2002 LAND ROVER DISCOVERY lock

ENGINE - TD5
12-1-98 OVERHAUL
Pistons, connecting rods and cylinder
bores
$% 12.17.02.03
Disassembly
1.Remove cylinder head gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.
2.Remove connecting rod bearings.

+ ENGINE - Td5, OVERHAUL,
Bearings - connecting rods.
3.Remove ridge of carbon from top of cylinder
bore.
4.Suitably identify each piston and connecting
rod assembly to its respective cylinder bore.
5.Carefully push connecting rod to top of cylinder
bore taking care that connecting rod does not
contact oil squirt jet or cylinder wall; remove
each piston and connecting rod in turn.
6.Using a suitable expander, remove and discard
piston rings from pistons.
7.Clean carbon from piston crown and skirt. Do
not use abrasives on graphited area of
piston skirt, do not use a wire brush or
scraper on any part of pistons.
8.Secure connecting rod in a soft jawed vice.
9.Suitably identify each piston to its connecting
rod and fitted position of piston on rod.
10.Using suitable circlip pliers, remove and
discard 2 circlips securing gudgeon pin.
11.Push gudgeon pin out of piston and connecting
rod; remove piston.
12.Suitably identify each gudgeon pin to its
respective piston.
13.Repeat above procedures for remaining
pistons. Inspect
1.Measure cylinder bore for wear at a point 70
mm (2.75 in) from top of cylinder bore:
Measurement must be taken from side to
side and front to rear.
lCylinder bore diameter = 84.460 to 84.442
mm (3.325 to 3.324 in)
CAUTION: Cylinder bore and ovality must
be within the limits given above, no
reboring, honing or de-glazing of
cylinder bores is permissible; cylinder
block must be replaced if bores are worn
or excessively scored.
2.Check piston for cracks, burning and damage.
3.Check connecting rods for alignment. Do not
attempt to straighten misaligned
connecting rods. Ensure small-end
lubrication holes in connecting rods are
clear.
4.Measure and record diameter of each piston at
right angles to gudgeon pin axis and 46 mm
(1.81 in) from bottom of skirt
lPiston diameter = 84.262 mm
± 0.009 mm
(3.317 in
± 0.0003 in)
CAUTION: Measurement point must be on
the ungraphited area of the piston.

ENGINE - TD5
OVERHAUL 12-1-99
5.Starting with No.1 piston, invert piston and with
arrow on piston crown pointing towards REAR
of cylinder block, insert piston into No.1
cylinder bore.
6.Position piston with bottom of skirt 25 mm (1.0
in) from top of cylinder bore.
7.Using feeler gauges, measure and record
clearance between piston skirt and LEFT
HAND side of cylinder bore 60 mm (2.4 in)
from top of bore:
lPiston to cylinder bore clearance = 0.171 to
0.207 mm (0.007 to 0.008 in)
8.Repeat above procedures for remaining
pistons.
CAUTION: Oversize pistons are not
available, if piston to cylinder bore
clearance exceeds limits given, repeat
check using a new piston; if clearances are
still excessive, replace cylinder block.
Pistons and lst compression rings fitted to
Engine Serial No. Prefixes 15P to 19P may
be fitted to Engine Serial No. Prefixes 10P to
14P in engine sets only.
9.Check fit of each gudgeon pin in its respective
piston, pin must be a tight, sliding fit with no
perceptible side play.10.Measure gudgeon pin diameter at each end
and side of pin.
CAUTION: Renew gudgeon pin and piston
as an assembly if diameters are less than
specified or if excessive pin to piston side
play is evident.
lGudgeon pin diameter = 29.995 to 30.000
mm (1.180 to 1.181 in)
11.Check connecting rod small end bushes for
wear, check that gudgeon pin is a sliding fit in
bush with no perceptible side play.
CAUTION: Small end bushes cannot be
replaced, a new connecting rod must be
fitted.

