1995 LAND ROVER DISCOVERY engine

ENGINE
OVERHAUL53
9.Position selected shims, spacer and drive plate
to crankshaft.
NOTE: Dowel located.
10.Fit and finger tighten 8 bolts.
NOTE: Locking plate is no longer required.
11.Restrain crankshaft using toolLRT-12-080
and tighten drive plate bolts to 146 Nm.
12.Remove toolLRT-12-080and crankshaft
pulley.FLYWHEEL/DRIVE PLATE HOUSING
Remove
1.Remove flywheel/drive plate.
NOTE: Flywheel housing illustrated.
2.Remove 2 bolts securing top of housing to
cylinder block.
3.Remove 4 bolts securing housing to engine
mountings.
4.Progressively slacken then remove 6 bolts
securing housing to cylinder block.
5.Remove housing.

ENGINE
54
OVERHAUL Refit
1.Remove all traces of sealant from mating faces
of housing and cylinder block using solvent
from kit GUG 705548GM.
2.Apply a bead of sealant from kit to cylinder
block.
3.Position housing to cylinder block.
4.Fit and finger tighten bolts.
5.Using sequence shown, tighten bolts to 45 Nm.
NOTE: If engine mounting bolts were not
fitted, omit bolts 8, 10, 11 and 12 from
tightening sequence and re-number
accordingly.
6.Fit flywheel/drive plate.

ENGINE
OVERHAUL55
CRANKSHAFT, CAMSHAFT, PISTONS AND
CYLINDER BLOCK
1.Remove timing belt rear cover.
2.Remove flywheel/drive plate housing.
3.Remove fuel lift pump.
4.Remove cylinder head.
5.Remove sump, oil pick-up and drain pipes.
6.Remove oil filter head.
7.Remove brake servo vacuum pump.Crankshaft rear oil seal - remove
1.Remove 5 bolts securing rear oil seal housing
to cylinder block.
2.Remove and discard oil seal and housing.
3.
Early engines:Remove and discard 'O' ring.
4.Remove and discard gasket.

ENGINE
56
OVERHAUL Big-end bearings - remove
1.Suitably identify each oil jet tube to its fitted
location.
2.Remove bolt securing each oil jet tube
assembly to cylinder block.
3.Remove oil jet tube assemblies.
NOTE: Dowel located.
4.Recover sealing washers.
CAUTION: Oil jet tube bolts incorporate a
non-return valve.
5.Temporarily fit crankshaft pulley bolt.
6.Suitably identify fitted position of each big-end
bearing cap to its connecting rod and each
connecting rod to its respective cylinder bore.
7.Rotate crankshaft to bring numbers 1 and 4
connecting rods to BDC.
8.Remove and discard 2 nuts securing each
big-end bearing cap.
9.Remove numbers 1 and 4 big-end bearing
caps, recover bearing shells.
10.Slide suitable pieces of plastic tubing over
each connecting rod bolt.
11.Push numbers 1 and 4 connecting rods up
cylinder bores until they are clear of crankshaft
journals.
12.Repeat above procedures to remove numbers
2 and 3 big-end bearings.
CAUTION: Big-end bearing shells must
always be replaced.

ENGINE
OVERHAUL57
Crankshaft and main bearings - remove
1.Suitably identify each main bearing cap and its
fitted direction in crankcase.
2.Starting at number 3 main bearing cap and
working outwards, progressively slacken, then
remove bearing cap bolts. Keep bolts with their
respective main bearing caps.
3.Using the fingers only, rock each main bearing
cap until it is released from its retaining dowels.
CAUTION: Do not tap main bearing caps
sideways to release.
4.Remove and discard oil seals from number 5
main bearing cap.
5.Recover lower main bearing shells from
bearing caps.
6.Using assistance, remove crankshaft.7.Recover grooved thrust washers and upper
main bearing shells.
CAUTION: Main bearing shells and thrust
washers must always be replaced.
8.Remove pistons and connecting rods.

