Land Rover Discovery Series 2 Manual
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10ORDER ON:01522 568000 / www.rimmerbros.co.uk DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. TENSIONER ERR6439 MORE STOCK MORE STOCK EVER EVER Y DA Y DA Y Y If the part you require is not listed here, please phone and enquire. By now we might well have it. For prices, terms & conditions etc, please refer to our latest price guide. Drivebelts Drivebelt - ancillary components; Td5 with ACE* air con (1)PQS101510 non air con (1)PQS101520 without ACE* air con (1)PQS101500 non air con (1)PQS101490 V8 (serpentine belt) with ACE* air con (1)ERR6896 non air con (1)ERR6897 without ACE* air con (1)ERR6898 non air con (1)ERR6899 Tensioner - drivebelt; Td5 (all models) (1)ERR6951 V8 (all models) (1)ERR6439 (*ACE = Active Cornering Enhancement) Cables Accelerator cable (1)SBB500010 Handbrake cable; up to VIN XA224663 (1)SPB101500 VIN XA224664 on (1)SPB000150 Bonnet release cable (1)FSE100600 Cruise control cable (1)SCD100070 Engine/Transmission Sensors Sensors - engine; Td5 temperature inlet manifold (1)MHK100640 fuel connector block (1)ERR2081 coolant elbow (1)ERR2081 crank sensor (1)NSC100790 V8 airflow sensor (1)ERR7171 seal - airflow sensor (1)PHN100200 crank sensor manual (1)ERR7352 automatic (1)ERR7354 knock sensor (2)NSC100650 temperature sensor (1)MEK100160 camshaft sensor (1)ERR6169 lambda sensor (2)MHK100920 Oil pressure switch; Td5 (1)NUC10003 V8 (1)STC4104 Transmission sensors/switches; reverse light switch manual (1)AMR3918 reverse (1)PRC2911 low ratio detect switch (1)IGM100000 Transfer box.temperature sensor - V8 (1)PRC7984 QUICK FINDER - SERVICE ITEMS BELT TENSIONER ERR6439 PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. 2 - p8 - 10 21/6/07 13:19 Page 2
TD5 ENGINE & COMPONENTS 11ORDER ON:01522 568000 / www.rimmerbros.co.uk DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. In this section, we have listed only the components commonly required for servicing and reconditioning the 2.5TD engine. However, we have a comprehensive range of parts available. If you require a part which is not listed, please contact us for price and availability. Td5 Diesel Engine Genuine Land Rover Units. Short engine (1)LBB001200RExchange.Stripped engine;Exchange.early (to 1A622423) (1)LBB001180R late (2A622424 on) (1)LBB001190R Cylinder Block Components - Td5 Engine Core plug set - cylinder block (1)LL1081 Crankshaft assembly (1)ERR5291 Bush - crankshaft (1)8566L Main bearings - engine set; standard size (1)STC3299 0.010” oversize (1)STC3299010 0.020” oversize (1)STC3299020 Thrust washer set (pair) (2)ERR5345 Piston; Supplied individually, complete with rings, gudgeon pin and circlips. up to VIN 1A736339 (5)LFL000460 VIN 2A736340 on (5)LFL105300 Piston rings only (per piston); up to eng.no.10P13888B (5)LFT500040 eng.no.10P13889B up to VIN 1A736339 (5)STC4668 VIN 2A736340 on (5)LFT500040 Jet - piston cooling (5)LFQ100310 Con rod (5)ERR6953 Complete with small end bush and bolts.Small end bush - conrod (5)ERR6978 Big end bearings - engine set; (1)STC3300 standard size (1)STC3300 0.010” oversize (1)STC330010 0.020” oversize (1)STC3300020 Cylinder Head - Td5 Cylinder head, complete reconditioned; up to VIN 1A736339 (1)LDF107860R VIN 2A736340 on (1)LDF000890R Gasket - cylinder head; 1.20mm (2 holes) (1)LVB000240 1.27mm (1 hole) (1)LVB000250 1.35mm (3 holes) (1)LVB000260 Bolt - cylinder head (12)ERR5384 Injector and sensor assembly; to VIN 1A736339 (blue) (5)MSC000040 VIN 2A736340 on (green) (5)MSC000030 ‘O’-ring - injector (all) (5)ERR7004 Washer - injector (all) (5)ERR6417 Heater plug - ignition (5)ERR6066 Valve; inlet (5)ERR6611 exhaust (5)ERR6612 Valve guide (10)ERR7225 Oil seal - valve stem (10)LJQ100940 Valve seat; inlet (10)ERR7049 exhaust (10)ERR7050 Valve spring (10)LGL500050 Cap - valve spring (10)ERR6013 Collet - valve (20)ERR3907 Follower assembly - valve (10)ERR7234 Adjuster - valve lash (10)ERR7233 Rocker and arm assembly (1)MUI000040 Without adjusting screws and nuts.Adjusting screw - rocker arm; up to VIN 1A736339 (5)ERR7065 VIN 2A736340 on (5)LGV000020 Nut - adjusting screw (5)ERR5529 Bolt - rocker shaft to cylinder head(6)LYG101510 Connector assembly - fuel block; up to eng. no. 10P15967B (1)MSX000010 eng. no. 10P15968B up to VIN 1A736340 (1)MSX100080 VIN 2A736340 on (1)MSX000010 Gasket - fuel connector block; up to eng. no. 10P15967B (1)MSX100080 eng. no. 10P15968B on (1)MSX000010 Temp’ sensor - fuel connector block(1)ERR2081 Washer - temperature sensor (1)ERR6192 Camshaft - Td5 Camshaft; up to VIN 1A622423 (1)LGC000320L VIN 2A622424 on (1)LGC000310 Follower - camshaft (10)ERR7234 Adjuster - lash (10)ERR7233 Seal - camshaft; front (1)LDI100030 rear (1)ERR5369 Timing Chain - Td5 Timing chain & sprocket kit (1)LHA000030Includes crankshaft sprocket.Sprocket - crankshaftUseLHA000030 Tensioner - timing chain; up to VIN 1A736339 (1)LHP000090 VIN 2A736340 on (1)LHP000080 Tensioner arm - timing chain (1)LGQ000020 Jet - chain lubrication (1)LNL100000 Oil pump chain & sprocket set (1)LQX100130 Oil Pump & Filter Oil pump (1)LPF101250 Gasket - oil pump (1)LVG100340 Oil filter (1)LPX100590 Gaskets - Td5 Gasket; cylinder head 1.20mm (2 holes) (1)LVB000240 1.27mm (1 hole) (1)LVB000250 1.35mm (3 holes) (1)LVB000260 camshaft cover (1)ERR7094 oil separator (1)ERR7155 oil cooler adaptor (1)ERR7220 oil filter housing (1)LVH100230 coolant elbow up to eng. 10P86382A (1)ERR7032 eng. 10P86383A on (1)LVJ000010 inlet manifold (1)LKJ000010 exhaust manifold cylinder head to manifold (1)LKG100470 manifold to turbo (1)ERR6768 sump (1)LVF500040 Washer - sump plug (1)CDU1001 ‘O’-ring - oil pick-up pipe (1)ERR6401 Oil seals - engine; crankshaft front (1)ERR5992 rear (1)LUF100420 camshaft oil seal front (1)LDI100030 rear (1)ERR5369 oil filler cap seal (1)LUD100040L Miscellaneous Components - Td5 Turbocharger -See page 21.Bearing - cooling fan (1)ERR5285Located in engine front cover.Circlip - cooling fan bearing (1)CR110625 INJECTOR ASSEMBLY MSC000030TIMING CHAIN KIT LHA000030 FUEL BLOCK CONNECTOR ASSY MSX000010 PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. 2 - p8 - 10 21/6/07 13:19 Page 3
IMPORTANT NOTES - SHORT ENGINES Please note the following important points regarding engine assembly: SHORT ENGINE BUILD-UP When building up a short engine to a complete assembly, it is essential to thoroughly examine every part you intend to re-use. We recommend that you pay special attention to the camshaft, followers, pushrods & rocker gear, checking carefully for signs of wear; re-using worn parts is false economy and you risk contaminating your new engine with abrasive particles. The following parts MUST be meticulously cleaned prior to fitting:- sump & oil pick-up pipe timing cover & oil pump assembly cylinder heads rocker covers Failure to observe these points may lead to engine damage and may invalidate the engine’s warranty. ANCILLARY COMPONENTS If you are re-fitting ancillary components - water pump, alternator, or fuel injection - check that they are suitable for re-using. We recommend having fuel injectors cleaned/ replaced before re- fitting. The cooling system - including the radiator and heater - should be flushed through with clean water and the hoses checked before re-using. The