lock LAND ROVER DISCOVERY 2002 Workshop Manual

ENGINE - V8
OVERHAUL 12-2-53
Gasket - engine sump
$% 12.60.38.01
Disassembly
1.Remove 3 nuts and 14 bolts securing sump to
cylinder block.
2.Remove sump.
3.Remove and discard gasket.
Reassembly
1.Clean all traces of sealant from the sump and
sump mating faces, using a solvent cleaner or
plastic scraper.
2.Apply a 5 mm (0.2 in) wide bead of sealant, Part
No. STC 50550 across the cylinder block to
front cover joint and across the cylinder block to
rear main bearing joint. Apply a globule of
sealant to cover the end of the cruciform seal,
(see illustration above).
3.Fit new sump gasket, dry, ensure location tags
are correctly positioned.
4.Fit the sump to the cylinder block.5. Noting that the two parts of the tool are
handed, fit tool LRT- 12-183 to the engine
back plate using bell housing nuts and bolts.
6.Secure the tool to the sump using the bolts
which are part of the tool. The holes in the tool
are larger than the diameter of the bolts,
allowing the tool and the sump to move as
the sump bolts are tightened.
7.Fit the sump nuts and bolts, and working in the
sequence shown, tighten to 22 Nm (16 lbf.ft).
8.Remove tool LRT-12-183.
M12 5741
M12 5713
14106248
12
16
17
15
117315913

ENGINE - V8
OVERHAUL 12-2-57
6.Apply smear of Retinax LX grease to oil seal
running surface on crankshaft.
7. Fit seal to timing gear cover using tool LRT-12-
089.
8.Clean and fit crankshaft pulley.
9.Fit crankshaft pulley bolt and tighten to 270 Nm
(200 lbf.ft).
10.Remove tool LRT-12-080 from crankshaft
pulley.
11.Clean oil filter mating face.
12.Lubricate new oil filter seal with clean engine oil
and fit filter.
13.Ensure coolant pump and pulley mating faces
are clean.
14.Remove all traces of thread locking material
from coolant pump pulley drive flange bolt
holes using an M8 tap.
15.Fit coolant pump pulley and tighten new
Patchlok bolts to 22 Nm (16 lbf.ft).
16.Fit oil pick up strainer.

+ ENGINE - V8, OVERHAUL, Strainer
- oil pick-up.
Timing chain and gears
$% 12.65.12.01
Disassembly
1.Remove timing gear cover gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
timing gear cover.
2.Fit crankshaft pulley bolt and rotate engine to
align timing marks. Remove crankshaft pulley
bolt.

ENGINE - V8
12-2-58 OVERHAUL
3.Restrain camshaft gear and remove gear
retaining bolt.
4.Remove timing chain and gears as an
assembly.
5.Remove gears from timing chain.
6.Remove key from crankshaft. Reassembly
1.Clean timing chain and gears and gear
locations.
2.Fit key to crankshaft.
3.Temporarily fit gears to camshaft and
crankshaft. If necessary, rotate shafts to align
timing marks. When aligned correctly, the
timing marks will face each other; crankshaft
gear timing mark at twelve o'clock position and
camshaft gear timing mark at six o'clock
position.
4.Remove gears from shafts and fit to timing
chain.
5.With timing marks aligned, fit timing chain and
gears as an assembly.
6.Restrain the camshaft gear and tighten
retaining bolt to 50 Nm (37 lbf.ft).
7.Fit timing gear cover gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
timing gear cover.

ENGINE - V8
12-2-60 OVERHAUL
Reassembly
1.Reassemble rocker shafts, ensuring that
components are returned to their original
positions, secure plain washers with new split
pins.
2.Ensure shaft identification groove is positioned
at one o'clock, with push rod locations of rocker
arms to the right. Oil feed restriction will
result if rocker shafts are incorrectly
assembled.
3.Position rocker shaft assembly to cylinder
head ensuring push rods are engaged in
rocker arms.
4.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
5.Clean mating faces of rocker covers and
cylinder heads.
6.Fit new rocker cover gaskets, dry, position
rocker cover, fit bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
7.Ensure that gasket is correctly positioned
around periphery of rocker cover.
8.Secure ht leads to rocker cover.
Gasket - cylinder head
$% 12.29.02.01
Disassembly
1.Remove inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.
2. RH cylinder head: Remove auxiliary drive belt
tensioner.
3. RH cylinder head: Remove bolts securing
alternator mounting bracket and remove
bracket.
4.Noting their fitted order, disconnect ht leads
from spark plugs.
5.Progressively remove 4 bolts securing the
rocker shaft and remove rocker shaft.
6.Remove push rods and store in their fitted
order.
7.Working in the sequence shown remove 10
bolts securing the cylinder head to block.
Discard the bolts.
8.Remove cylinder head.

