1995 LAND ROVER DISCOVERY lock

ENGINE
OVERHAUL11
ROCKER SHAFT
Remove
1.Disconnect breather hoses from crankcase
breather cyclone unit.
2.Remove bolt securing cyclone unit to rocker
cover.
3.Remove cyclone unit, remove and discard 'O'
ring.
4.Disconnect breather hoses from cylinder block
and rocker cover.
5.Remove 3 flange nuts securing rocker cover,
recover sealing washers.
6.Remove rocker cover, remove and discard
gasket.
7.Slacken locknut on each tappet adjusting
screw, slacken adjusting screws until they are
clear of push rods.
8.Working from the centre outwards,
progressively slacken then remove 3 nuts and
2 bolts securing rocker shaft pedestals to
cylinder head.
CAUTION: Insert a slave bolt into
pedestals 1 and 5 to prevent components
sliding off shaft.
9.Remove rocker shaft assembly.

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10.Withdraw push rods.
11.Remove valve caps.
CAUTION: Keep push rods and valve caps
in their fitted order.Rocker shaft - dismantling
1.Suitably identify each component to its fitted
position.
2.Remove locknut and tappet adjusting screw
from each rocker.
3.Remove slave bolt and pedestal from end of
rocker shaft.
4.Remove washer, rocker arm and spacer
followed by second rocker arm, spacer and
pedestal.
5.Repeat above procedures until all components
are removed.

ENGINE
14
OVERHAUL Rocker shaft - assembling
1.Lubricate all components with engine oil.
2.Assemble rocker arms, spacers, washers and
pedestals to rocker shaft ensuring that they are
in their original fitted positions.
3.Retain pedestals 1 and 5 with slave bolts.Rocker shaft - refit
1.Lubricate push rods with engine oil and fit to
their original positions. Ensure that ball end of
each push rod is correctly located in each cam
follower slide.
2.Screw each tappet adjusting screw into its
respective rocker arm until ball end is flush with
underside of arm; fit but do not tighten
locknuts.
3.Lubricate valve pads with engine oil and fit to
their original positions.
4.Position rocker shaft to cylinder head, fit but do
not tighten 3 nuts.
5.Remove slave bolts from pedestals 1 and 5, fit
but do not tighten 2 bolts.
6.Locate each push rod in turn beneath its
respective tappet adjusting screw and tighten
each screw until ball end locates in recess in
push rod.
7.Working from the centre outwards,
progressively tighten 3 nuts and 2 bolts to 5
Nm.

ENGINE
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OVERHAUL
18.Check sealing washers for damage or
distortion, replace as necessary.
19.Position a new gasket - dry to rocker cover.
20.Position rocker cover to cylinder head, fit 3
flange nuts and working from centre outwards,
tighten to 10 Nm.
21.Lubricate a new 'O' ring with engine oil and fit
to crankcase breather cyclone unit.
22.Fit cyclone unit to rocker cover, fit bolt and
tighten to 9 Nm.
23.Connect breather hoses to cyclone unit, rocker
cover and cylinder block.

ENGINE
OVERHAUL17
VALVE CLEARANCES - ADJUST
CAUTION: To prevent possibility of
damage to cam follower seatings, it is
essential that ball ends of tappet adjusting
screws are seated in recess in push rods and
that ball end of each push rod is correctly
located in cam follower slide.
1.Rotate crankshaft by means of crankshaft
pulley bolt in a clockwise direction until number
8 valve ( counting from front of engine ) is fully
open.
2.Using feeler gauges and a screwdriver, adjust
clearance of number 1 valve.
Valve clearance - all valves = 0.20 mm
3.Tighten tappet adjusting screw locknut when
clearance is correct.
4.Adjust the remaining valve clearances in the
following sequence:
Adjust number 3 clearance with number 6
valve fully open
Adjust number 5 clearance with number 4
valve fully open
Adjust number 2 clearance with number 7
valve fully open
Adjust number 8 clearance with number 1
valve fully open
Adjust number 6 clearance with number 3
valve fully open
Adjust number 4 clearance with number 5
valve fully open
Adjust number 7 clearance with number 2
valve fully open
5.Upon completion, re-check all clearances and
adjust as necessary.

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8.Insert a new valve into each guide in turn and
with head of valve positioned 8.0 mm above
seat insert, measure side to side movement of
valve head using a suitable DTI.
Maximum valve head movement = 0.15 mm
9.Replace any valve guide which permits valve
head movement in excess of the above figure.Valve guides - renew
1.Support cylinder head, combustion face
upwards on blocks of wood.
2.Using toolLRT-12-036,drift valve guide out of
cylinder head, discard guide.
3.Clean valve guide bore.
4.Heat cylinder head uniformily to 120°C.
WARNING: Take care when handling
heated cylinder head.

ENGINE
OVERHAUL23
5.Position cylinder head on bed of hand press.
6.Position replacement valve guide to cylinder
head, ensuring that groove for valve stem seal
is facing away from cylinder head.
7.Position distance piece, toolLRT-12-515and
valve guide replacerLRT-12-046to valve
guide.
8.Press valve guide into cylinder head until
distance piece contacts face of head; remove
tools.
9.Allow cylinder head to air cool.Valve seat inserts - refacing
CAUTION: Prior to refacing valve seats,
check valve head stand down. If, after
refacing, valve head stand down will be
below limits, seat inserts must be replaced.
1.Support cylinder head on its side on suitable
blocks of wood.
2.Loosely assemble pilot, toolLRT-12-502and
a suitable expandable collet, ensuring that
chamfered end of expander is towards the
collet.

ENGINE
OVERHAUL27
Valves and springs - refit
1.Lubricate valve stems, guides, spring seats,
valve springs, spring cups and collets with
engine oil.
2.Lubricate new valve stem oil seals with engine
oil and fit to valve guides.
3.Fit spring seat, insert valve into its respective
guide, fit valve spring and spring cup.
4.Compress valve spring using toolLRT-12-034
and fit collets.
5.Remove toolLRT-12-034.
6.Tap spring cup with a soft mallet to ensure that
collets are correctly seated.
7.Repeat above procedures for remaining
valves.Cylinder head gasket selection
CAUTION: New cylinder head gasket
should be same thickness as the original.
If, however, cylinder head, pistons or
crankshaft have been replaced, it will be
necessary to check piston stand proud in order
to determine the correct thickness of gasket.
1.Position a magnetic base DTI to cylinder block
top face adjacent to number 1 cylinder bore.
2.Position stylus of gauge to cylinder block top
face on edge of number 1 cylinder bore; zero
gauge.
3.Rotate crankshaft in a clockwise direction until
numbers 1 and 4 pistons are at TDC.
4.Position stylus of DTI gauge near edge of
piston crown, measure and record number 1
piston stand proud. Measurement must be
taken at front and rear of piston and highest
protrusion figure recorded.
5.Repeat above procedures for remaining
pistons.