correct ratio (minimum 33%) of antifreeze must be maintained at all times. Oil coolers should be flushed of old engine oil. Engine & gearbox mountings should be checked and renewed as necessary. The clutch operating system should be checked for wear. V8 ENGINE UNITS 12ORDER ON:01522 568000 / www.rimmerbros.co.uk PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. Long engine- Built-up block & cylinder heads assembly, including crank, rods & pistons, valves, guides & springs (less rocker gear), plus camshaft, followers & timing gear. LONG ENGINE Short engine- Built-up block assembly, comprising crank, rods & pistons. SHORT ENGINE IMPORTANT NOTES - LONG ENGINES Please note the following important points regarding engine assembly: LONG ENGINE BUILD-UP These engines are supplied less rocker gear, pushrods, sumps & timing covers. It is absolutely essential that these items are checked, cleaned and correctly assembled prior to running your engine. Check for wear on the underside of rocker shafts, on either side of the pedestals. Check for wear on the valve tips of rocker arms. Check pushrods for straightness and equal length. Clean the sump and oil pick-up pipe. Clean the timing cover and check the oil pump housing for wear and damage. Replace all seals and gaskets. If in any doubt, always replace with new components. ANCILLARY COMPONENTS If you are re-fitting ancillary components - water pump, alternator or fuel injection - check that they are suitable for re-using. We recommend having fuel injectors cleaned/replaced before re- fitting. The cooling system - including the radiator and heater - should be flushed through with clean water and the hoses checked before re-using. The correct ratio (minimum 33%) of antifreeze must be maintained at all times. Oil coolers should be flushed of old engine oil. Engine & gearbox mountings should be checked and renewed as necessary. The clutch operating system should be checked for wear. Rocker covers should be cleaned internally. Failure to observe these points may lead to engine damage and may also invalidate the engine’s warranty. We are pleased to be able to offer a fitting service for either our full or short engines. Please contact us for a quotation or to discuss your requirements. OUR CHARGES ARE VERY REASONABLE! ROVER V8 ENGINE NUMBERSEngine Number Application Approximate Year FACTORY 4.0 LITRE ENGINES42D00001A S2 R.Rover4.0 efi HC 1994-2002 44D00001A S2 R.Rover4.0 efi LC 1994-2002 55D00001A Discovery SII 4.0 LC 1998-2004 56D00001A Discovery SII 4.0 LC 1998-2004 57D00001A S2 R.Rover4.0 efi LC 1998-2002 58D00001A S2 R.Rover4.0 efi HC 1998-2002 69D00001A Discovery SII 4.0 LC 1998-2004 70D00001A Discovery SII 4.0 LC 1998-2004 71D00001A Discovery SII 4.0 LC 1998-2004 72D00001A Discovery SII 4.0 LC 1998-2004 85D00001A Discovery SII 4.0 LC 1998-2004 86D00001A Discovery SII 4.0 LC 1998-2004 87D00001A Discovery SII 4.0 LC 1998-2004 88D00001A Discovery SII 4.0 LC 1998-2004 89D00001A Discovery SII 4.0 LC 1998-2004 90D00001A Discovery SII 4.0 LC 1998-2004 91D00001A Discovery SII 4.0 LC 1998-2004 92D00001A S2 R.Rover Canada 4.0 efi LC 1998-2002 94D00001A Discovery SII 4.0 LC 1998-2004 95D00001A S2 R.Rover NAS 4.0 efi HC 1998-2002 V8 Factory - Long Engine Factory assembled unit comprising, block, crank, rods, pistons, heads & camshaft. Less anciliaries. Please enquire for availability and detailed specification. Exchange. Long Engine - 4.0 litre (1)ERR5012STRG Installation kit (1)RB8003 Inc. oil, filter, gaskets etc. V8 Factory - Short Engine Factory assembled unit comprising, block, crank, rods & pistons. Please enquire for availability and detailed specification. Exchange. Short Engine - 4.0 litre (1)STC1891 V8 ENGINE UNITS 3 - P11 - 18 21/6/07 13:37 Page 1
DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. 13ORDER ON:01522 568000 / www.rimmerbros.co.uk MORE STOCK MORE STOCK EVER EVER Y DA Y DA Y Y If the part you require is not listed here, please phone and enquire. By now we might well have it. For prices, terms & conditions etc, please refer to our latest price guide. V8 CYLINDER HEAD COMPONENTS PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. V8 Gaskets & Oil Seals Head gasket set (1)RA1233 Head gasket only (2)LVB500030 Sump gasket set (1)STC1639 Sump gasket only (1)LVF100400 Main bearing cap (rear) (2)611089A Cruciform seal.Timing cover gasket (1)ERR7280 Water pump gasket (1)ERR4077 Rocker cover gasket (2)LVC100260 Inlet manifold gasket; to cylinder heads (1)ERR7306 to inlet runners (1)ERR6621 end seals (2)ERR7283 Exhaust manifold; to cylinder heads (4)ERR6733 to downpipes (2)ETC4524 Crank oil seal; front (1)ERR6490 rear (1)ERR2640 Oil filter adaptor ‘O’ ring (1)ERR7308 V8 Cylinder Head Bolts Bolt - cylinder head (1995 onwards); Note: These bolts can be identified by their flanged head. They do not need a separate washer and can be used on earlier engines. However, they are not re-useable and must be replaced once removed. long (96mm) (6)ERR2944 medium (66mm) (14)ERR2943A Cylinder head stud kit (1)RB7680 Engine set of ARP cylinder head studs, washers and nuts to replace original bolts. Studs improve cylinder head sealing & prevent damage to block threads. STUD KIT RB7680 3 - P11 - 18 21/6/07 13:38 Page 2
V8 CYLINDER HEAD COMPONENTSDESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. 14 V8 Valves, Guides & Springs Note: all parts supplied are suitable for unleaded applications. Inlet valve; standard (8)ERC9088A Head diameter: 40mm. ‘big valve’ (8)RB7460Head diameter: 41.4mm. With waisted stem. Machining required to valve guide and seat. Exhaust valve; standard (8)LGH000040 Head diameter: 34mm. ‘big valve’ (8)RB7461Head diameter: 35.5mm. With waisted stem. Machining required to valve guide and seat. Valve seat insert - inlet; standard size (8)ERC224A oversize + 0.010 (8)ERC225A Valve seat insert - exhaust; standard (8)ETC8596A oversize + 0.010 (8)ERC211A Valve guide - standard (16)ERR3648 For use with standard cam. Stepped top, for use with neoprene seals (ERR1782) and matching valves. Valve guide - performance;Shortened & bulleted, for use with performance cam. Suitable for all valves. car set (inlet/exhaust) (1)RB7453 individual inlet (8)RB7463 exhaust (8)RB7464 Valve stem oil seal (16)ERR1782Inlet & exhaust. Neoprene type.Valve spring - standard (16)UKC8137 Valve spring - uprated - engine set; single (1)RB7454 Suitable for all engines with mild road camshaft. Uses standard retaining caps (ERC573). double (see Note below)(1)RB7455Suitable for all engines with fast road or road/rally camshaft. Special retaining caps required (ERC573S). Note: machining may be required to spring platform when fitting double valve springs to engines previously fitted with singles. Retaining cap - valve springs; single valve springs (16)ERC573A uprated double valve springs(16)ERC573S Split cotter - all models (32)ERC1637A V8 Rocker Gear Rocker shaft assembly (2)611660Assembled, ready to fit.Rocker build kit (2)611660KIncludes parts ready for assembly.Rocker shaft only (2)606661 Pedestal - rocker shaft (8)603734A Pedestal shims (1)603734SH Includes three sets of shims of different thickness. Use to set lifter preload when fitting a new cam with higher lift than standard. See also adjustable push rods, below. Rocker arm; original spec (alloy) right hand (8)602153 left hand (8)602154 Spacer spring - rocker shaft (6)602142A End spring - rocker shaft (4)602148A Wavy washer.End washer - rocker shaft (4)602186A Split pin - rocker shaft (4)PC34 Push rod; standard (16)603378 heavy duty (16)603378HD Larger diameter shaft. Cylinder head guide holes may need enlarging accordingly. adjustable (engine set) (1)603378ADJSet of pushrods, adjustable for length at the rocker end, allowing the lifter preload to be precisely set without shims. 