4.0 & 4.6 LITRE - land rover service factory manual …

1 & LITREV8 ENGINEOVERHAULMANUALT hese engines having Serial No. Prefix42D, 46D, 47D, 48D, 49D, 50D or 51D arefitted to the following models:New Range RoverDiscovery - North AmericanSpecification - 1996 MY OnwardsDefender - North American Specification- 1997 MY OnwardsDefender V8i AutomaticPublication Part No. LRL 0004 ENG - 3rd EditionPublished by rover Technical Communication 1998 rover Group AND to use this ManualTo assist in the use of this manual the section title isgiven at the top and the relevant sub-section is givenat the bottom of each manual contains procedures for overhaul of theV8 engine on the bench with the gearbox, clutch,inlet manifold, exhaust manifolds, coolant pump,starter motor, alternator, and all other ancillaryequipment removed. For information regardingGeneral Information, Adjustments, removal of oilseals, engine units and ancillary equipment, consultthe Repair manual is divided into 3 sections: Data, Torque & Tools Description and Operation and OverhaulTo assist filing of revised information eachsub-section is numbered from page items are to be overhauled in thesequence in which they appear in this manual .

2 Itemsnumbers in the illustrations are referred to in the operations include reference to Servicetool numbers and the associated illustration depictsthe tool. Where usage is not obvious the tool isshown in use. Land rover tool numbers are quoted,for the equivalent rover Cars tool number refer tothe service Tool section. Operations also includereference to wear limits, relevant data, and specialistinformation and useful assembly , CAUTIONSandNOTES have thefollowing meanings:WARNING: Procedures which must befollowed precisely to avoid the possibilityof : Calls attention to procedureswhich must be followed to avoid damageto : Gives helpful the engine and gearbox assembly removed,the crankshaft pulley end of the engine is referred toas the front. References to RH and LH banks ofcylinders are taken viewing from the flywheel end ofthe covered in this manual do not includereference to testing the vehicle after repair. It isessential that work is inspected and tested aftercompletion and if necessary a road test of thevehicle is carried out particularly where safetyrelated items are serial numberThe engine serial number and compression ratio willbe found stamped on a cast pad on the cylinderblock between numbers 3 and 5 cylinders.

3 Thecompression ratio is above the serial dimensions quoted are to design engineeringspecification with service Limits where AND REPLACEMENTSWhen replacement parts are required it is essentialthat only Land rover recommended parts are is particularly drawn to the following pointsconcerning repairs and the fitting of replacementparts and wrench setting figures given in this Manualmust be used. Locking devices, where specified,must be fitted. If the efficiency of a locking device isimpaired during removal it must be terms of the vehicle warranty may beinvalidated by the fitting of parts other than LandRover recommended parts. All Land Roverrecommended parts have the full backing of thevehicle rover dealers are obliged to supply only LandRover recommended rover are constantly seeking to improve thespecification, design and production of their vehiclesand alterations take place accordingly. While everyeffort has been made to ensure the accuracy of thisManual, it should not be regarded as an infallibleguide to current specifications of any manual does not constitute an offer for sale ofany particular component or vehicle.

4 Land Roverdealers are not agents of the Company and have noauthority to bind the manufacturer by any expressedor implied undertaking or WRENCH TOOLSSERVICE , TORQUE & TOOLS1 DATAF iring order1, 8, 4, 3, 6, 5, 7, 1, 3, 5, 7 - LH side of engineCylinders 2, 4, 6, 8 - RH side of engineCylinder headsMaximum inReface inValve springsFree inFitted inLoad - valve open736 10 2 lbfLoad - valve closed339 10 2 lbfValvesValve stem to to to to inValve head to to installed height - stem to guide to to to to inValve guidesValve guide installed inInside diameter after inValve seatsValve seat angle46 to 46 25 ..Valve seat inValve seating to to to to inValve seating face angle45 ..Oil pumpInner to outer rotor clearance - inRotors to cover plate clearance - inDrive gear wear step depth - inOil pressure relief valveSpring free to to inMaximum inINFORMATION2 DATA, TORQUE & TOOLSP iston ringsRing to groove clearance:1st to to in2nd to to inRing fitted gap:1st to to in2nd to to inOil control to to inOil control ring in - maximumPistonsPiston diameter:Production - Grade to to inProduction - Grade B* to to inClearance in to to inGudgeon to to to to inClearance in to to inConnecting rodsLength between to to to to inCylinder boreCylinder bore.

