2002 LAND ROVER DISCOVERY engine

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 - TD5
12-1-104 OVERHAUL
11.Using suitably padded levers, move crankshaft
rearwards and zero DTI.
12.Move crankshaft forwards and note end-float
reading on gauge:
lCrankshaft end-float = 0.02 to 0.025 mm
(0.001 to 0.11 in)
CAUTION: Oversize thrust washers are
not available, if end-float exceeds figure
given, crankshaft must be replaced.
13.Remove DTI.
14.Fit connecting rod bearings.

+ ENGINE - Td5, OVERHAUL,
Bearings - connecting rods.
15.Fit timing chain and sprockets.

+ ENGINE - Td5, OVERHAUL, Timing
chain and sprockets.
16.Fit crankshaft rear oil seal.

+ ENGINE - Td5, OVERHAUL, Seal -
crankshaft - rear - manual models.

ENGINE - V8
DESCRIPTION AND OPERATION 12-2-1
ENGIN E - V 8 DESCRIPTION AND OPERAT ION
V8 Engine

ENGINE - V8
12-2-2 DESCRIPTION AND OPERATION
Cylinder head components

ENGINE - V8
DESCRIPTION AND OPERATION 12-2-3
1Split pin
2Washers
3Spring
4Rocker arm
5Pedestal bolt
6Pedestal
7Push rod
8Hydraulic tappet
9Rocker shaft
10Cylinder head - left hand
11Gasket - rocker cover
12Rocker cover - left hand
13Bolt - rocker cover
14Valve spring cap
15Valve stem oil seals
16Collets
17Valve spring18Bolt - engine lifting bracket
19Engine lifting bracket
20Valve seat insert
21Exhaust valve
22Clamp - inlet manifold gasket
23Seal - inlet manifold gasket
24Bolt - inlet manifold gasket clamp
25Gasket - inlet manifold
26Inlet valve
27Gasket - cylinder head
28Gasket - exhaust manifold
29Cylinder head - right hand
30Spark plug
31Bolt - cylinder head
32Valve guide
33Rocker cover - right hand
34Engine oil filler cap

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