602154A (16) 602142A (6) 602148A (4) 602097 (8) 603734A (8) ERC4949A (16)HYDRAULIC TAPPETPUSHROD REFER TO LISTINGS ROCKER SHAFT ASSEMBLY 611660A (2) V8 ROCKER GEAR WHAT IS LIFTER PRELOAD? “Lifter preload” refers to the position of the pushrod seat in the lifter (cam follower) when the engine has been assembled and the lifter is positioned on the heel of the cam. Lifter preload must be checked whenever a non-standard component which alters the distance between the rocker arm and the lifter - such as a high lift camshaft or performance cylinder head - has been fitted. Incorrect lifter preload will cause poor running, premature wear or, at worst, engine failure. Check the lifter preload as follows: With the lifters empty of oil, assemble the rocker shaft & pushrod components, making sure there is no wear in the rocker shafts, rocker arms & pushrods. Checking each lifter in turn, positioned on the heel of the cam, measure the gap between the pushrod seat and the bottom of the circlip groove. There must be a clearance of .020” minimum and .060” maximum at this position. If the clearance is greater than .060”, use pedestal shims (603734SH) to decrease. Remember to use equal thickness shims under each pedestal of a shaft to avoid distortion or breakage. HEAVY DUTY & ADJUSTABLE PUSH RODS V8 ROCKER GEAR ORDER ON:01522 568000 / www.rimmerbros.co.uk PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. 3 - P11 - 18 21/6/07 13:38 Page 3
V8 ROCKER COVERS & CAMSHAFTDESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. 15ORDER ON:01522 568000 / www.rimmerbros.co.uk V8 Rocker Covers Rocker covers - single; rh (1)LDR000210 lh (1)LDR000200 Rocker covers - pairs; unpainted (1)RB7431 powder coated black (1)RB7431PCB red (1)RB7431PCR Gasket - rocker cover (rubber) (2)LVC100260 Screw - rocker cover retaining; long (4)ERR2944 short (4)ERR2943A Rocker cover T-Bolts - chrome (2)RB7440 American style rocker cover hold down bolts, supplied in sets of 4 (2 sets reqd). Breather/flame trap;Right hand rocker cover, where fitted.standard (1)RB7432 powder coated black (1)RB7432PCB red (1)RB7432PCR chrome (1)RB7432C Breather grommet (pair) (1)RB7432ZG ‘O’ ring/seal-flame trap (1)564258A Oil filler neck (1)ERR7335 Gasket - filler neck (1)564258A Oil filler cap (1)ERR5218 ‘O’ ring/seal - filler cap (1)ERR5219 Breather filter (1)ERC3209A Rear of LH rocker cover. Cap - breather filter (1)ERC3208A Plug lead retainer (where fitted) (2)603672A Holds 4 leads. V8 Camshaft Components Camshaft - standard - 4.0 litre (1)ERR3720 Uprated camshaft kit (1)RA2015 Suitable for 4.0 litre engine - no modifications necessary to the fuelling. Driveability is improved, along with a noticeable increase in low-end torque over the standard camshaft. Kit contains uprated camshaft, new followers, timing chain and sprockets, plus gaskets. Collar - camshaft retaining (1)ERR2609 Cam follower; each (16)ERC4949A set of 16 (1)ERC4949K Cam lube (1)RX1358 Gasket - inlet manifold; to cylinder heads (1)ERR7306 to inlet runners (1)ERR6621 End seal for gasket (2)ERR7283 Clamp for seal (2)ERR7282 Screw for clamp (2)602236 ERR2944 (LONG) (4) ERR2943A (SHORT) (4) ERC3208A ERC3209A ERR5218 ERR5219 ERR7335 LVC100260 (2)LDR000210 (RH) LDR000200 (LH) ROCKER COVER POWDER COATED ROCKER COVERS MOULDED RUBBER ROCKER COVER GASKETS - LVC100260 STANDARD CAMSHAFT - ERR3720 AND COLLAR - ERR2609 DESCRIPTION QTY REQ. PART No. PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. 3 - P11 - 18 21/6/07 13:38 Page 4
