Discovery 2. Manual — part 423

ENGINE - TD5

OVERHAUL 12-1-89

Reassembly

1. Clean drive plate, spacer, starter ring gear and

crankshaft mating faces.

2. Position starter ring gear on crankshaft, fit

spacer and drive plate.

3. Fit new bolts to retain assembly and tighten by

diagonal selection to:

l

Stage 1 - 40 Nm (30 lbf.ft)

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Stage 2 - Further 90

°

CAUTION: Do not carry out stages 1 and 2 in
one operation.

4. Remove tool LRT-51-003, fit damper and

tighten bolts to 80 Nm (59 lbf.ft).

Starter ring gear

$% 12.53.19

Disassembly

1. Manual models: Remove flywheel.

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ENGINE - Td5, OVERHAUL,

Flywheel.

2. Automatic models: Remove drive plate.

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ENGINE - Td5, OVERHAUL, Drive

plate.

3. Drill a 3 mm (0.12 in) diameter hole at root of 2

teeth.

4. Apply a cold chisel to root of teeth, break ring

gear and remove from flywheel.

WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.

Reassembly

1. Heat ring gear evenly to 350

°

C, indicated by

light blue colour.

2. Locate ring gear on to flywheel and press on to

flange.

3. Allow ring gear to air cool.
4. Manual models: Fit flywheel.

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ENGINE - Td5, OVERHAUL,

Flywheel.

5. Automatic models: Fit drive plate.

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ENGINE - Td5, OVERHAUL, Drive

plate.

ENGINE - TD5

12-1-90 OVERHAUL

Pump - oil

$% 12.60.26.02

Disassembly

1. Remove sump gasket.

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ENGINE - Td5, OVERHAUL, Gasket

- engine sump.

2. Remove bolt securing oil pump drive sprocket.
3. Release drive sprocket from chain, remove

sprocket.

4. Remove 3 Torx screws securing oil pick-up

strainer, remove strainer.

5. Remove and discard 'O' ring.

6. Using sequence shown, remove and discard 22

bolts securing oil pump and stiffener plate
assembly to cylinder block.

7. Release stiffener plate from locating dowels,

remove oil pump and stiffener plate assembly.

8. Remove and discard 'O' ring from oil pump

housing outlet.

Inspection

1. Inspection/overhaul procedures for the oil

pump are limited to carrying out
dimensional checks. In the event of wear or
damage being found, a replacement pump
and stiffener plate assembly must be fitted.

ENGINE - TD5

OVERHAUL 12-1-91

2. Remove and discard 5 screws securing cover

to oil pump, remove cover.

3. Using a felt tipped pen, make suitable

alignment marks between inner and outer
rotors and oil pump body.

4. Remove inner and outer rotors.
5. Check rotors and pump body for signs of

scoring and wear.

6. Fit rotors ensuring that marks are aligned and

identification mark on inner rotor is facing
outwards.

7. Using feeler gauges, check pump outer rotor to

body clearance:

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Outer rotor to body clearance = 0.295 to
0.375 mm (0.012 to 0.015 in)

8. Using feeler gauges, check clearance of inner

to outer rotor in 2 positions; both clearances
must be within limit given:

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Inner to outer rotor clearance = 0.13 mm
(0.05 in)

ENGINE - TD5

12-1-92 OVERHAUL

9. Place a straight edge across pump body and

using feeler gauges, measure end-float of
outer rotor:

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Outer 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:

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Spring 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.

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ENGINE - Td5, OVERHAUL, Gasket

- engine sump.