Land Rover 4.0 & 4.6 Litre V8 Engine Overhaul Manual (LRL 0004ENG – 4th Edition)

Land Rover 4.0 & 4.6 Litre V8 Engine Overhaul Manual (LRL 0004ENG – 4th Edition) PDF free online

These engines are fitted to the following models:

  • New Range Rover
  • Discovery – North American
  • Specification – 1996 MY Onwards
  • Defender – North American Specification – 1997 MY Onwards
  • Defender V8i Automatic

Land Rover used a 3,946 cc (240.8 cu in) version of the Rover V8 throughout the 1990s. Bore was increased to 94.0 mm (3.70 in) and stroke remained the same at 71.0 mm (2.80 in). The engine was revised in 1995 (and thereafter referred to as a 4.0 to differentiate it from the earlier version, although displacement remained the same at 3,946 cc) with a new intake and exhaust system, extra block ribbing, revised pistons, and larger cross-bolted main-bearings. The 1995 4.0 produced 190 hp (142 kW) and 236 lb⋅ft (320 N⋅m).

Production of the 4.0 ended in 2003. The final version of the engine, used in the 2003 Land Rover Discovery, produced 188 hp (140 kW) at 4,750 rpm and 250 lb⋅ft (340 N⋅m) at 2,600 rpm.

Applications:

  • 1990–2004 Morgan Plus 8
  • 1991–1995 Ginetta G33
  • 1992–1996 MG RV8
  • 1986–1993 TVR S Series
  • 1989–1995 Land Rover Range Rover (known as a 3.9 in this application)
  • 1991–2000 TVR Griffith
  • 1992–2001 TVR Chimaera
  • 1995–1999 Land Rover Range Rover in SE trim
  • 1994–1998 Land Rover Defender (only used as standard on USA-spec vehicles- available only to special order in other markets.)
  • 1986–1991 Sisu NA-140 BT all-terrain transport vehicle
  • 1998 Land Rover Defender 50th Anniversary Limited Edition
  • 1996-2002 Land Rover Discovery Series I,II

In the early 1980s TVR approached Andy Rouse with a view to using his race-developed 3.9L variant of the V8 in their Rover-powered 350i ‘wedge’; Rouse had successfully campaigned a Rover SD1 with a modified V8 on the track. For a number of reasons (primarily cost) Rouse’s version was not used, but the concept was passed to alternative engineering firms which resulted in a rare variant of the 3.9. This unit has 93.5mm cylinder bores (instead of Rover’s own 94mm that was introduced some years later) and thus has a capacity of 3,905cc. Flat-topped pistons and high-lift camshaft gave a compression ratio of 10.5:1. TVR claimed 275 bhp as the output and whilst this is generally disregarded by aficionados, a healthy 3,905 cc engine will produce in excess of 240 bhp. Once a reproducible specification had been determined, the bulk of engine production was undertaken by North Coventry Kawasaki (NCK), which company was subsequently purchased by TVR to become their in-house engine division known as TVR Power. About 100 cars (TVR 390SE) were built with the 3,905 cc engine; TVR’s later ‘400’ offering being based on the then-current Range Rover 4L of 3,946 cc.

Applications:

  • 1986–1989 TVR 390SE

In 1996, Land Rover enlarged the Rover V8 to 4,552 cc (277.8 cu in). The bore remained the same size as the previous 4.0 at 94.0 mm (3.70 in), but the engine was stroked by 10.9 mm (0.43 in) giving 82 mm (3.2 in) in total. Output was 225 hp (168 kW) and 280 ft•lbf (380 N•m).

Production of the 4.6 ended at Solihull, UK, in 2002. The final version, used in the Range Rover, produced 222 hp (166 kW) at 4,750 rpm and 300 ft•lbf (407 N•m) at 2,600 rpm.

The last mass-produced application of the Rover V8 was the Land Rover Discovery, up until the vehicle was redesigned in 2005. It is still used by some hand-built sports cars built by some independent manufacturers.