5 Grade A piston to to inGrade B piston to to inCylinder bore maximum inCrankshaftMain journal to to inMinimum regrind to to inMaximum out of inBig-end journal to to inMinimum regrind to to inMaximum out of to to inMaximum inMain bearingsMain bearing diametrical to to , , inINFORMATIONDATA, TORQUE & TOOLS3 Big-end bearingsBig-end bearing diametrical to to , , inEnd-float on to to inFlywheelFlywheel minimum plateDrive plate setting height:Up to engine no. 42D00593A - to to inUp to engine no. 46D00450A - to to in* Grade B piston supplied as service replacementINFORMATIONTORQUE WRENCH SETTINGS1 ENGINEC rankshaft pulley bolt270 gear bolt50 thrust plate bolts25 cover bolts: +Stage 14 28 3 - re-torque to:8 shaft to cylinder head bolts38 head bolts: +*Stage 120 2 Then 90 3 Further 90 eye to cylinder head bolts40 rod bolts:Stage 120 2 Further 80 bearing cap bolts - Nos.

6 1 to 8: +Stage 1 - initial 2 - final torque72 main bearing cap bolts - Nos. 9 and 10: +Stage 1 - initial 2 - final torque92 bearing cap side bolts - Nos. 11 to 20: +Stage 1 - initial 2 - final torque45 bolts80 plate assembly bolts45 plate hub aligner to crankshaft socket headcap screws85 sump drain plug45 sump nuts and bolts +23 pump cover plate screws **4 pump cover plate bolt **8 plugs20 cover/coolant pump to cylinder block bolts+ pick-up pipe to oil pump bolts8 pick-up pipe nut24 sensors to cylinder block16 sensor to timing cover bolt8 position sensor bolts6 cooler connections15 + Tighten in sequence* Lightly oil threads prior to assembly.** Coat threads with Loctite 222 prior WRENCH SETTINGSGENERALFor bolts and nuts not otherwise specifiedM54 UNC and UNF25 and UNF40 UNC and UNF75 and UNF90 and UNF135 TOOLS1 service TOOLSLand rover NumberRover NumberDescriptionLRT-12-01318G1150 Remover/replacer - gudgeon pinLRT-12-126/1-Adapter - remover/replacer - gudgeon pinLRT-12-126/2-Adapter - remover/replacer - gudgeon pinLRT-12-126/3-Parallel sleeve - gudgeon pinLRT-12-03418G1519 AValve spring compressorLRT-12-037RO274401 Drift - remover - valve guideLRT-12-038RO600959 Drift - replacer - valve guideLRT-12-055-Distance piece - valve guideLRT-12-089-Replacer - timing cover oil sealLRT-12-090-Retainer - oil pump gearsLRT-12-091-Replacer - crankshaft rear oil sealLRT-12-095-Protection sleeve - crankshaft rear oil sealLRT-12-501MS76 BBasic handle set - valve seat valve seat pilotLRT-12-515RO605774 ADistance piece - valve guideLRT-12-517-Adjustable valve seat cutterService tools must be

