2002 LAND ROVER DISCOVERY ESP

ENGINE - TD5
OVERHAUL 12-1-79
24.Compare figures obtained with camshaft
bearing clearance:
lCamshaft bearing clearance = 0.04 to 0.10
mm (0.002 to 0.004 in)
25.If any bearing clearance is found to exceed
figures given, repeat the above procedures
using a new camshaft. If, after repeating the
clearance check using a new camshaft the
clearances are still excessive, a new cylinder
head and camshaft carrier assembly must be
fitted.
26.Remove all traces of Plastigage using an oily
cloth, do not use a scraper.
27.On completion, discard camshaft carrier bolts.
28.Check free length of valve springs:
lFree length = 46.75 to 47.25 mm (1.84 to
1.86 in)
29. Replace valve springs as a set, if springs
are to be refitted, keep them in their fitted
order.
30.Clean carbon from valves, check valves for
burning, pitting or cracking; replace as
necessary.
31.Clean carbon from valve seat inserts, remove
all loose particles on completion.
32.Check valve seat inserts for pitting and burning.
It is not permissible to recut or replace valve
seat inserts.
33.Remove carbon deposits from valve guides
using tool LRT-12-186 inserted from the
combustion chamber face side of cylinder
head. Ensure all loose particles of carbon are
removed on completion.
34.Check and record diameter of each valve stem:
lValve stem diameter - Inlet = 6.907 to 6.923
mm (0.2719 to 0.2725 in)
lValve stem diameter - Exhaust = 6.897 to
6.913 mm (0.2715 to 0.2721 in)35.Renew any valve if stem diameter is less than
specified.
36.Check and record valve stem to guide
clearance using the following procedures.
37.Insert each valve into its respective guide.
38.Extend valve head 10 mm (0.375 in) out of
valve seat and position a DTI gauge to rear of
valve head.
39.Move valve towards front of cylinder head and
zero DTI gauge ensuring that stylus of gauge
remains in contact with valve head.
40.Move valve towards rear of cylinder head,
record gauge reading to give valve stem to
guide clearance:
lInlet valve = 0.025 to 0.059 mm (0.0009 to
0.0023 in)
lExhaust valve = 0.035 to 0.069 mm (0.0013
to 0.0027 in)
41.If stem to guide clearance exceeds figures
given and valve stem diameters were as
specified, cylinder head assembly must be
replaced; it is not possible to replace valve
guides.
42.Repeat above procedures for remaining valves.
Keep valves in their fitted order.
43.Check face angle of each valve, renew any
valve with incorrect face angles, do not attempt
to recut.
lValve face angle - inlet = 29
° 48' ± 12'
lValve face angle - exhaust = 44
° 48' ± 12'
44.Lap each valve to its seat using grinding paste.
45.Apply Prussion Blue to valve seat, insert valve
into guide and press it firmly, without rotating
on to seat.
46.Remove valve and check that a continuous,
even line of Prussian Blue has been
transferred on to valve face. Note that line
does not have to be across whole width of
valve face.
47.Remove all traces of grinding paste on
completion.
48.Check valve head stand down using the
following procedures.

ENGINE - TD5
12-1-80 OVERHAUL
49.Insert each valve into its respective guide.
50.Using a straight edge and feeler gauges, check
and record stand down of each valve head.
51.Compare figures obtained with those given
below:
lValve head stand down - Inlet valve A =
0.555 to 0.825 mm (0.022 to 0.032 in)
lValve head stand down - Exhaust valve B =
0.545 to 1.35 mm (0.021 to 0.053 in)
52. If any valve has a stand down greater than
specified, repeat check using a new valve.
If, after checking with a new valve, stand
down is still excessive, cylinder head
assembly must be replaced. It is not
possible to replace valve seat inserts.53.Suitably identify each rocker arm to its fitted
position and type of rocker arm fitted.
NOTE:
lEngine Serial No. Prefixes 10P to 14P -
Type A rocker arms
lEngine Serial No. Prefixes 15P to 19P -
Type B rocker arms.
Type B rocker arms and shafts may be fitted to
Engine Serial No. Prefixes 10P to 14P as an
assembly.

