LAND ROVER DISCOVERY 1995 Service Repair Manual

ENGINE
56
OVERHAUL Big-end bearings - remove
1.Suitably identify each oil jet tube to its fitted
location.
2.Remove bolt securing each oil jet tube
assembly to cylinder block.
3.Remove oil jet tube assemblies.
NOTE: Dowel located.
4.Recover sealing washers.
CAUTION: Oil jet tube bolts incorporate a
non-return valve.
5.Temporarily fit crankshaft pulley bolt.
6.Suitably identify fitted position of each big-end
bearing cap to its connecting rod and each
connecting rod to its respective cylinder bore.
7.Rotate crankshaft to bring numbers 1 and 4
connecting rods to BDC.
8.Remove and discard 2 nuts securing each
big-end bearing cap.
9.Remove numbers 1 and 4 big-end bearing
caps, recover bearing shells.
10.Slide suitable pieces of plastic tubing over
each connecting rod bolt.
11.Push numbers 1 and 4 connecting rods up
cylinder bores until they are clear of crankshaft
journals.
12.Repeat above procedures to remove numbers
2 and 3 big-end bearings.
CAUTION: Big-end bearing shells must
always be replaced.

ENGINE
OVERHAUL57
Crankshaft and main bearings - remove
1.Suitably identify each main bearing cap and its
fitted direction in crankcase.
2.Starting at number 3 main bearing cap and
working outwards, progressively slacken, then
remove bearing cap bolts. Keep bolts with their
respective main bearing caps.
3.Using the fingers only, rock each main bearing
cap until it is released from its retaining dowels.
CAUTION: Do not tap main bearing caps
sideways to release.
4.Remove and discard oil seals from number 5
main bearing cap.
5.Recover lower main bearing shells from
bearing caps.
6.Using assistance, remove crankshaft.7.Recover grooved thrust washers and upper
main bearing shells.
CAUTION: Main bearing shells and thrust
washers must always be replaced.
8.Remove pistons and connecting rods.

ENGINE
58
OVERHAUL Crankshaft - inspection
NOTE: Crankshafts may be reground 0.25
mm undersize on both main and big-end
journals.
See Crankshaft - regrinding.
1.Clean crankshaft and main bearing caps,
ensure oilways are clear.
2.Check main and big-end journals for signs of
scoring, excessive wear and overheating.
3.Check main and big-end bearing journals for
wear and ovality, make 3 checks at 120
°intervals in centre of journals.
Maximum ovality = 0.040 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 bearing journal diameter = 58.725 to
58.744 mm
Service limit = 58.637 mm
Regrind diameter = 58.475 to 58.494 mm
4.If bearing journal diameters are less than
service limit, crankshaft may be reground to
specified regrind diameter and 0.25 mm
oversize bearing shells fitted.
5.Using a micrometer, measure diameter at each
end of main and big-end bearing journals.
6.From measurements obtained, calculate taper
of each journal.
Maximum journal taper - end to end = 0.025
mm
7.Support each end of crankshaft in Vee blocks.
8.Position a DTI with stylus contacting centre
main bearing journal.
9.Rotate crankshaft and check run-out does not
exceed 0.076 mm.
CAUTION: If run-out exceeds above figure,
renew crankshaft.

ENGINE
OVERHAUL59
Crankshaft - regrinding
NOTE: Crankshaft journals may be
reground to the following dimensions.
Main bearing journals = 63.225 to 63.237 mm
Big-end bearing journals = 58.475 to 58.494 mm
CAUTION: Rotation of crankshaft must be
in an ANTI-CLOCKWISE direction when
viewed from flywheel end of crankshaft.
1.Grind journals ensuring that grinding wheel
travels beyond edge of journalAto avoid
formation of a stepB.
CAUTION: Take care not to damage fillet
radius C.
2.Final finishing should be carried out using a
static lapping stone with crankshaft rotating in
a CLOCKWISE direction when viewed from
flywheel end of crankshaft.
3.On completion of grinding operations,
thoroughly clean crankshaft ensuring that all oil
passages are clear.Main bearing caps and saddles - inspection
1.Ensure main bearing cap bolts and bolt holes
are clean and dry.
2.Fit each main bearing cap less bearing shells
to its correct location ensuring that direction
marks on cap are facing the correct way.
3.Fit and tighten each pair of main bearing cap
bolts to 133 Nm.
4.Slacken the bolt on one side of each main
bearing cap.
5.Using feeler gauges, check that there is no gap
between each main bearing cap and saddle on
the side of the cap with the slackened bolt.
6.If a gap exists, replace main bearing cap and
re-check.
7.If gap still exists, cylinder block must be
replaced.
CAUTION: Do not attempt to machine
main bearing caps or saddles.
8.Remove main bearing caps.
CAUTION: Keep main bearing cap bolts
with their respective caps.

