groove clearance:
Top compression . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd compression . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring fitted gap:
Top compression . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd compression . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil control rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil control ring width . . . . . . . . . . . . . . . . . . . . . . . . .
0.05 to 0.10 mm
0.05 to 0.10 mm
0.44 to 0.57 mm
0.44 to 0.57 mm
0.38 to 1.40 mm
3.00 mm, maximum
Pistons
Clearance in bore, measured at bottom of
skirt at right angles to bore . . . . . . . . . . . . . . . . . . . . 0.018 to 0.033 mm
Gudgeon pins
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.67 to 72.79 mm
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.215 to 22.220 mm
Clearance in piston . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 to 0.007 mm
Connecting rods
Length between centres . . . . . . . . . . . . . . . . . . . . . . 143.81 to 143.71 mm
Cylinder bore
Cylinder bore diameter:
3.5 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.90 mm
3.9 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.00 mm
4.2 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.00 mm
Crankshaft
Main journal diameter . . . . . . . . . . . . . . . . . . . . . . . .
Minimum regrind diameter . . . . . . . . . . . . . . . . . . . .
Maximum out of round . . . . . . . . . . . . . . . . . . . . . . .
Big-end journal diameter . . . . . . . . . . . . . . . . . . . . . .
Minimum regrind diameter . . . . . . . . . . . . . . . . . . . .
Maximum out of round . . . . . . . . . . . . . . . . . . . . . . .
End-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58.409 to 54.422 mm
57.393 to 57.406 mm
0.040 mm
50.800 to 50.812 mm
49.784 to 49.797 mm
0.040 mm
0.10 to 0.20 mm
Main bearings
Main bearing diametrical clearance . . . . . . . . . . . . . . 0.010 to 0.048 mm
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 mm, 0.508 mm
Big-end bearings
Big-end bearing diametrical clearance . . . . . . . . . . . 0.015 to 0.055 mm
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 mm, 0.508 mm
Endfloat on journal . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 to 0.36 mm
Flywheel
Flywheel minimum thickness . . . . . . . . . . . . . . . . . . . 39.93 mm
Drive plate
Drive plate setting height . . . . . . . . . . . . . . . . . . . . . . 8.08 to 8.20 mm
GENERAL DATA
INFORMATION
ENGINE
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . .
Timing cover to cylinder block bolts ** . . . . . . . . . . . .
Camshaft gear bolt . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker shaft to cylinder head bolts . . . . . . . . . . . . . .
Cylinder head bolts: *
Outer row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centre row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head bolts - Engine Nos with suffix B: *
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting eye to cylinder head bolts . . . . . . . . . . . . . . . .
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing cap bolts *** . . . . . . . . . . . . . . . . . . . . .
Rear main bearing cap bolts *** . . . . . . . . . . . . . . . . .
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive plate and ring gear assembly bolts . . . . . . . . . .
Drive plate adapter bolts . . . . . . . . . . . . . . . . . . . . . .
Oil sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure relief plug . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump cover to timing cover . . . . . . . . . . . . . . . . .
Oil pump cover plate screws - Engine Nos with
suffix B **** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil strainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . .
Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant pump/timing cover to cylinder block . . . . . . .
*
**
***
****
270 Nm
22 Nm
50 Nm
8 Nm
38 Nm
60 Nm
90 Nm
90 Nm
20 Nm
Then 90
Further 90
25 Nm
50 Nm
70 Nm
90 Nm
80 Nm
40 Nm
80 Nm
40 Nm
23 Nm
45 Nm
12 Nm
4 Nm
10 Nm
20 Nm
15 Nm
22 Nm
INFORMATION
GENERAL
For bolts and nuts not otherwise specified:
METRIC
M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Nm
6 Nm
18 Nm
35 Nm
65 Nm
80 Nm
130 Nm
UNC / UNF
1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10 Nm
25 Nm
40 Nm
75 Nm
90 Nm
135 Nm
ENGINE
ENGINE
ENGINE
CYLINDER BLOCK COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Cylinder block
Piston and gudgeon pin
Connecting rod
Core plugs
Camshaft
Dipstick
Camshaft key
Timing chain
Camshaft sprocket
Spacer
Distributor drive gear
Distributor
Oil pump gears *
Timing cover and gasket *
Timing cover oil seal *
Crankshaft pulley
Crankshaft sprocket
Woodruff key
Crankshaft
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
ENGINE
Cylinder head
Rocker cover
PCV filter
Rocker shaft
Tappet
Pushrod
Rocker shaft bracket
Rocker arm
Rocker shaft spring
PCV air intake filter
11.
