engine LAND ROVER DISCOVERY 1995 Service Repair Manual

ENGINE
OVERHAUL71
6.Check ring to groove clearances:
Top compression = 0.167 to 0.232 mm
2nd compression = 0.05 to 0.08 mm
Oil control rails = 0.05 to 0.08 mm
7.If new ring to groove clearances are excessive,
new pistons must be fitted.Oil jet tubes - inspection
1.Check that oil passage in each oil jet tube is
clear.
2.Thoroughly clean banjo bolts.
3.Insert a piece of stiff wire in end of banjo bolt
and check that non-return valve can be
depressed to open position and returns to
closed position under spring pressure.
CAUTION: If non-return valve is not
working correctly, replace banjo bolt.
4.Check sealing washers for damage, replace as
necessary.

ENGINE
72
OVERHAUL Pistons and connecting rods - refit
1.Position piston ring gaps at 60°to each other
and away from thrust side of piston (left hand
side of piston when viewed from front).
2.Slide suitable lengths of tubing over connecting
rod bolts.
3.Ensure cylinder bores are clean.
4.Lubricate pistons, rings and cylinder bores with
engine oil.
5.Compress piston rings using a suitable clamp.
6.Insert piston and connecting rod into cylinder
bore ensuring that piston is in its correct fitted
order and arrow on piston crown is towards
front of cylinder block.
7.Push piston into cylinder bore.
CAUTION: Ensure that connecting rods do
not contact cylinder bores. Do not pull
connecting rods fully down cylinder bores
at this stage.
8.Repeat above procedures for numbers 2 and 3
pistons and connecting rods.Oil jet tubes - refit
1.Position sealing washers in cylinder block.
2.Fit oil jet tubes to their original locations.
3.Fit banjo bolts and washers, tighten bolts to 17
Nm.

ENGINE
OVERHAUL73
Camshaft - remove
1.Remove oil jet tube.
2.Clean area around baffle plate.
3.Note fitted position of 3 bolts securing baffle
plate.
4.Remove 3 bolts securing baffle plate to
cylinder block, remove plate.
5.Remove and discard gasket.
CAUTION: Do not remove cam follower
guide retaining bolts until slides and
rollers have been removed, keep
components of each cam follower assembly in
their fitted order.
6.Using long nosed pliers, remove cam follower
slide.
7.Remove roller and suitably identify which side
of roller faces towards front of cylinder block.
8.Remove and discard bolt retaining cam
follower guide.
9.Remove cam follower guide.
10.Repeat above procedures for remaining cam
follower assemblies.

ENGINE
74
OVERHAUL
11.Remove 2 bolts securing camshaft thrust plate
to cylinder block, remove and discard plate.
12.Carefully withdraw camshaft taking care not to
drop end of camshaft on to bearings.Camshaft, bearings and cam followers -
inspection
1.Check camshaft cams and bearing journals for
overheating, wear and scoring, replace
camshaft if necessary.
2.If camshaft is replaced, new bearings must be
fitted.
3.Check timing gear drive pin for security.
4.Check camshaft bearings for overheating, wear
and scoring and that lubrication holes are
clear, replace as necessary. Bearings must be
replaced as a set.
5.Check cam follower slides, rollers and cam
follower guides for signs of wear.
6.Check that each slide moves freely in its guide
and that oilways are clear. Cam followers must
be replaced as an assembly.
7.Check that oil passage in oil jet tube is clear.
8.Insert a piece of stiff wire in end of oil jet tube
and check that non-return valve can be
depressed and closes under spring pressure.

ENGINE
OVERHAUL75
Camshaft - refit and check end-float
1.Remove all traces of gasket from baffle plate
and cylinder block using suitable gasket
removal spray and a plastic scraper.
2.Lubricate cams, journals and bearings with
engine oil.
3.Ensure thrust plate bolt holes in cylinder block
are clean and dry.
4.Carefully insert camshaft into cylinder block
taking care not to drop end of camshaft on to
bearings.
5.Fit a new thrust plate, fit bolts and tighten to 9
Nm.
6.Temporarily fit camshaft timing gear, fit and
tighten bolt sufficiently to pull gear fully on to
camshaft.
7.Attach a magnetic base DTI to front of cylinder
block with stylus of gauge contacting machined
face of gear adjacent to gear teeth.
8.Push camshaft fully rearwards and zero gauge.
9.Pull camshaft fully forwards and check that
end-float is between 0.1 and 1.2 mm.
10.If end-float exceeds 0.2 mm with new thrust
plate fitted, camshaft must be replaced.
11.Remove DTI and timing gear.
12.Fit oil jet tube and tighten to 17 Nm.
13.Lubricate components of each cam follower
with engine oil.
14.Lubricate cam follower bores with engine oil.