ENGINE
60
OVERHAUL Main bearing clearance - checking
CAUTION: If crankshaft has been
reground, oversize main bearing shells
must be fitted.
1.Degrease new main bearing shells and ensure
all traces of oil are removed from crankshaft
journals.
2.Fit new main bearing shells to saddles and
main bearing caps ensuring that tags are
located in recesses in saddles and bearing
caps.
NOTE: Number 5 main bearing shells are
wider than numbers 1 to 4.
3.Using assistance, fit crankshaft.
4.Place a piece of Plastigage across width of
each main journal.
5.Fit main bearing caps to their correct location
ensuring that direction marks are facing the
correct way; fit each pair of main bearing cap
bolts and tighten to 133 Nm.
CAUTION: Do not rotate crankshaft.
6.Remove main bearing caps and bearing shells.
CAUTION: Retain main bearing shells and
cap bolts with their respective main
bearing caps.
7.Measure widest portion of Plastigage on each
main bearing journal using the scale supplied;
the graduation that corresponds to the widest
portion of Plastigage indicates main bearing
clearance.
Main bearing clearance = 0.031 to 0.079 mm8.If main bearing clearances are incorrect, use a
combination of standard and oversize main
bearing shells and re-check clearances.
CAUTION: Keep main bearing shells
selected in their fitted order.
9.Remove all traces of Plastigage using an oily
rag.
10.Using assistance, remove crankshaft.
11.Remove upper main bearing shells and keep in
their fitted order.

ENGINE
OVERHAUL61
Crankshaft end-float - checking
1.Lubricate upper main bearing shells and
crankshaft main bearing journals with engine
oil.
2.Lubricate new standard size thrust washers
with engine oil and position washers in recess
in centre main bearing saddle.
NOTE: Grooved side of washers must face
outwards.
3.Using assistance, fit crankshaft.
4.Attach a DTI to rear face of cylinder block with
stylus contacting end of crankshaft; push
crankshaft fully rearwards and zero gauge.
5.Push crankshaft fully forwards and measure
end-float.
6.If end-float exceeds 0.05 to 0.15 mm, remove
crankshaft, fit combinations of standard and
oversize thrust washers to achieve correct
end-float.
CAUTION: Variations of thrust washer
thicknesses on each side of crankshaft
must not exceed 0.08 mm.
7.When end-float is correct, remove DTI.
8.Using assistance, remove crankshaft and
thrust washers. Ensure that thrust washers are
identified to their location.

ENGINE
62
OVERHAUL Big-end bearing clearance - checking
1.Fit pistons and connecting rods.
2.Degrease new big-end bearing shells.
3.Fit big-end bearing shells to connecting rods
ensuring that tag is located in recess in
connecting rod.
4.Fit big-end bearing shells to bearing caps
ensuring that tag is located in recess in cap.
5.Temporarily fit crankshaft pulley bolt and rotate
crankshaft to bring numbers 1 and 4 journals to
BDC.
6.Remove all traces of oil from crankshaft
journals.
7.Pull numbers 1 and 4 connecting rods on to
crankshaft journals, remove plastic tubing from
connecting rod bolts.
8.Place a strip of Plastigage across width of
numbers 1 and 4 big-end journals.
9.Fit bearing caps and shells to connecting rods
ensuring that reference marks on caps and
rods are aligned.
10.Fit big-end bearing cap nuts and tighten to 59
Nm.
CAUTION: Do not rotate crankshaft.
11.Remove big-end bearing caps and shells.
12.Measure widest portion of Plastigage on
crankshaft journals using the scale supplied;
the graduation that corresponds to the widest
portion of Plastigage indicates big-end bearing
clearance.
Big-end bearing clearance = 0.025 to 0.075
mm13.If big-end bearing clearances are incorrect, use
a combination of standard and oversize
bearing shells and re-check clearance.
CAUTION: Retain selected shells with their
respective connecting rods and caps.
14.Remove all traces of Plastigage using an oily
rag.
15.Repeat above procedures for numbers 2 and 3
big-end bearings.

