check oil LAND ROVER DISCOVERY 2002 Owner's Guide

ENGINE - TD5
12-1-92 OVERHAUL
9.Place a straight edge across pump body and
using feeler gauges, measure end-float of
outer rotor:
lOuter rotor end-float = 0.038 to 0.075 mm
(0.0001 to 0.003 in)
10.Check drive shaft bush in pump cover for signs
of scoring and wear.
11.Renew oil pump and stiffener plate assembly if
excessive scoring or wear exists.
12.Lubricate pump rotors and drive shaft bush with
engine oil.
13.Fit rotors ensuring reference marks are aligned
and identification mark on outer rotor is facing
outwards.
14.Fit cover to pump, fit 5 new screws and tighten
by diagonal selection to 6 Nm (4.5 lbf.ft).
15.Remove and discard oil pressure relief valve
plug.
16.Remove spring and relief valve plunger.
17.Clean valve plunger and spring.
18.Check valve plunger and relief valve bore for
scoring and corrosion, light scoring and
corrosion may be removed using grade 600
emery cloth soaked in oil.19.Check spring for distortion, check free length of
spring:
lSpring free length = 42.0 mm (1.65 in)
20.Lubricate valve plunger and seating.
21.Fit valve plunger and spring to oil pump.
22.Apply Loctite 243 sealant to threads of a new
plug. Do not attempt to fit original plug.
23.Fit plug and tighten to 23 Nm (17 lbf.ft).
Reassembly
1.Clean mating faces of oil pump, stiffener plate
assembly and cylinder block; ensure bolt and
dowel holes are clean and dry.
2.Lubricate a new 'O' ring with engine oil and fit to
oil pump housing outlet.
3.Position oil pump and stiffener plate assembly
on to cylinder block ensuring 2 dowels are
correctly located.
4.Fit new bolts and using sequence shown,
tighten to 13 Nm (10 lbf.ft).
5.Lubricate a new 'O' ring with engine oil and fit to
oil pick-up strainer.
6.Clean threads of oil pick-up strainer Torx
screws and apply Loctite 242 to screw
threads.
7.Fit oil pick-up strainer, fit Torx screws and
tighten to 10 Nm (8 lbf.ft).
8.Position oil pump drive sprocket to chain and oil
pump ensuring that the 'D' shape on the drive
sprocket is located on the flat on the oil pump
drive shaft.
9.Clean oil pump drive sprocket retaining bolt and
apply Loctite 242 to bolt threads.
10.Fit oil pump drive sprocket and tighten bolt to
25 Nm (18 lbf.ft).
11.Fit new sump gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- engine sump.

ENGINE - TD5
12-1-94 OVERHAUL
15.Remove bolt and remove timing chain
adjustable guide.
16.Remove bolt and remove timing chain
lubrication jet.
17.Using tool LRT-12-092, remove and discard oil
seal from timing cover.
Inspection
1.Clean all components.
2.Check condition of timing chain running
surfaces on adjustable and fixed guides.
CAUTION: Adjustable guide fitted to Engine
Serial No. Prefixes 15P to 19P may be fitted
to early engines provided that timing chain
tensioner having a YELLOW coloured body
is also fitted.
3.Check timing chains and sprockets for signs of
wear.
CAUTION: Timing chains and sprockets
fitted to Engine Serial No. Prefixes 15P to
19P may be fitted to early engines as an
assembly only, oil pump drive sprockets are
interchangeable. Later timing chains have
BRONZE coloured timing links.
4.Check that drilling in timing chain lubrication jet
is clear.
5.Clean oil seal recess in timing cover and oil seal
running surface on crankshaft.
6.Remove all traces of sealant from mating faces
of timing cover and cylinder block using
suitable solvent.
CAUTION: Do not use metal scrapers.
7.Ensure bolt and dowel holes are clean and dry.
8.Clean oil pump sprocket bolt threads.Reassembly
1.Fit timing chain lubrication jet.
2.Fit timing chain lubrication jet Torx screw and
tighten to 10 Nm (7 lbf.ft).
3.If crankshaft has been rotated, check that No.1
piston is at TDC using the following
procedures:
4.Temporarily fit and lightly tighten a new
crankshaft pulley bolt.
5.Assemble a magnetic base DTI to cylinder
block top face, position stylus to cylinder block
face and zero gauge.
6.Using crankshaft pulley bolt, rotate crankshaft
clockwise until No.1 piston is at top of its stroke
and woodruff key slot in crankshaft is at 12
o'clock position.
7.Position stylus of DTI to No.1 piston crown and
rotate crankshaft until highest reading is
indicated on DTI.
8.Check that Woodruff key slot is still at 12
o'clock position indicating No.1 piston is at
TDC firing.
9.Remove DTI.
10.Remove and retain crankshaft pulley bolt.
11.Fit Woodruff key to crankshaft.
12.Fit oil pump drive chain to rear row of teeth on
crankshaft sprocket - i.e. teeth furthest away
from timing mark on sprocket.
13.Fit sprocket to crankshaft ensuring that timing
mark on sprocket is facing towards front end of
crankshaft.
14.Fit oil pump drive sprocket to oil pump and drive
chain ensuring that 'D' shape on sprocket is
located on flat on oil pump drive shaft.