ENGINE
76
OVERHAUL
15.Insert each cam follower guide into its original
location in the cylinder block.
16.Fit new retaining bolt, locate end of bolt in cam
follower guide.
17.Tighten bolt to 14 Nm.
18.Fit roller ensuring that reference mark made
during removal is towards front of cylinder
block.
19.Fit cam follower slide ensuring that word
'FRONT' or mark 'F' is towards front of cylinder
block.
20.Repeat above procedures for remaining cam
follower assemblies.
21.Fit a dry, new gasket to baffle plate.
22.Fit baffle plate, fit 3 bolts and finger tighten in
their original locations.
23.Bolts are tightened when fuel injection pump is
fitted.Cylinder block - inspection
1.Thoroughly clean cylinder block, ensure all bolt
holes are clean and dry.
2.Remove all traces of carbon from cylinder head
gasket face.
3.Remove all traces of gaskets using suitable
gasket removal spray and a plastic scraper.
4.Check all studs for damage, replace as
necessary.
5.Check core plugs for corrosion and signs of
leakage, replace as necessary.
6.Using an internal micrometer, take 2
measurements at 90°to each other at top of
bore. The difference between the 2
measurements is the ovality of the bore.
Maximum ovality = 0.127 mm
7.Repeat measurements 50 mm from bottom of
each cylinder bore.
8.Measure from side to side from below wear
ridge at top of bore and above wear ridge at
bottom of bore. The difference between the 2
measurements is the taper.
Maximum taper = 0.254 mm

ENGINE
OVERHAUL77
9.Check cylinder bore overall wear, measure at
several points from side to side, the largest
diameter recorded is the maximum wear.
Cylinder bore - standard = 90.47 mm
1st rebore oversize = 90.73 mm
2nd rebore oversize = 90.98 mm
Maximum wear = 0.177 mm
CAUTION: Do not de-glaze cylinder bores.
10.Cylinder bores which are worn in excess of
0.177 mm over the above bore sizes must be
rebored and the appropriate oversize pistons
and rings fitted.
CAUTION: Cylinder bores must be honed
to finished size.
11.Fit oil pick-up and drain pipes and sump.
12.Fit cylinder head.
13.Fit flywheel/drive plate housing.
14.Fit timing belt rear cover and oil pump.
15.Fit timing belt.
16.Fit fuel injection pump.
17.Fit oil filter head.
18.Fit fuel lift pump.
19.Fit brake servo vacuum pump.

ENGINE
DATA, TORQUE & TOOLS1
ENGINE DATA
Rocker shaft
Rocker shaft wear - maximum 0.025 mm..................
Rocker arm shaft to bush clearance - maximum 0.12 mm....
Valve clearance - inlet and exhaust 0.20 mm..............
Oil pump
Outer rotor to housing clearance 0.025 to 0.075 mm................
Inner to outer rotor clearance 0.025 to 0.075 mm..................
Outer rotor end-float 0.026 to 0.135 mm.........................
Relief valve spring free length 68.0 mm..................
Cylinder head
Cylinder head maximum warpage 0.08 mm...............
Maximum movement of valve to guide 0.15 mm...........
Valve stem diameter:
Inlet 7.96 mm......................................
Exhaust 7.94 mm...................................
Valve head stand down:
Inlet 0.81 to 1.09 mm......................................
Exhaust 0.86 to 1.14 mm...................................
Valve seat insert face angle:
Inlet 60° ......................................
Exhaust 45° ...................................
Valve face angle:
Inlet 60°00' to 60°30' ......................................
Exhaust 45°00' to 45°30' ...................................
Valve spring free length 46.28 mm.......................
Timing belt tension on torque wrench
Used belt 12 Nm..................................
New belt 15 Nm...................................
Drive plate - automatic gearbox
Setting height 12.4 mm...............................