ENGINE
OVERHAUL63
Crankshaft, main and big-end bearings - refit
Crankshaft and main bearings
CAUTION: Cylinder bores must be
inspected before crankshaft is refitted -
See cylinder block - inspection
1.Lubricate selected main bearing shells, thrust
washers and crankshaft journals with engine
oil, ensure bolt holes in bearing saddles are
clean and dry; fit bearing shells in main bearing
caps and saddles.
2.Fit seal guidesLRT-12-035to cylinder block
ensuring that edges of guides are parallel to
edge of main bearing cap recess.
3.Using a sharp blade, cut a 0.40 to 0.80 mm
wide chamfer on edge of new seals.
4.Lubricate oil seals with engine oil and fit to
number 5 main bearing cap.
5.Fit selected thrust washers to centre main
bearing saddle.
NOTE: Grooved side of thrust washers
must face outwards.
6.Using assistance, fit crankshaft.
7.Fit main bearing caps and bolts ensuring that
they are in their fitted order and direction marks
are facing the correct way. Lightly lubricate
main bearing cap bolts, fit and finger tighten
bolts.

ENGINE
64
OVERHAUL 8.Tighten centre main bearing cap bolts to 133
Nm.
9.Temporarily fit crankshaft pulley bolt and check
that crankshaft rotates freely and smoothly.
10.Tighten each pair of main bearing cap bolts to
133 Nm in the order No. 2, No. 4, No. 1 and
No. 5. Check that crankshaft rotates freely and
smoothly after tightening each pair of bolts.
11.Remove seal guidesLRT-12-035and select
feeler gauges to a thickness of 0.80 mm,
position gauges on number 5 main bearing cap
adjacent to oil seals.
12.Position a sharp blade on feeler gauges and
keeping blade parallel to bearing cap, slice
excess material off oil seal
13.Repeat above procedures for remaining seal.
CAUTION: Seals should be left to settle for
as long as possible before they are
trimmed.Big-end bearings
1.Lubricate big-end bearing shells and
crankshaft journals with engine oil.
2.Fit numbers 1 and 4 big-end bearing caps and
shells, fit bearing cap nuts and tighten to 59
Nm.
3.Move numbers 1 and 4 connecting rods fully to
one side of crankshaft journal and using feeler
gauges, check end-float of both connecting
rods on journals is between 0.15 and 0.35 mm.
4.If end-float is outside limits, replace connecting
rod.
5.Check that crankshaft rotates smoothly.
6.Repeat above procedures for numbers 2 and 3
big-end bearings.

ENGINE
OVERHAUL65
Crankshaft rear oil seal - refit
1.Ensure that oil seal running surface on
crankshaft and oil seal housing mating surface
on cylinder block are clean and oil free and that
bolt holes in cylinder block are clean and dry.
2.Screw 2 slave guide studs into cylinder block.
3.Position new gasket to cylinder block ensuring
that groove along bottom edge of gasket is
towards block.
NOTE: 'O' ring fitted to early engines is no
longer required.4.Slide oil seal protector sleeve over crankshaft,
fit oil seal and housing over guide studs and
crankshaft, fit and finger tighten 3 bolts,
recover oil seal protector sleeve.
CAUTION: Do not lubricate oil seal or
running surface on crankshaft. Do not
separate protector sleeve from oil seal and
do not touch lip of seal. If protector sleeve is
removed or seal is inadvertently handled, it must
not be fitted as the coating applied to the oil seal
during manufacture will be destroyed and oil
leakage will result.
5.Remove 2 guide studs, fit and finger tighten
remaining 2 bolts.
6.Tighten 5 bolts by diagonal selection to 25 Nm.