ENGINE - TD5
OVERHAUL 12-1-97
8. Remove and discard big-end bearing shell
from connecting rod.
NOTE: Engine Serial No. Prefixes 10P to 14P:–
The 'sputter type' connecting rod bearing shells
fitted to these engines, identified by them
having a slightly darker colour than the bearing
cap shells should be replaced with the 'plain
type' bearing shells fitted to Engine Serial No.
Prefixes 15P to 19P.
9.Repeat above procedures for remaining big-
end bearings. Keep bearing caps in their
fitted order.
Inspection
1. If crankshaft is to be removed, big-end
bearing journals should be checked when
crankshaft is inspected.
2.Check each big-end bearing journal for scoring,
wear and ovality, make 3 checks at 120
°
intervals in centre of journal:
lBig-end bearing journal diameter = 54.000
±
0.01 mm (2.125
± 0.0004 in)
CAUTION: Big-end journals may not be
ground undersize, only one size of big-end
bearing shell is available and if journals are
found to be scored, oval or worn, crankshaft
must be replaced. Big-end bearing shells
must be replaced whenever they are
removed.
Reassembly
1.Clean connecting rod journals and bearing
shell locations.
2.Lubricate new big-end bearing shells with
engine oil and fit to connecting rods and
bearing caps.
CAUTION: Do not fit the 'sputter type'
bearings fitted to early engines.3.Rotate crankshaft until No.1 big-end bearing
journal is at BDC.
4.Taking care not to damage oil squirt jet or to
displace bearing shell, pull connecting rod on
to crankshaft journal.
5.Check that bearing shell is correctly located in
big-end bearing cap.
6.Fit No.1 big-end bearing cap ensuring that
reference marks are aligned
7.Fit new big-end bearing cap bolts and tighten
to:
lStage 1 - 20 Nm (15 lbf.ft)
lStage 2 - Further 80
°
CAUTION: Do not carry out stages 1 and
2 in one operation.
8.Carefully move connecting rod to one side of
journal and using feeler gauges measure end-
float of connecting rod on journal:
lConnecting rod end-float = 0.2 to 0.5 mm
(0.008 to 0.021 in)
9.Repeat end-float check for remaining
connecting rods.
10. If end-float exceeds limits given, replace
connecting rod and repeat end-float check.

+ ENGINE - Td5, OVERHAUL, Pistons,
connecting rods and cylinder bores.
11.Fit oil pump.

+ ENGINE - Td5, OVERHAUL, Pump -
oil.

ENGINE - TD5
12-1-98 OVERHAUL
Pistons, connecting rods and cylinder
bores
$% 12.17.02.03
Disassembly
1.Remove cylinder head gasket.

+ ENGINE - Td5, OVERHAUL, Gasket
- cylinder head.
2.Remove connecting rod bearings.