12.
13.
14.
15.
16.
17.
18.
ENGINE
Operation
The V8 engine is an eight cylinder, water cooled unit
comprising of cast aluminium cylinder block and
cylinder heads.
The two banks of steel cylinder liners which are
pressed down to stops in the cylinder block, are set
at 900 to each other. The crankshaft is carried in five
main bearings, end-float being controlled by the
thrust faces of the upper centre main bearing shell.
ENGINE
1.
2.
3.
4.
Oil strainer
Crankshaft main bearing oil feed
Oil pressure relief valve
Oil pump
5. Main gallery
A Oil to cooler
B Oil from cooler
ENGINE
1.
2.
3.
4.
Oil strainer
Oil pump
Pressure relief valve
Oil pressure switch
5. Main gallery
A Oil to cooler
B Oil from cooler
All engines
ENGINE
Distributor drive and timing chain lubrication
1.
2.
3.
4.
5.
6.
Bearing
Camshaft
Key
Camshaft timing chain sprocket
Spacer
Distributor drive gear
Hydraulic tappets
1.
2.
3.
4.
5.
6.
7.
8.
Clip
Pushrod seat
Inner sleeve
Upper chamber
Non-return ball valve
Spring
Outer sleeve
Lower chamber - high pressure
ENGINE
ROCKER SHAFTS
Rocker shaft - remove
OVERHAUL
ENGINE
Dismantle
OVERHAUL
ENGINE
OVERHAUL
ENGINE
CYLINDER HEAD
Cylinder head - remove
1. Remove rocker shaft assembly.
2. Mark heads LH and RH for reassembly.
All engines
5. Release cylinder head from 2 dowels and
remove cylinder head.
6. Remove and discard cylinder head gasket.
Valves and springs - remove
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ENGINE
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ENGINE
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ENGINE
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ENGINE
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ENGINE
Engine numbers without suffix B
All engines
10. Fit rocker shaft assembly.
Distributor - remove
1. Remove distributor cap.
2. Rotate crankshaft until centre line of rotor arm
is aligned with No. 1 spark plug segment in
distributor cap and No. 1 piston is at TDC.
OVERHAUL
ENGINE
Sump - remove
1. Remove dipstick.
2. Remove screw securing dipstick tube to LH
rocker cover.
10
OVERHAUL
ENGINE
1.
2.
3.
4.
OVERHAUL
11
ENGINE
12
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ENGINE
OVERHAUL
13
ENGINE
Distributor - refit
Sump - refit
1. Remove all traces of old sealant from mating
faces of cylinder block and sump.
14
OVERHAUL
ENGINE
6. Engine numbers without suffix B: Locate
slotted adaptor to oil pump drive shaft tongue.
7. Check that centre line of rotor arm is aligned
with No.1 spark plug segment in distributor cap
and reference marks on distributor body and
clamp are aligned; reposition distributor if
necessary.
8. Remove rotor arm.
9. Rotate distributor to position pick-up opposite
nearest reluctor tooth.
OVERHAUL
15
ENGINE
OIL PUMP - ENGINE NUMBERS WITHOUT
SUFFIX B
Oil pump - remove
1.
2.
3.
4.
Remove sump.
Remove distributor.
Remove timing cover.
Remove oil cooler adapter - if fitted.
16
OVERHAUL
ENGINE
OVERHAUL
17
ENGINE
1. Remove circlip.
2. Remove relief valve plug, remove and discard
O ring.
