Discovery 2. Manual — part 10
GENERAL DATA
04-5
Idle speed:
⇒
All loads off
660
±
50 rev/min
⇒
Base idle speed
Non-adjustable
⇒
Idle air control (IAC) valve position
Checked via TestBook
CO at idle:
⇒
Catalyst vehicles
0.5 %
⇒
Non-catalyst vehicles
0.5 - 1.0 %
Valve timing
Inlet valves:
⇒
Opens
28
°
BTDC
⇒
Closes
77
°
ABDC
Exhaust valves:
⇒
Opens
66
°
BBDC
⇒
Closes
39
°
ATDC
Fuel grade:
⇒
High compression catalyst vehicles
95 RON minimum unleaded
⇒
Low compression catalyst vehicles
91 RON minimum unleaded
⇒
Non-catalyst vehicles
97 RON leaded
Lubrication
Type
Wet sump, pressure fed
Pump type
Crankshaft driven eccentric rotor
Oil filter
Disposable canister with full flow by-pass
Pressure at idle - minimum
0.7 bar (10 lbf.in
2
)
Pressure at 2000 rev/min (hot)
3.4 bar (50 lbf.in
2
)
Relief valve opening pressure
3.4 bar (50 lbf.in
2
)
Low oil pressure switch opening pressure
0.24-0.41 bar (3.5-6.0 lbf.in
2
)
Crankshaft
Main journal diameter
63.487 - 63.500 mm (2.4995 - 2.520 in)
Crankpin journal diameter
55.500 - 55.513 mm (2.20 - 2.22 in)
End float
0.08 - 0.26 mm (0.003 - 0.010 in)
Maximum ovality
0.040 mm (0.002 in)
Main bearings
Quantity
5
Material
Glacier Vandervell / AS 15
Diametrical clearance
0.015 - 0.016 mm (0.00059 - 0.00063 in)
Connecting Rods
Type
Horizontally split big-end, plain small end
Distance between centres
155.120 - 155.220 mm (6.1071 - 6.1110 in)
Big-end bearings
Quantity
8
Material
Glacier Vandervell GPL 2120/AS 124A
Diametrical clearance
0.015 - 0.016 mm (0.00059 - 0.00063 in)
End float
0.15 - 0.35 mm (0.0006 - 0.0138 in)
GENERAL DATA
04-6
Gudgeon pins
Diameter
23.995 - 24.000 mm (0.9447 - 0.9449 in)
Clearance in piston
0.006 - 0.015 mm (0.00024 - 0.00059 in)
Fit in connecting rod
Press fit
Length
60.00 - 60.50 mm (2.362 - 2.382 in)
Pistons
Type
Solid skirt, elliptical open end with offset gudgeon pin
Material
Aluminium AE413P
Clearance in cylinder bore.
Measured 10 mm (0.4 in) from bottom of skirt, 90
°
to
gudgeon pin.
0.015 - 0.045 mm (0.001 - 0.002 in)
Diameter - Grade A
93.970 - 93.985 mm (3.6996 - 3.7002 in)
Diameter - Grade B
93.986 - 94.001 mm (3.7002 - 3.7008 in)
Piston rings
Type:
2 compression, 1 oil control
⇒
Top compression ring
Barrel faced nitrided steel
⇒
2nd compression ring
Tapered spherical
⇒
Oil control ring
3 piece AE Conoform
Piston ring fitted gap in cylinder bore:
⇒
Top compression ring gap
0.3 - 0.5 mm (0.012 - 0.020 in)
⇒
2nd compression ring gap
0.40 - 0.65 mm (0.016 - 0.026 in)
⇒
Oil control ring gap
0.38 - 1.40 mm (0.015 - 0.055 in)
Piston ring width:
⇒
Top compression ring width
1.21 - 1.23 mm (0.0476 - 0.0484 in)
⇒
2nd compression ring width
1.478 - 1.490 mm (0.0582 - 0.0587 in)
⇒
Oil control ring width
3.00 mm (0.1181 in)
Piston ring to groove clearance:
⇒
1st and 2nd compression rings
0.05 - 0.10 mm (0.002 - 0.004 in)
Camshaft
Bearings
5
Drive
Chain, 9.52 mm (0.3748 in) pitch x 54 pitches
End float
0.075 - 0.25 mm (0.002 - 0.010 in)
Tappets
Type
Hydraulic self adjusting
Outside diameter
21.386 - 21.407 mm (0.8420 - 0.8427 in)
GENERAL DATA
04-7
Valves
Stem diameter:
⇒
Inlet
8.664 - 8.679 mm (0.3411 - 0.3417 in)
⇒
Exhaust – 4.0 litre up to engine nos. 55D 05677A;
56D 50787A; 97D 05504A
⇒
Exhaust – 4.0 litre from engine nos. 55D 05678A;
56D 50788A; 97D 05505A and all 4.6 litre
8.651 - 8.666 mm (0.3406 - 0.3412 in)
8.641 to 8.656 mm (0.340 to 0.341 in)
Head diameter:
⇒
Inlet
39.75 - 40.00 mm (1.5650 - 1.5748 in)
⇒
Exhaust
34.227 - 34.481 mm (1.3475 - 1.3575 in)
Seat face angle:
⇒
Inlet
46
°
25' - 46
°
00'
⇒
Exhaust
46
°
25' - 46
°
00'
Valve face angle:
⇒
Inlet
45
°
00' - 45
°
30'
⇒
Exhaust
45
°
00' - 45
°
30'
Valve springs
Free length
48.8 mm (1.92 in)
Fitted length
40.93 mm (1.61 in)
GENERAL DATA
04-8
Fuel system - Td5
Fuel system - V8
Type
Direct injection from pressure regulated supply with cooled return flow
and in-line pressure regulator
Pressure regulator setting
4 bar (58 lbf.in
2
)
Pump
Electric two stage submersible
Pump output:
⇒
Low pressure
30 l/h (6.6 gal/h) (7.93 US gal/h) at 0.5 bar (7.25 lbf.in
2
)
⇒
High pressure
180 l/h (39.6 gal/h) (47.55 US gal/h) at 4 bar (58 lbf.in
2
)
Maximum consumption
30 l/h (6.6 gal/h) (7.93 US gal/h)
Injectors Make/type
Lucas EV1/Dual stage
Injector operating pressures:
Pre EU3 models
⇒
Initial opening pressure
270 bar (3915 lbf.in
2
)
⇒
Fully opened pressure
440 bar (6380 lbf.in
2
)
⇒
Maximum pressure
1560 bar (22620 lbf.in
2
)
EU3 models:
⇒
Initial opening pressure
270 bar (3915 lbf.in
2
)
⇒
Fully opened pressure
440 bar (6380 lbf.in
2
)
⇒
Maximum pressure
1750 bar (25375 lbf.in
2
)
Filter
In-line canister filter/water separator with water detection
Air cleaner
Mann and Hummell P0037
Type
Multiport injection from pressure regulated, returnless supply
Pump
Electric submersible
Regulated pump output pressure
3.5 bar (50.75 lbf.in
2
)
Fuel pump delivery
120 litres/hr (211 pints/hr) (234 US pints/hr)
Filter
In-line canister
Air filter
Mann and Hummell P0036
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