+ ENGINE - Td5, OVERHAUL,
Bearings - connecting rods.
3.Remove ridge of carbon from top of cylinder
bore.
4.Suitably identify each piston and connecting
rod assembly to its respective cylinder bore.
5.Carefully push connecting rod to top of cylinder
bore taking care that connecting rod does not
contact oil squirt jet or cylinder wall; remove
each piston and connecting rod in turn.
6.Using a suitable expander, remove and discard
piston rings from pistons.
7.Clean carbon from piston crown and skirt. Do
not use abrasives on graphited area of
piston skirt, do not use a wire brush or
scraper on any part of pistons.
8.Secure connecting rod in a soft jawed vice.
9.Suitably identify each piston to its connecting
rod and fitted position of piston on rod.
10.Using suitable circlip pliers, remove and
discard 2 circlips securing gudgeon pin.
11.Push gudgeon pin out of piston and connecting
rod; remove piston.
12.Suitably identify each gudgeon pin to its
respective piston.
13.Repeat above procedures for remaining
pistons. Inspect
1.Measure cylinder bore for wear at a point 70
mm (2.75 in) from top of cylinder bore:
Measurement must be taken from side to
side and front to rear.
lCylinder bore diameter = 84.460 to 84.442
mm (3.325 to 3.324 in)
CAUTION: Cylinder bore and ovality must
be within the limits given above, no
reboring, honing or de-glazing of
cylinder bores is permissible; cylinder
block must be replaced if bores are worn
or excessively scored.
2.Check piston for cracks, burning and damage.
3.Check connecting rods for alignment. Do not
attempt to straighten misaligned
connecting rods. Ensure small-end
lubrication holes in connecting rods are
clear.
4.Measure and record diameter of each piston at
right angles to gudgeon pin axis and 46 mm
(1.81 in) from bottom of skirt
lPiston diameter = 84.262 mm
± 0.009 mm
(3.317 in
± 0.0003 in)
CAUTION: Measurement point must be on
the ungraphited area of the piston.

ENGINE - TD5
12-1-100 OVERHAUL
12.Insert new compression and oil control rings in
turn into No.1 cylinder bore 30 mm (1.25 in)
from top of bore and check ring fitted gaps;
ensure rings are kept square to bore when
checking gaps:
l1st compression ring fitted gap = 0.30 to
0.40 mm (0.012 to 0.016 in).
l2nd compression ring fitted gap = 0.40 to
0.60 mm (0.016 to 0.024 in).
lOil control ring fitted gap = 0.25 to 0.50 mm
0.01 to 0.02 in).
CAUTION: 1st compression rings fitted to
Engine Serial No. Prefixes 10P to 14P are
not interchangeable with those fitted to
Engine Serial No. Prefixes 15P to 19P. The
later rings may, however, be fitted to early
engines together with the later type pistons
in engine sets only.
13.Repeat for each cylinder bore in turn.
CAUTION: Ensure rings are suitably
identified with the cylinder bore in which
they were checked and are fitted to the
piston for that bore.
14.Fit oil control expander and ring to piston.
15.Fit 2nd compression ring with 'TOP' marking
upwards. 16.Fit 1st compression ring with 'TOP' marking
upwards.
17.Check piston ring to groove clearance:
l1st compression ring = Not measured
l2nd compression ring = 0.050 to 0.082 mm
(0.02 to 0.003 in)
lOil control ring = 0.050 to 0.082 mm (0.02 to
0.003 in)
Reassembly
1.Lubricate gudgeon pin, gudgeon pin holes in
piston and small end bush with engine oil.
2.Position piston to connecting rod with arrow on
piston crown on the same side as the cast boss
on the connecting rod.
3.Fit gudgeon pin to its respective piston and
connecting rod; secure with new circlips
ensuring circlips are fully seated in their
grooves.
4.Repeat above procedures for remaining
pistons.
5.Lubricate piston rings and cylinder bores with
engine oil.
6.Check that rings are free to rotate, position ring
gaps at 120
° to each other and away from the
thrust, LEFT HAND side of piston - viewed
from front of piston.
7.Using a suitable ring clamp, compress piston
rings.
8.Insert connecting rod and piston into its
respective cylinder bore ensuring that the
arrow on piston crown and the cast boss on
connecting rod are facing towards the front of
the cylinder block.
9.Ensure that connecting rod does not contact
cylinder bore or oil squirt jet. Do not pull
connecting rod fully down cylinder bore at this
stage.
10.Check that cut-out in piston skirt is positioned
above oil squirt jet.

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 - V8
ADJUSTMENTS 12-2-11
ADJUST ME NTS
Engine oil pressure check
$% 12.90.09.01
Check
1.Remove oil pressure switch.