ENGINE - TD5
12-1-100 OVERHAUL
12.Insert new compression and oil control rings in
turn into No.1 cylinder bore 30 mm (1.25 in)
from top of bore and check ring fitted gaps;
ensure rings are kept square to bore when
checking gaps:
l1st compression ring fitted gap = 0.30 to
0.40 mm (0.012 to 0.016 in).
l2nd compression ring fitted gap = 0.40 to
0.60 mm (0.016 to 0.024 in).
lOil control ring fitted gap = 0.25 to 0.50 mm
0.01 to 0.02 in).
CAUTION: 1st compression rings fitted to
Engine Serial No. Prefixes 10P to 14P are
not interchangeable with those fitted to
Engine Serial No. Prefixes 15P to 19P. The
later rings may, however, be fitted to early
engines together with the later type pistons
in engine sets only.
13.Repeat for each cylinder bore in turn.
CAUTION: Ensure rings are suitably
identified with the cylinder bore in which
they were checked and are fitted to the
piston for that bore.
14.Fit oil control expander and ring to piston.
15.Fit 2nd compression ring with 'TOP' marking
upwards. 16.Fit 1st compression ring with 'TOP' marking
upwards.
17.Check piston ring to groove clearance:
l1st compression ring = Not measured
l2nd compression ring = 0.050 to 0.082 mm
(0.02 to 0.003 in)
lOil control ring = 0.050 to 0.082 mm (0.02 to
0.003 in)
Reassembly
1.Lubricate gudgeon pin, gudgeon pin holes in
piston and small end bush with engine oil.
2.Position piston to connecting rod with arrow on
piston crown on the same side as the cast boss
on the connecting rod.
3.Fit gudgeon pin to its respective piston and
connecting rod; secure with new circlips
ensuring circlips are fully seated in their
grooves.
4.Repeat above procedures for remaining
pistons.
5.Lubricate piston rings and cylinder bores with
engine oil.
6.Check that rings are free to rotate, position ring
gaps at 120
° to each other and away from the
thrust, LEFT HAND side of piston - viewed
from front of piston.
7.Using a suitable ring clamp, compress piston
rings.
8.Insert connecting rod and piston into its
respective cylinder bore ensuring that the
arrow on piston crown and the cast boss on
connecting rod are facing towards the front of
the cylinder block.
9.Ensure that connecting rod does not contact
cylinder bore or oil squirt jet. Do not pull
connecting rod fully down cylinder bore at this
stage.
10.Check that cut-out in piston skirt is positioned
above oil squirt jet.

ENGINE - TD5
OVERHAUL 12-1-101
11.Repeat above procedures for other pistons in
turn ensuring that pistons and connecting rods
are fitted in cylinder bores from which they
were removed.
12.Fit connecting rod bearings.

+ ENGINE - Td5, OVERHAUL,
Bearings - connecting rods.
CAUTION: If new pistons, connecting rods
or crankshaft have been fitted, it will be
necessary to select correct thickness of
cylinder head gasket using the following
procedures:
13. There are three thicknesses of cylinder
head gasket available and in order that the
correct gasket is fitted, it is necessary to
determine the stand proud (protrusion) of
each piston above the top face of the
cylinder block. Gaskets have either 1, 2 or 3
identification holes and the following
procedures must be followed in order that
the correct gasket is selected.
14.Temporarily fit and lightly tighten new
crankshaft pulley bolt. 15.Assemble a magnetic base DTI to cylinder
block top face adjacent to No.1 cylinder bore.
16.Position stylus to cylinder block top face and
zero gauge.
17.Using crankshaft pulley bolt, rotate crankshaft
in a clockwise direction until No. 1 piston is at
TDC - Woodruff key slot in crankshaft is at 12
o'clock.
18.Position stylus of DTI at rear edge of piston and
directly over gudgeon pin axis.
19.Measure and record No.1 piston protrusion.
20.Repeat measurement at front edge of piston.
21.Establish average of 2 readings taken.
22.Repeat above procedures for remaining
pistons.
23.From readings obtained, determine HIGHEST
piston protrusion figure and select the
appropriate cylinder head gasket:
lPiston protrusion = 0.351 to 0.50 mm (0.014
to 0.02 in) select the 2 hole gasket
lPiston protrusion = 0.501 to 0.57 mm (0.021
to 0.022 in) select the 1 hole gasket
lPiston protrusion = 0.571 to 0.65 mm (0.022
to 0.025 in) select the 3 hole gasket
24.Remove the DTI.
25.Remove and retain crankshaft pulley bolt.
26.Fit cylinder head gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.

ENGINE - TD5
12-1-102 OVERHAUL
Crankshaft
$% 12.21.33.01
Disassembly
1.Remove timing chain and sprockets.

+ ENGINE - Td5, OVERHAUL, Timing
chain and sprockets.
2.Remove crankshaft rear oil seal.

+ ENGINE - Td5, OVERHAUL, Seal -
crankshaft - rear - manual models.
3.Remove connecting rod bearings.

+ ENGINE - Td5, OVERHAUL,
Bearings - connecting rods.
4.Check that cylinder reference number is on
each main bearing cap and make alignment
marks between each main bearing cap and
cylinder block.
5.Starting at No.3 main bearing cap and working
outwards, progressively loosen, then remove 2
bolts securing each cap. Discard main bearing
cap bolts. 6.Fit 2 slave bolts into main bearing cap in turn
and ease bearing caps from cylinder block.
7.Remove and discard plain bearing shells from
each main bearing cap.
8.Using assistance, remove crankshaft.
9.Remove and discard grooved main bearing
shells and 2 thrust washers from cylinder
block.
10.Remove Torx screw securing each oil squirt jet
to cylinder block, remove squirt jets.
11.Clean main bearing shell and thrust washer
locations in cylinder block, ensure bolt holes
are clean and dry.
12.Clean main bearing caps.
13.Clean crankshaft bearing journals, check
oilways are clear.
14.Ensure drillings in oil squirt jets are clear.