ENGINE
58
OVERHAUL Crankshaft - inspection
NOTE: Crankshafts may be reground 0.25
mm undersize on both main and big-end
journals.
See Crankshaft - regrinding.
1.Clean crankshaft and main bearing caps,
ensure oilways are clear.
2.Check main and big-end journals for signs of
scoring, excessive wear and overheating.
3.Check main and big-end bearing journals for
wear and ovality, make 3 checks at 120
°intervals in centre of journals.
Maximum ovality = 0.040 mm
Main bearing journal diameter = 63.475 to
63.487 mm
Service limit = 63.36 mm
Regrind diameter = 63.225 to 63.237 mm
Big-end bearing journal diameter = 58.725 to
58.744 mm
Service limit = 58.637 mm
Regrind diameter = 58.475 to 58.494 mm
4.If bearing journal diameters are less than
service limit, crankshaft may be reground to
specified regrind diameter and 0.25 mm
oversize bearing shells fitted.
5.Using a micrometer, measure diameter at each
end of main and big-end bearing journals.
6.From measurements obtained, calculate taper
of each journal.
Maximum journal taper - end to end = 0.025
mm
7.Support each end of crankshaft in Vee blocks.
8.Position a DTI with stylus contacting centre
main bearing journal.
9.Rotate crankshaft and check run-out does not
exceed 0.076 mm.
CAUTION: If run-out exceeds above figure,
renew crankshaft.

ENGINE
OVERHAUL59
Crankshaft - regrinding
NOTE: Crankshaft journals may be
reground to the following dimensions.
Main bearing journals = 63.225 to 63.237 mm
Big-end bearing journals = 58.475 to 58.494 mm
CAUTION: Rotation of crankshaft must be
in an ANTI-CLOCKWISE direction when
viewed from flywheel end of crankshaft.
1.Grind journals ensuring that grinding wheel
travels beyond edge of journalAto avoid
formation of a stepB.
CAUTION: Take care not to damage fillet
radius C.
2.Final finishing should be carried out using a
static lapping stone with crankshaft rotating in
a CLOCKWISE direction when viewed from
flywheel end of crankshaft.
3.On completion of grinding operations,
thoroughly clean crankshaft ensuring that all oil
passages are clear.Main bearing caps and saddles - inspection
1.Ensure main bearing cap bolts and bolt holes
are clean and dry.
2.Fit each main bearing cap less bearing shells
to its correct location ensuring that direction
marks on cap are facing the correct way.
3.Fit and tighten each pair of main bearing cap
bolts to 133 Nm.
4.Slacken the bolt on one side of each main
bearing cap.
5.Using feeler gauges, check that there is no gap
between each main bearing cap and saddle on
the side of the cap with the slackened bolt.
6.If a gap exists, replace main bearing cap and
re-check.
7.If gap still exists, cylinder block must be
replaced.
CAUTION: Do not attempt to machine
main bearing caps or saddles.
8.Remove main bearing caps.
CAUTION: Keep main bearing cap bolts
with their respective caps.

ENGINE
60
OVERHAUL Main bearing clearance - checking
CAUTION: If crankshaft has been
reground, oversize main bearing shells
must be fitted.
1.Degrease new main bearing shells and ensure
all traces of oil are removed from crankshaft
journals.
2.Fit new main bearing shells to saddles and
main bearing caps ensuring that tags are
located in recesses in saddles and bearing
caps.
NOTE: Number 5 main bearing shells are
wider than numbers 1 to 4.
3.Using assistance, fit crankshaft.
4.Place a piece of Plastigage across width of
each main journal.
5.Fit main bearing caps to their correct location
ensuring that direction marks are facing the
correct way; fit each pair of main bearing cap
bolts and tighten to 133 Nm.
CAUTION: Do not rotate crankshaft.
6.Remove main bearing caps and bearing shells.
CAUTION: Retain main bearing shells and
cap bolts with their respective main
bearing caps.
7.Measure widest portion of Plastigage on each
main bearing journal using the scale supplied;
the graduation that corresponds to the widest
portion of Plastigage indicates main bearing
clearance.
Main bearing clearance = 0.031 to 0.079 mm8.If main bearing clearances are incorrect, use a
combination of standard and oversize main
bearing shells and re-check clearances.
CAUTION: Keep main bearing shells
selected in their fitted order.
9.Remove all traces of Plastigage using an oily
rag.
10.Using assistance, remove crankshaft.
11.Remove upper main bearing shells and keep in
their fitted order.