ENGINE - V8
OVERHAUL 12-2-61
9.Remove cylinder head gasket.
CAUTION: Support both ends of cylinder
head on blocks of wood.
Inspect
1.Clean mating faces of cylinder block and head
using suitable gasket removal spray and a
plastic scraper, ensure that bolt holes in block
are clean and dry.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Check head and block faces for warping and
pitting.
lMaximum cylinder head warp = 0.05 mm
(0.002 in).
Note: Cylinder head can be refaced to 0.50
mm (0.02 in) maximum below head height –
See cylinder head overhaul.Reassembly
1.Fit cylinder head gasket with the word TOP
uppermost.
CAUTION: Gaskets must be fitted dry.
2.Carefully fit cylinder head and locate on
dowels.
3.Lightly lubricate new cylinder head bolt threads
with clean engine oil.
4.Noting that bolts 1, 3 and 5 are longer than the
remainder, fit bolts and tighten in the sequence
shown to 20 Nm (15 lbf.ft) then turn through 90
°, then a further 90 °. CAUTION: Do not
tighten bolts 180
° in one operation.
5.Clean the push rods, Lubricate ends of push
rods with clean engine oil, and fit in their
removed order.
6.Clean bases of rocker pillars and mating faces
on cylinder head.
7.Clean contact surfaces on rockers, valves and
push rods.
8.Lubricate contact surfaces and rocker shaft
with clean engine oil.
9.Fit rocker shaft assembly and engage push
rods.
10.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
11.Connect ht leads to spark plugs in their correct
fitted order.
12. RH cylinder head: Position alternator
mounting bracket, fit bolts and tighten to 40 Nm
(30 lbf.ft).
13. RH cylinder head: Fit auxiliary drive belt
tensioner.
14.Fit inlet manifold gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
inlet manifold.

ENGINE - V8
12-2-62 OVERHAUL
Cylinder head - overhaul
$% 12.29.19.01
Disassembly
1.Remove cylinder head gasket.

+ ENGINE - V8, OVERHAUL, Gasket -
cylinder head.
2.Loosen screw on tool LRT-12-034.
3.Fit tool LRT-12-034 to valve and tighten screw
to compress valve spring sufficiently to release
collets from valve spring cap.
4.Remove 2 collets and release valve spring
compressor.
5.Remove valve spring cap and valve spring.
6.Remove valve from cylinder head.
7.Remove and discard valve stem oil seal.
8.Repeat above operations for remaining valves.
9.Keep valves, springs, caps and collets in their
fitted order. Inspect
1.Clean mating faces of cylinder block and head
using suitable gasket removal spray and a
plastic scraper, ensure that bolt holes in block
are clean and dry.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Clean cylinder head, valve springs, valves and
inlet valve guide bores. Ensure all loose
particles of carbon are removed on completion.
3.Check head and block faces for warping and
pitting. Maximum warp = 0.05 mm (0.002 in).
4.Check cylinder head height at each end of
head. Renew a head which is outside limits.
a22.94 mm (0.903 in) - New
b62.56 mm (2.463 in) - New
5.Cylinder head can be refaced to 0.50 mm (0.02
in) max. below head height.

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
12-2-68 OVERHAUL
Inspect
1.Clean carbon from piston. Inspect piston for
distortion, cracks and burning.
2.Remove piston rings from piston.
3.Measure and record piston diameter at 90
° to
gudgeon pin axis and 10 mm (0.4 in) from
bottom of the skirt. The piston must be 0.02 to
0.045 mm (0.001 to 0.002 in) smaller than the
cylinder bore.
4.Check gudgeon pin bore in piston for signs of
wear and overheating.
5.Pistons fitted on production are graded 'A' or
'B', the grade letter is stamped on the piston
crown.
lPiston diameter: Grade 'A' = 93.970 to
93.985 mm (3.6996 to 3.7002 in).
lPiston diameter: Grade 'B' = 93.986 to 94.00
mm (3.7002 to 3.7007 in).
6.Worn cylinders fitted with grade 'A' pistons may
be honed to accept the grade 'B' piston
provided that specified cylinder bore and
ovality limits are maintained. Grade 'B'
pistons are supplied as service
replacements. Do not attempt to de-glaze
cylinder bores.
7.Check gudgeon pins for signs of wear and
overheating.
8.Check clearance of gudgeon pin in piston.
l Gudgeon pin to piston clearance = 0.006 to
0.015 mm (0.0002 to 0.0006 in).
9.Check overall dimensions of gudgeon pin.
Gudgeon pins are only supplied as an
assembly with replacement pistons.
lGudgeon pin length = 60.00 to 60.50 mm
(2.362 to 2.382 in).
lGudgeon pin diameter = 23.995 to 24.00
mm (0.9446 to 0.9448 in)10.Measure cylinder bore wear and ovality in two
axis 40 to 50 mm (1.6 to 2 in) from top of bore.
The temperature of piston and cylinder
block must be the same to ensure accurate
measurement. Do not attempt to de-glaze
cylinder bores.
lGrade 'A' pistons: Cylinder bore = 94.00 to
94.015 mm (3.7007 to 3.7013 in).
lGrade 'B' pistons: Cylinder bore = 94.016 to
94.030 mm (3.7014 to 3.7019 in).
lMaximum ovality = 0.013 mm (0.0005 in).
11.Check alignment of connecting rods.
Reassembly
1.Pistons have a 5 mm (0.2 in) offset gudgeon pin
which can be identified by an arrow mark on
the piston crown. This arrow must always point
towards the front of the engine.
2.Assemble pistons to connecting rods with
arrow on piston pointing towards domed
shaped boss on connecting rod for RH bank of
cylinders and arrow pointing away from domed
shaped boss for LH bank of cylinders.

