Discovery 2. Manual — part 424

ENGINE - TD5

OVERHAUL 12-1-93

Timing chain and sprockets

$% 12.65.13.01

Disassembly

1. Remove cylinder head gasket.

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ENGINE - Td5, OVERHAUL, Gasket

- cylinder head.

CAUTION: If timing chain tensioner is to be
replaced, ensure tensioner is correct for
engine. Tensioner bodies are colour coded
as follows: Engine Serial No. Prefixes 10P to
14P – BLACK with, additionally on later
engines, YELLOW on tensioner hex. head.
Serial No. Prefixes 15P to 19P – body is
colour coded YELLOW. Later tensioners
may be fitted to early engines provided that
the modified adjustable guide is also fitted.

2. Remove 3 bolts securing damper to crankshaft

pulley, remove damper.

3. Fit LRT-51-003 to crankshaft pulley.
4. Secure tool using 2 bolts.
5. Using assistance, restrain engine and remove

crankshaft pulley bolt; discard bolt.

WARNING: CRANKSHAFT BOLT IS
TIGHTENED TO 460 Nm (340 lbf.ft), ENSURE
ENGINE IS ADEQUATELY RESTRAINED.

6. Remove crankshaft pulley.

7. Remove sump gasket.

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ENGINE - Td5, OVERHAUL, Gasket

- engine sump.

8. Noting their fitted position, remove 8 bolts

securing timing chain cover.

9. Release timing chain cover from locating

dowels, remove cover.

10. Remove bolt securing oil pump drive sprocket.
11. Remove oil pump drive sprocket.
12. Remove camshaft and crankshaft sprockets

together with timing and oil pump drive chains.

13. Remove Woodruff key from crankshaft.

14. Remove 2 bolts and remove timing chain fixed

guide.

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 12-1-95

15. Apply Loctite 242 to threads of oil pump drive

sprocket bolt, fit bolt and tighten to 25 Nm (18
lbf.ft).

16. Fit timing chain fixed guide, fit bolts and tighten

to:

l

M6 bolt – 10 Nm (7 lbf.ft)

l

M10 bolt – 45 Nm (34 lbf.ft)

17. Fit timing chain adjustable guide, fit bolt and

tighten to 25 Nm (18 lbf.ft).

18. Fit camshaft sprocket to timing chain with

timing mark on sprocket between the 2
coloured links, suitably retain sprocket on
chain.

19. Fit timing chain to crankshaft sprocket aligning

coloured link to timing mark on sprocket.

20. Ensure timing marks are positioned as shown -

No.1 piston at TDC firing.

21. Apply an even film of sealant Part No. STC

4600 to mating face of timing cover and
spread to an even film using a roller.

CAUTION: Assembly and bolt tightening
must be completed within 20 minutes of
applying sealant.

22. Fit timing cover, fit bolts in their original fitted

positions and working from the centre
outwards, tighten progressively to 27 Nm (20
lbf.ft).

23. Fit oil seal guide, from seal kit over end of

crankshaft.

24. Fit new oil seal into timing cover using tool

LRT-12-156.

CAUTION: Oil seal must be fitted dry.

25. Remove tool LRT-12-156 and oil seal guide.
26. Fit crankshaft pulley, fit and lightly tighten

crankshaft pulley bolt.

ENGINE - TD5

12-1-96 OVERHAUL

27. Fit tool LRT-51-003 to crankshaft pulley,

secure with 2 bolts. Using assistance, restrain
engine and using a torque multiplier tighten
bolt to 450 Nm (340 lbf.ft).

WARNING: DUE TO THE HIGH TORQUE
LOADING REQUIRED, IT IS ESSENTIAL
THAT ENGINE IS ADEQUATELY
RESTRAINED.

28. Remove tool LRT-51-003.
29. Position damper to crankshaft pulley, fit 3 bolts

and tighten to 80 Nm (60 lbf.ft).

30. Fit sump gasket.

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ENGINE - Td5, OVERHAUL, Gasket

- engine sump.

31. Fit cylinder head gasket.

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ENGINE - Td5, OVERHAUL, Gasket

- cylinder head.

Bearings - connecting rods

$% 12.17.16.01

Disassembly

1. Remove oil pump.

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ENGINE - Td5, OVERHAUL, Pump -

oil.

2. Mark cylinder reference number on each

connecting rod big-end bearing cap.

3. Make suitable alignment marks between each

big-end bearing cap and connecting rod.

CAUTION: Due to the 'fracture split' method
of manufacturing connecting rods,
incorrect fitment of cap to rod will damage
mating faces and necessitate replacement
of connecting rod assembly.

4. Rotate crankshaft clockwise until No.1 big-end

is at BDC.

5. Remove and discard 2 bolts securing each

connecting rod big-end bearing cap.

6. Remove bearing cap, remove and discard big-

end bearing shell.

7. Push connecting rod up cylinder bore until

connecting rod is clear of crankshaft journals.

CAUTION: Ensure that connecting rod does
not contact cylinder bore or oil squirt jet and
piston does not contact the valves or EUI's
if the cylinder head is fitted.