7 Obtained direct from the Churchill, Box No 3,London Road,Daventry,Northants, NN11 AND OPERATIONCYLINDER BLOCK HEAD shafts - shafts - shafts - shafts - head - and springs - head - , valve springs and guides - guides - seat inserts - seat inserts - seats and seat inserts - - and springs - head - CHAIN AND - cover - gears - chain and gears - gears - cover - - PUMP AND OIL PRESSURE RELIEF pump - pressure relief valve - pump - pressure relief valve - pump - pressure relief valve - AND end-float - and tappets - and tappets - and tappets - , CONNECTING RODS, PISTON RINGS AND CYLINDER and connecting rods - rings - rings - - - pins - liner bore - - to cylinder bore clearance - and connecting rods - AND STARTER RING - and starter ring gear - ring gear - - PLATE AND RING GEAR plate and ring gear assembly - remove - Up to engine nos. 42D00593 Aand plate and ring gear assembly - remove - From engine nos.

8 42D00594 Aand 46D00451A and all engines having serial no. prefixes from 47D to plate and ring gear - plate and ring gear assembly - refit - Up to engine nos. 42D00593A plate and ring gear assembly - refit - From engine nos. 42D00594A and46D00451A and all engines having serial no. prefixes from 47D to , MAIN AND BIG-END bearings - bearings - - sensor - position sensor - - spigot bearing - - end - float - sensor - position sensor - AND OPERATION1 This page is intentionally left blankENGINE2 DESCRIPTION AND OPERATIONENGINEDESCRIPTION AND OPERATION3 CYLINDER BLOCK and gudgeon Woodruff cover and oil pump assembly * pressure cover oil pressure relief valve cover main bearing shell - rear oil bearing socket head cap bearing hexagonal head knock main bearing cap and side main bearing end bearing end bearing end bearing and front main bearing bearing cap pick-up pick-up pipe spacer, washers and nut* New Range rover timingcover illustratedENGINE4 DESCRIPTION AND OPERATIONENGINEDESCRIPTION AND OPERATION5 CYLINDER HEAD shaft shaft valve seal, spring, cap and valve seal, spring.

9 Cap and valve and manifold gasket and valve and head guideENGINE6 DESCRIPTION AND OPERATIONOPERATIONThe V8 engine is an eight cylinder, water cooled unitcomprising cast aluminium cylinder block andcylinder cast iron cylinder liners are shrink fitted andlocated on stops in the cylinder block. The banks ofcylinders are at 90 to each other. The crankshaft iscarried in five main bearings, end-float beingcontrolled by the thrust faces of the upper centremain bearing centrally located camshaft is driven by thecrankshaft via a chain. The valves are operated byrockers, pushrods and hydraulic tappets. Exhaustvalves used on later engines are of the carbonbreak type which incorporate a machined undercutat the combustion chamber end of the valve. Thedesign prevents carbon build-up on the valve stemwhich could lead to valves sticking. These valvesare interchangeable with valves fitted to of the aluminium alloy pistons has twocompression rings and an oil control ring.

10 Thepistons are secured to the connecting rods bysemi-floating gudgeon pins. The gudgeon pin isoffset mm ( in), identified by an arrow markon the piston crown, which must always point to thefront of the engine. Plain, big-end bearing shells arefitted to each connecting AND relief pressure switchAOil to coolerBOil from coolerLubricationThe full flow lubrication system uses a gear type oilpump driven from the crankshaft. The assembly isintegral with the timing cover which also carries thefull flow oil filter, oil pressure switch and pressurerelief is drawn from the pressed steel sump through astrainer and into the oil pump, excess pressurebeing relieved by the pressure relief valve. The oilpressure warning light switch is screwed into thetiming cover and registers the oil pressure in themain oil gallery on the outflow side of the oil passes through an oil coolermounted in front of the radiator to the full flow oilfilter. The oil then passes through internal drillings tothe crankshaft where it is directed to each mainbearing and to the big end bearings via numbers 1,3 and 5 main internal drilling in the cylinder block directs oil tothe camshaft where it passes through further internaldrillings to the hydraulic tappets, camshaft journalsand rocker shaft.