3. Remove relief valve spring and piston.
18
OVERHAUL
ENGINE
OVERHAUL
19
ENGINE
CAMSHAFT AND TAPPETS
Camshaft and tappets - remove
1. Remove rocker shaft assemblies.
2. Remove pushrods and store in fitted order.
3. Remove timing chain and gears.
20
OVERHAUL
ENGINE
OVERHAUL
21
ENGINE
Pistons - remove
Pistons - inspection
1. Clean carbon from pistons
2. Inspect pistons for distortion and cracks.
22
OVERHAUL
ENGINE
Pistons - refit
CAUTION: On later 4.2L engines the piston
has a 0.5 mm offset gudgeon pin which
can be identified by an arrow mark on the
piston crown. This arrow MUST always point to
the front of the engine.
OVERHAUL
23
ENGINE
8. Fit gudgeon pin onto centre screw and into
piston bore up to connecting rod.
9. Fit remover/replacer bush with flanged end
towards gudgeon pin.
10. Screw the stop nut onto centre screw and
position piston against face of adaptor
LRT-12-014.
11. Lubricate centre screw threads and thrust race
with graphited oil, fit, and screw large nut up to
thrust race.
12. Adjust stop nut leaving clearance B, between
nut and remover/replacer bush.
Clearance B = 0.8 mm.
13. Lock the stop nut securely with lockscrew.
14. Set torque wrench to 16 Nm, and using socket
on large nut, pull gudgeon pin in until flange of
remover/replacer bush is distance C from face
of piston.
Distance C = 4 mm.
CAUTION: Flange of remover/replacer
must not be allowed to contact piston. If
torque figure is not achieved during above
operation, fit of gudgeon pin to connecting rod is
not acceptable and necessitates renewal of
components. The centre screw and thrust race
must be kept well lubricated throughout
operation.
24
OVERHAUL
ENGINE
FLYWHEEL
Flywheel- remove
OVERHAUL
25
ENGINE
Flywheel - refit
1. Fit flywheel and locate on 2 dowels.
2. Fit flywheel bolts.
3. With assistance, restrain crankshaft and
tighten flywheel bolts to correct torque.
26
OVERHAUL
ENGINE
DRIVE PLATE AND RING GEAR ASSEMBLY
Drive plate and ring gear assembly - remove
1. Mark each component to enable reassembly in
original position.
OVERHAUL
27
ENGINE
7. Measure existing shim and, if necessary, select
appropriate shim to maintain setting height.
Shims available:
1.20 - 1.25mm
1.30 - 1.35mm
1.40 - 1.45mm
1.50 - 1.55mm
1.60 - 1.65mm
1.70 - 1.75mm
1.80 - 1.85mm
1.90 - 1.95mm
2.00 - 2.05mm
2.10 - 2.15mm
8. Fit shim selected, position adapter, ensuring
marks previously made line up, fit socket head
bolts and tighten to correct torque.
9. Fit ring gear assembly, hub aligner, flexible
drive plate and clamp ring. ensuring marks
previously made line up.
10. Apply Loctite 242 to threads of bolts, fit bolts
and tighten to correct torque.
28
OVERHAUL
ENGINE
OVERHAUL
29
ENGINE
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.
30
OVERHAUL
Crankshaft - inspection
1. Clean crankshaft and blow out oil passages.
ENGINE
Crankshaft dimensions:
Crankshaft - refit
1. Clean main bearing caps, bearing shell
recesses and mating surfaces of cylinder
block.
OVERHAUL
31
ENGINE
5. Apply EXP16A (Marston Lubricants) lubricant
to threads of main bearing cap bolts.
6. Lubricate main bearing shells and fit numbers
1 to 4 bearing caps, fit and lightly tighten bolts.
32
OVERHAUL
ENGINE
SERVICE TOOLS
Land Rover Number
Rover Number
Description
LRT-12-010*
LRT-12-013
LRT-12-014
LRT-12-034
LRT-12-037
LRT-12-038
LRT-12-055
LRT-12-089**
LRT-12-090**
LRT-12-091**
LRT-12-095**
LRT-12-501
LRT-12-503
LRT-12-504
LRT-12-515
18G 1014*
18G 1150
18G 1150E
18G 1519
RO.274401
RO.600959
MS76B
MS150-8.5
MS76-621
RO.605774A
SERVICE TOOLS