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 - V8
12-2-64 OVERHAUL
10.Check the following valve dimensions. Renew
valves as necessary.
lValve head diameter 'A': Inlet = 39.75 to
40.00 mm (1.56 to 1.57 in).
lValve head diameter 'A': Exhaust = 34.23 to
34.48 mm (1.35 to 1.36 in).
lValve stem diameter 'B': Inlet = 8.664 to
8.679 mm (0.341 to 0.342 in).
lValve stem diameter 'B': Exhaust – 4.0 litre
engines up to engine nos. 55D 05677A; 56D
50787A and 97D 05504A = 8.651 to 8.666
mm (0.340 to 0.341 in).
lValve stem diameter 'B': Exhaust – 4.0 litre
engines from engine nos. 55D 05678A; 56D
50788A and 97D 05505A and all 4.6 litre
engines = 8.641 to 8.656 mm (0.340 to
0.341 in)
11.Check installed height of valve.
lValve installed height, end of valve to base
of spring seat, 'C' = 44.163 to 45.288 mm
(1.741 to 1.802 in).12.Check condition of valve springs. Valve
springs must be replaced as a complete
set.
lValve spring free length = 48.30 mm (1.90
in).
lValve spring fitted length = 40.40 mm (1.59
in).
l Spring load - valve closed = 339
± 10 N (76
± 2.25 lbf).
lSpring load - valve open = 736
± 10 N (166
± 2.25 lbf).
13.Check valve stem to guide clearance using the
following procedures:
14.Insert each valve into its respective guide.
15.Extend valve head approximately 13 mm (0.6
in) out of valve seat and position a DTI gauge
to rear of valve head.
16.Move valve towards front of cylinder head and
zero DTI gauge ensuring that stylus of gauge
remains in contact with valve head.
17.Move valve towards rear of cylinder head and
record gauge reading to give valve stem to
guide clearance.
l Valve stem to guide clearance 'D': Inlet =
0.025 to 0.066 mm (0.001 to 0.002 in).
l Valve stem to guide clearance 'D': Exhaust
– 4.0 litre engines up to engine nos. 55D
05677A; 56D 50787A; 97D 05504A = 0.038
to 0.078 mm (0.0015 to 0.003 in).
lValve stem to guide clearance 'D': Exhaust
– 4.0 litre engines from engine nos. 55D
05678A; 56D 50788A; 97D 05505A and all
4.6 litre engines = 0.048 to 0.088 mm
(0.0019 to 0.0035 in).
18.Renew valve guides as necessary.
19.Using valve guide remover tool LRT-12-037
press valve guide into combustion face side of
cylinder head.

ENGINE - V8
OVERHAUL 12-2-67
Piston assemblies
$% 12.17.02.01
Disassembly
1.Remove cylinder head.

+ ENGINE - V8, OVERHAUL, Gasket -
cylinder head.
2.Remove oil pick-up strainer

+ ENGINE - V8, OVERHAUL, Strainer
- oil pick-up.
3.Suitably identify each connecting rod and
piston assembly to its respective cylinder bore.
4.Remove 2 bolts securing each connecting rod
bearing cap.
5.Remove connecting rod bearing cap and
collect connecting rod bearings.
6.Remove ridge of carbon from top of cylinder
bores.
7.Carefully push each piston assembly from the
top of the cylinder.
CAUTION: Ensure that connecting rods do
not contact cylinder bores.
8.Refit bearing cap onto connecting rod, lightly
tighten dowel bolts.
9.Suitably identify each piston to its respective
connecting rod.10.Position body of tool LRT-12-013 in vice.
11.Screw large nut back until flush with end of
centre screw.
12.Push centre screw forward until nut contacts
thrust race.
13.Fit piston adapter tool LRT-12-126/2 .
14.Position guide pin tool LRT-12-126/3 in LRT-
12-126/2 with groove facing away from piston.
15.Locate piston and connecting rod assembly on
centre screw and up to adapter tool LRT-12-
126/2.
16.Fit remover/replacer bush tool LRT-12-126/1
on centre screw with flanged end facing away
from gudgeon pin.
17.Screw stop nut onto centre screw leaving
clearance of 3 mm (0.125 in), dimension 'A',
between nut and remover/replacer bush.
18.Lock the stop nut securely with lock screw.
19.Push connecting rod to locate end of gudgeon
pin in adapter tool LRT-12-126/2.
20.Ensure remover/replacer is located in gudgeon
pin bore of piston.
21.Screw large nut up to tool LRT-12-013.
22.Hold lock nut and turn large nut until gudgeon
pin is withdrawn from piston.
23.Dismantle tool and remove piston, connecting
rod and gudgeon pin.

ENGINE - V8
12-2-70 OVERHAUL
23.Fit 2nd compression ring marked 'TOP' with
marking uppermost in 2nd groove.
24.Fit 1st compression ring in first groove either
way round.
25.Check piston ring to groove clearance.
l1st compression ring = 0.05 to 0.10 mm
(0.002 to 0.004 in).
l2nd compression ring = 0.05 to 0.10 mm
(0.002 to 0.004 in).
26.Position oil control expander ring joint and ring
rail gaps all at one side, between gudgeon pin
and away from LH side of piston - viewed from
front of piston. Position the gaps in ring rails
approximately 25 mm (1.0 in) each side of
expander ring joint.
27.Position compression rings with gaps on
opposite side of piston between gudgeon pin
and RH side of piston - viewed from front of
piston.
28.Thoroughly clean cylinder bores.
29.Lubricate piston rings and gudgeon pin with
clean engine oil.
30.Lubricate cylinder bore with clean engine oil.
31.Using LRT-12-204, compress piston rings. 32.Insert connecting rod and piston into its
respective cylinder bore, ensuring domed
shaped boss on connecting rod faces towards
front of engine on RH bank of cylinders and
towards rear on LH bank of cylinders.
33.Clean connecting rod journal and bearing cap.
34.Lubricate connecting rod journal and
connecting rod bearings.
35.Fit connecting rod bearings and connecting rod
bearing caps ensuring they are in their correct
fitted order.
NOTE: The rib on the edge of the bearing cap
must face towards the front of the engine on the
RH bank of cylinders and towards the rear on
the LH bank.
36.Fit bolts and tighten to 20 Nm (15 lbf.ft) then
turn a further 80
°.
37.Fit oil pick-up strainer.

+ ENGINE - V8, OVERHAUL, Strainer
- oil pick-up.
38.Fit cylinder head gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
cylinder head.