ENGINE - V8
OVERHAUL 12-2-69
3.Clamp hexagon body of tool LRT-12-013 in
vice.
4.Loosen large nut and pull the centre screw 50
mm (2 in) out of hexagon body.
5.Fit piston adapter tool LRT-12-126/2 .
6.Position guide pin tool LRT-12-126/3 in LRT-
12-162/2 with groove towards piston, up to
shoulder on centre screw.
7.Lubricate gudgeon pin and bores of connecting
rod and piston with graphite oil.
8.Locate connecting rod and piston to centre
screw with connecting rod entered on sleeve
up to groove.
9.Fit gudgeon pin on to centre screw and into
piston bore up to connecting rod.
10.Fit remover/replacer tool LRT-12-126/1 with
flanged end towards gudgeon pin.
11.Screw the stop nut on to centre screw and
position piston against groove of tool LRT-12-
126/3.
12.Lubricate centre screw threads and thrust race
with graphite oil, screw large nut up to tool
LRT-12-013.
13.Lock the stop nut securely with lock screw.
14.Set torque wrench to 16 Nm (12 lbf.ft) and using
socket on large nut, pull gudgeon pin in until
flange of tool LRT-12-126/1 is 0.40 mm (0.016
in), dimension 'A' from face of piston. If
torque is exceeded during this procedure, fit of
gudgeon pin to connecting rod is not
acceptable and components must be replaced.
CAUTION: The centre screw and thrust race
must be kept well lubricated throughout the
operation.
15.Dismantle tool, remove piston and check no
damage has occurred during pressing and that
piston moves freely on gudgeon pin.
16.Remove compression rings, oil control rails
and expander from new piston. 17.Invert piston and with arrow pointing towards
rear of cylinder block, insert piston into cylinder
liner.
18.Position piston with bottom of skirt 30 mm (1.12
in) from top cylinder liner.
19.Using feeler gauges, measure and record
clearance between piston and left hand side of
cylinder- viewed from the front of cylinder
block.
lPiston to bore clearance = 0.020 to 0.045
mm (0.001 to 0.002 in).
20.Insert piston rings into cylinder bore, use the
piston to hold the rings square to bore and
check the ring gap.
l1st compression ring = 0.30 to 0.50 mm
(0.012 to 0.02 in).
l2nd compression ring = 0.40 to 0.65 mm
(0.016 to 0.026 in).
lOil control ring rails = 0.38 to 1.40 mm
(0.015 to 0.055 in).
21.Remove piston rings from bore.
22.Fit oil control ring rails and expander, ensuring
ends butt and do not overlap.

ENGINE - V8
OVERHAUL 12-2-73
6.Reference mark main bearing caps to aid
assembly.
7.Remove 10 side bolts securing main bearing
caps to block.
8.Collect 'Dowty' washers from side bolts. Rear
side bolts have Allen heads.
9.Starting at the centre main bearing cap,
progressively loosen, then remove 2 bolts
securing each main bearing cap.
10.Release and remove main bearing caps.
CAUTION: Keep bearing caps, bearings and
bolts in their fitted order.
11.Remove crankshaft.
12.Remove main bearings from cylinder block and
main bearing caps.
13.Remove key from keyway.
14.Remove rear main sealing washers.
Inspect
1.Clean crankshaft journals and bearing
locations in cylinder block.
2.Inspect main bearings for wear and renew if
necessary. Main bearings are available in two
oversizes. If 2nd oversize bearing is being
fitted, it may be necessary to grind thrust
face of centre main bearing to achieve
correct end-float.
lMain bearing 1st oversize = 0.254 mm (0.01
in).
lMain bearing 2nd oversize = 0.508 mm
(0.02 in).3.Check main bearing journals for wear and
scoring. Measure for ovality; taking 3
measurements at 120
° intervals at each end
and at centre of journals.
lJournal diameter - standard = 63.487 to
63.500 mm (2.499 to 2.520 in).
l1st undersize journal = 63.223 to 63.246
mm (2.511 to 2.512 in).
l2nd undersize journal = 62.979 to 62.992
mm (2.509 to 2.510 in).
lJournal width - standard = 26.975 to 27.026
mm (1.061 to 1.064 in).
lMaximum ovality = 0.040 mm (0.002 in)