• 3.5, 3.9 & 4.2 V8 Engine Overhaul Manual - 2nd Edition - Eng
  • 3.5, 3.9 & 4.2 V8 Engine Overhaul Manual - 2nd Edition
  • Page 3
  • Page 4
  • Page 5
  • INFORMATION
  • Page 10
  • Page 11
  • GENERAL DATA
  • Page 14
  • Page 15
  • Page 16
  • TORQUE WRENCH SETTINGS
  • Page 21
  • SERVICE TOOLS
  • Page 24
  • Page 25
  • Page 26
  • Page 27
  • DESCRIPTION AND OPERATION
  • Page 33
  • Page 34
  • Page 35
  • 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
  • Page 48
  • Page 49
  • 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
  • Distributor - if fitted - remove
  • Sump - remove
  • Timing cover - remove - engine numbers without suffix B
  • Timing cover - remove - engine numbers with suffix B
  • Timing gears - remove
  • Timing chain and gears - inspection
  • Timing gears - refit
  • Page 66
  • Timing cover - refit - engine numbers without suffix B
  • Timing cover - refit - engine numbers with suffix B
  • Page 69
  • Sump - refit
  • Distributor - if fitted - refit
  • OIL COOLER ADAPTER - ENGINE NUMBERS WITHOUT SUFFIX B
  • Oil cooler adapter - remove
  • Oil cooler adapter - refit
  • OIL PUMP - ENGINE NUMBERS WITHOUT SUFFIX B
  • Oil pump - remove
  • Oil pump - inspection
  • Oil pump - refit
  • OIL PUMP - ENGINE NUMBERS WITH SUFFIX B
  • 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 and connecting rods - 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 plate and ring gear - inspection
  • Drive plate and ring gear assembly - check setting height
  • Drive plate and ring gear assembly - refit
  • CRANKSHAFT, MAIN AND BIG-END BEARINGS
  • Big-end bearings - remove
  • Big-end bearings - refit
  • Crankshaft - remove
  • Crankshaft - inspection
  • Page 120
  • Crankshaft spigot bearing - renew
  • Crankshaft - refit
  • Page 123
  • Crankshaft end - float - check