Applications:

  • 1995–2002 Land Rover Range Rover in the HSE trim (Optional for SE trim)
  • 2003–2004 Land Rover Discovery
  • 1996–2002 TVR Chimaera

CONTENTS

  • CONTENTS
    • DESCRIPTION AND OPERATION
    • CYLINDER BLOCK COMPONENTS
    • CYLINDER HEAD COMPONENTS
    • OPERATION
  • OVERHAUL
    • ROCKER SHAFTS
      • Rocker shafts – remove
      • Rocker shafts – dismantling
      • Inspecting components
      • Rocker shafts – assembling
      • Rocker shafts – refit
    • CYLINDER HEAD 
      • Cylinder head – remove .
      • Valves and springs – remove
      • Cylinder head – inspection
      • Valves, valve springs and guides – inspection
      • Valve guides – renew
      • Valve seat inserts – inspection
      • Valve seat inserts – renew
      • Valve seats and seat inserts – refacing
      • Valves – lapping-in
      • Engines fitted with secondary air injection (SAI)
      • Valves and springs – refit
      • Cylinder head – refit
    • TIMING CHAIN AND GEARS
      • Sump – remove
      • Timing cover – remove
      • Timing gears – remove
      • Timing chain and gears – inspection
      • Timing gears – refit
      • Timing cover – refit
      • Sump – refit
    • OIL PUMP
      • Oil pump – remove
      • Oil pressure by-pass valve – remove
      • Oil pressure relief valve – remove
      • Oil pump – inspection
      • Oil pressure by-pass valve – inspection
      • Oil pressure relief valve – inspection
      • Oil pump – refit
      • Oil pressure by-pass valve – refit
      • Oil pressure relief valve – refit
    • CAMSHAFT AND TAPPETS
      • Camshaft end-float – check
      • Camshaft and tappets – remove
      • Camshaft and tappets – inspection
      • Camshaft and tappets – refit
    • PISTONS, CONNECTING RODS, PISTON RINGS AND CYLINDER BORES
      • Pistons and connecting rods – remove
      • Piston rings – remove
      • Piston rings – inspection
      • Pistons – remove
      • Pistons – inspection
      • Gudgeon pins – inspection
      • Cylinder liner bore – inspection
      • Pistons – refit
      • Piston to cylinder bore clearance – checking
      • Pistons and connecting rods – refit
    • FLYWHEEL AND STARTER RING GEAR
      • Flywheel – remove
      • Flywheel and starter ring gear – inspection
      • Starter ring gear – renew
      • Flywheel – refit
    • DRIVE PLATE AND RING GEAR ASSEMBLY
      • Drive plate and ring gear assembly – remove – Drive plates fitted with shimmed hub aligner
      • Drive plate and ring gear assembly – remove – Drive plates fitted with unshimmed hub aligner or modified ’one-piece’ starter ring gear
      • Drive plate and ring gear – inspection
      • Drive plate and ring gear assembly – refit – Drive plates fitted with shimmed hub aligner
      • Drive plate and ring gear assembly – refit – Drive plates fitted with unshimmed hub aligner or modified ’one-piece’ starter ring gear
    • CRANKSHAFT, MAIN AND BIG-END BEARINGS
      • Big-end bearings – remove
      • Big-end bearings – refit
      • Crankshaft – remove
      • Knock sensor – remove
      • Crankshaft position sensor – remove
      • Crankshaft – inspection
      • Crankshaft spigot bearing – renew
      • Crankshaft – refit
      • Crankshaft end – float – check
      • Knock sensor – refit
      • Crankshaft position sensor – refit

Part No.: LRL 0004ENG
Language: English
Format: PDF
Pages: 82

Land Rover 4.0 & 4.6 Litre V8 Engine Overhaul Manual (LRL 0004ENG – 4th Edition) PDF free online

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