LAND ROVER DISCOVERY 1995 Service Repair Manual

ENGINE
26
OVERHAUL Lapping-in valves
1.Lap each valve to its seat using grinding paste.
2.Apply Prussian Blue to valve seat insert. Insert
valve into guide and press it firmly, without
rotating on to seat.
3.Remove valve and check that a continuous,
even line of Prussian Blue has been
transferred to valve face, continue lapping-in
valve as necessary.
NOTE: Line does not have to be across
whole width of valve face.
4.Remove all traces of grinding paste on
completion.
5.Check valve head stand down of each valve.Valve head stand down - checking
1.Insert each valve into its respective guide.
2.Using a straight edge and feeler gauges, check
and record stand down of each valve head.
3.Compare figures obtained with those given
below. If any valve head has a stand down
outside that specified, valve and/or seat insert
must be replaced.
Valve head stand down:
Inlet valveA= 0.81 to 1.09 mm
Exhaust valveB= 0.86 to 1.14 mm

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.

ENGINE
28
OVERHAUL 6.From all of the readings obtained, determine
highest protrusion figure and select the
appropriate cylinder head gasket.
Protrusion 0.50 to 0.60 mm - select gasket with
1 identification hole.
Protrusion 0.61 to 0.70 mm - select gasket with
2 identification holes.
Protrusion 0.71 to 0.80 mm - select gasket with
3 identification holes.
Protrusion 0.81 to 0.90 mm - select gasket with
0 identification holes.
NOTE: Identification holes are located on
the edge of the gasket.
7.Remove DTI.
8.Rotate crankshaft in a clockwise direction until
all pistons are half-way up cylinder bores.Cylinder head - refit
1.Ensure that mating faces of cylinder head and
block are clean and dry and that 2 locating
dowels are fitted in cylinder block.
2.Lubricate threads of new cylinder head bolts
with engine oil.
3.Check that cylinder head bolt holes in cylinder
block are clean and dry.
4.Rotate crankshaft in a clockwise direction until
pistons are half-way up cylinder bores.
5.Position the selected cylinder head gasket on
cylinder block ensuring that word "TOP" is
facing upwards.
6.Using assistance, fit cylinder head ensuring
that it is located on dowels.

ENGINE
OVERHAUL29
7.Fit cylinder head bolts of the correct length in
positions shown.
CAUTION: Do not drop bolts into cylinder
block.
8.Tighten bolts until bolt heads just contact
cylinder head.
9.Using sequence shown, tighten cylinder head
bolts to 40 Nm.

ENGINE
30
OVERHAUL
10.Assemble degree plateLRT-12-007to a
torque wrench or extension bar.
11.Make a suitable pointer from welding rod and
attach it to the rocker shaft pedestal bolt hole
adjacent to number 1 cylinder head bolt.
12.Using sequence shown, tighten cylinder head
bolts a further 60°.
NOTE: Re-position the pointer as
necessary to enable degree of tightening
to be measured.
13.Using sequence shown, tighten each bolt a
further 60°.
CAUTION: Bolts must be tightened in
sequence 60°at a time - never 120°in one
operation.
14.Using sequence shown, tighten bolts numbers
1, 2, 7, 8, 9, 10, 15, 16, 17 and 18 a further
20°.
15.Remove pointer.
16.Position a new thermostat housing gasket to
cylinder head.
17.Fit thermostat housing, fit bolts and tighten to
25 Nm.
18.Position thermostat in housing.
19.Fit coolant outlet elbow, fit bolts and tighten to
25 Nm.
20.Position engine front lifting bracket to cylinder
head, fit 2 bolts and tighten to 25 Nm.
21.Fit fuel injectors.
22.Fit glow plugs.
23.Fit rocker shaft assembly.

ENGINE
OVERHAUL31
TIMING BELT REAR COVER AND OIL PUMP
Timing belt rear cover - remove
1.Remove timing belt, tensioner and gears.
2.Remove fuel injection pump.
3.Remove sump and oil pick-up pipe.
4.Using sequence shown, progressively slacken
then remove bolts securing timing belt rear
cover; remove cover.
5.Remove and discard gasket.
6.Remove and discard camshaft and crankshaft
front oil seals.Oil pump and oil pressure relief valve - remove
Oil pump
1.Make suitable alignment marks between oil
pump and timing belt rear cover.
2.Progressively slacken then remove 7 screws
securing oil pump cover.
3.Remove oil pump cover.
4.Make suitable alignment marks between oil
pump inner and outer rotors and outer rotor
and timing belt rear cover.

ENGINE
32
OVERHAUL Oil pressure relief valve
1.Remove plug retaining oil pressure relief valve.
2.Withdraw spring and plunger.Inspecting components
1.Check rotor clearances.
A- Outer rotor to housing = 0.025 to 0.075 mm
B- Inner rotor to outer rotor = 0.025 to 0.075
mm
C- Rotor end-float = 0.026 to 0.135 mm
2.Remove inner and outer rotors.
3.Check rotors for damage, wear and scoring.
4.Check oil pump cover for wear and scoring.
5.Check oil pressure relief valve spring free
length is 68.0 mm.
6.Check plunger and relief valve bore for wear
and scoring.
7.Clean all traces of sealant from oil pump cover
using solvent from kit GUG 705548GM.
8.Remove all traces of sealant from relief valve
plug threads in oil pump body.
CAUTION: Do not use a tap.

ENGINE
OVERHAUL33
Oil pump and oil pressure relief valve - refit
Oil pump
1.Thoroughly clean timing belt rear cover,
remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
Remove all traces of sealant using solvent
from kit GUG 705548GM.
2.Ensure oil pump cover screw holes are clean
and dry.
3.Clean oil pump rotors and recess, lubricate
rotors and recess with engine oil.
CAUTION: Ensure alignment marks made
during dismantling are not erased.
4.Position inner and outer rotors in housing
ensuring that reference marks are aligned.
5.Apply bead of sealant from kit to outer edge of
oil pump cover, fit cover to housing ensuring
that reference marks are aligned.
6.Fit oil pump cover, fit and progressively tighten
7 screws.
7.Check that pump rotates freely.Oil pressure relief valve
1.Thoroughly clean oil pressure relief valve
plunger, spring and relief valve bore then
lubricate components with engine oil.
2.Insert plunger and spring into bore.
3.Smear threads of relief valve plug with Loctite
577.
4.Fit plug and tighten to 17 Nm.

ENGINE
34
OVERHAUL Timing belt rear cover - refit
1.Remove all traces of gasket material from
cylinder block using suitable gasket removal
spray and a plastic scraper.
2.Screw 2 slave guide studs into cylinder block.
3.Fit new gasket over guide studs.
4.Note position of oil pump drive flats on
crankshaft.
5.Rotate oil pump inner rotor to align with drive
flats on crankshaft and position timing belt rear
cover on guide studs.
6.Fit timing belt rear cover.
CAUTION: Do not remove guide studs at
this stage.
7.Fit 8 bolts of the correct length in positions
shown, remove guide studs and fit remaining 2
bolts.

ENGINE
OVERHAUL35
8.Using sequence shown, tighten bolts to 25 Nm.
9.Fit oil pick-up pipe and sump.
10.Lubricate a new crankshaft front oil seal with
engine oil.
11.Fit oil seal using toolLRT-12-079.
12.Lubricate a new camshaft oil seal with engine
oil.
13.Fit oil seal using toolLRT-12-082.
14.Fit fuel injection pump.
15.Fit timing belt, tensioner and gears.