+ ENGINE - V8, REPAIRS, Switch - oil
pressure.
2.Connect pressure check kit LRT-12-052C
adaptor and gauge to oil pressure switch
position on timing gear cover.
3.Check and if necessary top up engine oil.
4.Run engine at idle speed and check that oil
pressure is within limits given.

+ GENERAL DATA, Engine - V8.
5.Switch off ignition.
6.Remove pressure check kit LRT-12-052C.
7.Clean oil spillage.
8.Fit oil pressure switch.

+ ENGINE - V8, REPAIRS, Switch - oil
pressure.
Adjust
1.If engine oil pressure is below figures given,
check condition of oil pump and/or main and
big end bearings.

ENGINE - V8
REPAIRS 12-2-15
10.Remove cylinder head.
CAUTION: Support both ends of cylinder
head on blocks of wood.
11.Remove cylinder head gasket.
Refit
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. Clean mating faces of
cylinder head and exhaust manifold.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Check head and block faces for warping and
pitting. If out of specification, renew head.
3.Fit cylinder head gasket with the word 'TOP'
uppermost.
CAUTION: Gaskets must be fitted dry.
4.Carefully fit cylinder head and locate on
dowels.
5.Lightly lubricate new cylinder head bolt threads
with clean engine oil. 6.Noting that bolts 1, 3 and 5 are longer than the
remainder, fit cylinder head bolts and tighten in
the sequence shown to 20 Nm (15 lbf.ft) then
90
° , and finally a further 90° .
CAUTION: Do not tighten bolts 180
° in one
operation.
7. Models with SAI: Fit new air injection adapters
and tighten to 33 Nm (24 lbf.ft).
8.Clean push rods.
9.Lubricate ends of push rods with clean engine
oil.
10.Fit push rods in their removed order.
11.Clean bases of rocker pillars and mating faces
on cylinder head.
12.Clean contact surfaces on rockers, valves and
push rods.
13.Lubricate contact surfaces and rocker shaft
with clean engine oil.
14.Fit rocker shaft assembly and engage push
rods.
15.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft).
16.Using new gaskets, position exhaust manifold
to cylinder head, fit bolts and using sequence
shown, tighten initially to 15 Nm (11 lbf.ft), then
finally to 36 Nm (28 lbf.ft).

ENGINE - V8
12-2-18 REPAIRS
Refit
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. Clean mating faces of
cylinder head and exhaust manifold.
CAUTION: Do not use a metal scraper or
machined surfaces may be damaged.
2.Check head and block faces for warping and
pitting. If out of specification, renew head.
3.Fit cylinder head gasket with the word 'TOP'
uppermost.
CAUTION: Gaskets must be fitted dry.
4.Carefully fit cylinder head and locate on
dowels.
5.Lightly lubricate new cylinder head bolt threads
with clean engine oil.
6.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 90
°, and finally
a further 90
°.
CAUTION: Do not tighten bolts 180
° in one
operation.
7. Models with SAI: Fit new air injection adapters
and tighten to 33 Nm (24 lbf.ft).
8.Clean push rods.
9.Lubricate ends of push rods with clean engine
oil.
10.Fit push rods in their removed order.
11.Clean bases of rocker pillars and mating faces
on cylinder head.
12.Clean contact surfaces on rockers, valves and
push rods.
13.Lubricate contact surfaces and rocker shaft
with clean engine oil.
14.Fit rocker shaft assembly and engage push
rods.
15.Fit rocker shaft bolts and progressively tighten
to 40 Nm (30 lbf.ft). 16.Position alternator mounting bracket, fit bolts
and tighten to 40 Nm (30 lbf.ft).
17.Position auxiliary drive belt tensioner, fit bolt
and tighten to 45 Nm (33 lbf.ft).
18.Connect ht leads to spark plugs in their fitted
order.
19. Using new gaskets, fit exhaust manifold to
cylinder head. Fit bolts and using sequence
shown, tighten initially to 15 Nm (11 lbf.ft), then
finally tighten to 36 Nm (28 lbf.ft).
20. RH drive models: Fit brake servo heat shield.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Heat shield -
brake servo - Without Secondary Air
Injection.
21.Position engine earth lead, fit bolt and tighten to
22 Nm (16 lbf.ft).
22.Fit inlet manifold gasket.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - lower.