Land Rover 3.5L/3.9L/4.2L V8 Engine Overhaul 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 INTRODUCTION 1 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, CAUTIONS and NOTES have 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 DATA 1 ........................................................................................................................ TORQUE WRENCH SETTINGS ENGINE 1 .................................................................................................................... GENERAL 2 ................................................................................................................. SEALANTS 3 ............................................................................................................... SERVICE TOOLS SERVICE TOOLS 1 .....................................................................................................

INFORMATION GENERAL DATA 1 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 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 ............ 1.9 in 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° ............................

Land Rover 3.5L/3.9L/4.2L V8 Engine Overhaul Manual

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