ENGINE - TD5
OVERHAUL 12-1-103
15.Check core plugs in cylinder block for corrosion
or signs of leakage, seal replacement plugs
with Loctite 243.
Crankshaft - Inspection
1.Check crankshaft main and big-end bearings
for scoring, wear and ovality, make 3 checks at
120
° intervals in centre of journals.
lMain bearings = 62.0 mm
± 0.013 mm
(2.441 in
± 0.001 in).
lBig-end bearings = 54.000 mm
± 0.01 mm
(2.125 in
± 0.0004 in).
2. Crankshafts may not be reground, only one
size of main and big-end bearing shell is
available and if journals are found to be
scored, oval or worn, crankshaft must be
replaced. Main and big-end bearing shells
and thrust washers must be replaced
whenever they are removed.
3.Check crankshaft spigot bush for wear, replace
if necessary using the following procedures:
4.Secure crankshaft in a suitably padded vice.
5.Tap a thread in spigot bush to accommodate a
suitable impulse extractor.
6.Fit impulse extractor to spigot bush.
7.Remove spigot bush.
8.Clean spigot bush recess in crankshaft.
9.Fit new spigot bush to crankshaft using a
suitable mandrel. Reassembly
1.Fit oil squirt jets, fit Torx screws and tighten to
8 Nm (6 lbf.ft).
2.Lubricate new, grooved, main bearing shells
with engine oil and fit to cylinder block.
3.Lubricate new thrust washers with engine oil
and fit, grooved side facing outward, to recess
in each side of No.3 main bearing in cylinder
block.
4.Lubricate crankshaft journals with engine oil
and using assistance, position crankshaft in
cylinder block.
5.Lubricate new, plain, main bearing shells with
engine oil and fit to main bearing caps.
6.Fit main bearing caps in their original fitted
positions ensuring reference marks are
aligned.
7.Fit and lightly tighten new main bearing cap
bolts. Do not lubricate bolt threads.
8.Starting with No.3 main bearing cap and
working outwards, tighten main bearing cap
bolts to:
lStage 1 - 33 Nm (24 lbf.ft)
lStage 2 - Further 90
°
CAUTION: Do not carry out stages 1 and
2 in one operation.
9.Check that crankshaft rotates smoothly.
10. Attach a magnetic base DTI to front of cylinder
block with stylus of gauge on end of crankshaft.

ENGINE - V8
12-2-4 DESCRIPTION AND OPERATION
Cylinder block components

ENGINE - V8
DESCRIPTION AND OPERATION 12-2-5
1Core plugs
2Cylinder block
3Camshaft
4Dipstick tube, clamp and bolt
5Woodruff key
6Timing chain
7Camshaft timing gear
8Washer
9Bolt - camshaft timing gear
10Thrust plate - camshaft end-float
11Bolt - camshaft thrust plate
12Gasket - timing cover
13Timing cover
14Oil pressure switch
15Bolt
16Crankshaft front oil seal
17Oil filter element
18Crankshaft front pulley
19Washer
20Bolt - crankshaft front pulley
21Upper main bearing shell
22Upper centre main bearing shell and thrust
washer
23Crankshaft
24Woodruff key
25Crankshaft timing gear
26Lower main bearing shells
27Numbers 1, 2 and 3 main bearing caps
28Bolt - main bearing caps
29Oil pick-up pipe and strainer
30'O' ring31Bolt - oil pick-up pipe
32Gasket - sump
33Sump
34Bolt - sump
35Sump oil drain plug
36Sealing washer
37Spacer, washers and nut - oil pick-up pipe
38Number 4 main bearing cap
39Bolt - connecting rod big-end bearing cap
40Connecting rod big-end bearing shell - lower
41Connecting rod big-end bearing cap
42Number 5 - rear main bearing cap
43Cruciform seal - rear main bearing cap
44Number 5 - rear main bearing shell
45Crankshaft rear oil seal
46Crankshaft knock sensor
47Side bolt - main bearing cap
48Side Allen bolt - main bearing cap
49Dowty washers
50Connecting rod big-end bearing shell - upper
51Connecting rod
52Piston
53Gudgeon pin
54Oil control ring
55Top compression ring
562nd compression ring
57Flywheel/drive plate and starter ring gear
58Bolt - flywheel/drive plate