Discovery I (LJ) V8-4.0L (1996)
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1. Clamp hexagon body of LRT-12-013 in vice.
2. Screw large nut back until flush with end of centre screw.
3. Push centre screw forward until nut contacts thrust race.
4. Locate remover/replacer adapter LRT-12-126/2 with its long spigot inside bore of hexagon body.
5. Position remover/replacer adapter LRT-12-126/3 on LRT-12-126/2 with cut-out facing away from body of LRT-12-013.
6. Locate piston and connecting rod assembly on centre screw and up to adapter LRT-12-126/2.
7. Position cut-out of adapter LRT-12-126/3 to piston.
CAUTION: Ensure cut-out does not contact gudgeon pin.
8. Fit remover/replacer bush LRT-12-126/1 on centre screw with flanged end away from gudgeon pin. Screw stop nut on to centre screw.
9. Lock the stop nut securely with lock screw.
10. Push connecting rod to right to locate end of gudgeon pin in adapter LRT-12-126/2.
11. Screw large nut up to LRT-12-013.
12. Hold lock screw and turn large nut until gudgeon pin is withdrawn from piston.
13. Dismantle tool and remove piston, connecting rod and gudgeon pin.
NOTE: Keep each piston and gudgeon pin with their respective connecting rod.
14. Repeat above operation for remaining pistons.
Pistons - inspection
1. Clean carbon from pistons.
2. Inspect pistons for distortion, cracks and burning.
3. Measure and record piston diameter at 90 ° to gudgeon pin axis and 10 mm (0.4 in) from bottom of skirt.
4. Check gudgeon pin bore in piston for signs of wear and overheating.
NOTE: Pistons fitted on production are graded 'A' or 'B', the grade letter is stamped on the piston crown.
Production piston diameter:
Grade A = 93.970 to 93.985 mm (3.700 to 3.7002 in)
Grade B = 93.986 to 94.00 mm (3.7003 to 3.701 in)
Grade B pistons are supplied as service replacements. Worn cylinder liners fitted with grade 'A' pistons may be honed to accept grade 'B' pistons
provided that specified cylinder bore and ovality limits are maintained.
CAUTION: Ensure replacement pistons are correct for the compression ratio of the engine. The compression ratio will be found on the
cylinder block above the engine serial number. Ensure that replacement connecting rods are correct length for engine being overhauled.
Connecting rod length between centres:
4.0 litre = 155.12 to 155.22 mm (6.10 to 6.11 in)
4.6 litre = 149.68 to 149.78 mm (5.89 to 5.91 in)
Gudgeon pins - inspection