ENGINE
2
DATA, TORQUE & TOOLS Crankshaft
Maximum bearing journal ovality 0.040 mm................
Maximum bearing journal run-out 0.076 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 journal diameter 58.725 to 58.744 mm......................
Service limit 58.637 mm................................
Regrind diameter 58.475 to 58.494 mm............................
Main and big-end bearing oversizes available 0.25 mm......
Main bearing clearance 0.031 to 0.079 mm.......................
Crankshaft end-float 0.05 to 0.15 mm.........................
Thrust washer oversizes available:
1st oversize 0.063................................
2nd oversize 0.127 mm...............................
Big-end bearing clearance 0.025 to 0.075 mm.....................
Connecting rod end-float 0.15 to 0.35 mm......................
Camshaft
End-float 0.1 to 0.2 mm..................................
Pistons and connecting rods
Piston diameter:
Standard 90.395 mm..................................
1st oversize 90.649 mm................................
2nd oversize 90.903 mm...............................
Piston to cylinder bore clearance 0.075 mm................
Connecting rod misalignment - maximum 0.075 mm per 25.4 mm.........
Piston rings
Fitted gap in cylinder bore:
Top compression 0.40 to 0.65 mm............................
2nd compression 0.30 to 0.50 mm............................
Oil control rails 0.30 to 0.60 mm..............................
Ring to groove clearance:
Top compression 0.167 to 0.232 mm............................
2nd compression 0.05 to 0.08 mm............................
Oil control ring assembly 0.05 to 0.08 mm......................
Cylinder block
Cylinder bore maximum ovality 0.127 mm.................
Cylinder bore maximum taper 0.254 mm..................
Cylinder bore maximum wear 0.177 mm..................
Cylinder bore size:
Standard 90.47 mm..................................
For 1st oversize piston 90.73 mm.......................
For 2nd oversize piston 90.98 mm.......................

ENGINE
DATA, TORQUE & TOOLS3
TORQUE FIGURES
Timing belt tensioner bolt 45 Nm.....................
Timing belt idler pulley nut 45 Nm.....................
Flywheel/drive plate housing plug 12 Nm...............
Timing belt front cover bolts 25 Nm....................
Crankshaft pulley bolt 80 Nm then further 90° ........................
Rocker shaft nuts and bolts 5 Nm then further 50° ....................
Rocker cover nuts 10 Nm...........................
Crankcase breather cyclone unit bolt 9 Nm............
Rear timing cover bolts 25 Nm.......................
Oil pressure relief valve plug 17 Nm...................
Flywheel bolts 146 Nm..............................
Drive plate bolts 146 Nm.............................
Drive plate to starter ring gear bolts 25 Nm..............
Flywheel/drive plate housing bolts 45 Nm...............
Coolant outlet elbow bolts 9 Nm.....................
Thermostat housing bolts 25 Nm.....................
Oil filter head bolts 45 Nm...........................
Cylinder head bolts:
Stage 1 40 Nm...................................
Stage 2 Further 60° ...................................
Stage 3 Further 60° ...................................
Stage 4 - Bolts 1, 2, 7, 8, 9, 10, 15, 16, 17 and 18
onlyFurther 20°
......................................
Sump drain plug 35 Nm............................
Oil sump bolts 25 Nm..............................
Oil pick-up pipe bolts:
To main bearing cap 9 Nm.........................
To timing belt rear cover 25 Nm......................
Oil drain pipe bolts 25 Nm...........................
Fuel pump timing gear to hub plate bolts 25 Nm..........
Injector clamp nut 25 Nm...........................
Spill return pipe banjo bolts 10 Nm....................
Glow plugs 20 Nm.................................
Brake servo vacuum pump bolts 25 Nm................
Camshaft gear bolt 80 Nm..........................
Spill return pipe to injection pump banjo bolts 25 Nm......
Mounting bracket to fuel injection pump bolts 25 Nm......
Fuel injection pump and baffle plate to cylinder
block bolts25 Nm
.................................
Crankshaft rear oil seal housing bolts 25 Nm............
Camshaft thrust plate bolts 9 Nm....................
Camshaft oil jet tube 17 Nm.........................
Piston oil jet banjo bolts 17 Nm.......................
Cam follower guide bolts 14 Nm......................
Big-end bearing cap nuts 59 Nm......................
Main bearing cap bolts 133 Nm.......................