V8 ENGINE COMPONENTSDESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. 16 Crank Pulley, Flywheel & Auto Drive Plate Please enquire for price and availability quoting vIn number & engine number. V8 Timing Chain Timing chain; standard (1)ERC7929A adjustable kit (1)RB7449 Includes vernier camshaft sprocket and double roller chain. Also includes timing protractor and Allen key. Fully adjustable cam sprocket allows extremely accurate cam timing whilst eliminating stretch. Instructions included. Replacement chain (adjustable kit) - double roller (1)RB7450 Camshaft sprocket - standard (1)ERR7375 Thrust plate - cam (1)ERR2609 Cam retaining collar (1)ERR5926 Screw - thrust plate (2)SH505061 Woodruff key (1)ERC2838A V8 Timing Cover & Fittings Timing cover (fitted with oil pump rotors);up to VIN XA231750 (1)ERR6438 VIN XA231751on (1)LJR105040 Oil pump rotors (1)RA2016 Replacement rotors (inner and outer) for the crank-driven oil pump inside the timing cover. Gasket - timing cover (1)ERR7280 Oil seal - front crankshaft (1)ERR6490 Oil pressure switch (1)STC4104 Adaptor - oil filter (1)LPY000010 ‘O’-ring seal - oil filter adaptor (1)ERR7308 V8 Cylinder Block & Components Cylinder block - V8 (1)LCF1045604.0 litre engine. Supplied with main bearing caps, cam bearings, core plugs and liners. Less crankshaft, pistons etc. Core plug set - block (1)RB7105 Cam bearing set (1)STC1961 Crankshaft oil seal; front (1)ERR6490 rear (1)ERR2640 Bolt - main bearing cap (10)602130A Cross-bolt - mains cap (9)FB110137 Hex bolt - mains cap (1)SS110555 Oil seal - mains cap bolt; for FB110137 (9)ERR3330 for SS110555 (1)ERR3331 Crank sensor housing - block (1)ERR3693 V8 Sump & Dipstick Sump pan (1)LSB102810 Sump gasket set (1)STC1639 Sump gasket only (1)LVF100400 Drain plug - sump (1)LSF100040L Washer - drain plug (1)UAM2857 Oil pick-up strainer/pipe (1)ERR4795 Dipstick (1)LQM100920 Tube - dipstick (1)ERR4550 V8 Crankshaft Crankshaft (New less bearings);4.0 litre (1)ERR5090 Main bearings; standard size (1)STC1425 oversize + 0.10” (1)STC1425.010 oversize + 0.20” (1)STC1425.020 Main bearing set - standard (1)STC4299 Bolt - main bearing cap (10)602130A Spigot bush - crankshaft (1)549911 Woodruff key - crankshaft (1)ERR2846 Sprocket - crankshaft (1)90602372A V8 Pistons & Con Rods Piston - single - standard ;4.0 litre. Includes rings. For oversize pistons, see Piston Set. 8.13:1cr (8)ERR5555 9.35:1cr (8)ERR5553 Piston set - oversize +0.20 (1)RA2017 4.0 litre. Set of 8 oversize pistons with rings. Piston ring set - standard (1)STC1427 Con rod (4.0 litre)(8)ERR4837 Bolt - con rod (16)ERR1772 Big end bearing set; standard (1)STC1426 oversize + 0.10” (1)STC1426.010 oversize + 0.20” (1)STC1426.020 V8 Gaskets & Oil Seals Head gasket set (1)RA1233 Head gasket only (2)LVB500030 Sump gasket set (1)STC1639 Sump gasket only (1)LVF100400 Main bearing cap (rear) (2)611089A Cruciform seal.Timing cover gasket (1)ERR7280 Water pump gasket (1)ERR4077 Rocker cover gasket (2)LVC100260 Inlet manifold gasket; to cylinder heads (1)ERR7306 to inlet runners (1)ERR6621 end seals (2)ERR7283 Exhaust manifold; to cylinder heads (4)ERR6733 to downpipes (2)ETC4524 Crank oil seal; front (1)ERR6490 rear (1)ERR2640 Oil filter adaptor ‘O’ ring (1)ERR7308 STANDARD TIMING CHAIN - ERC7929A CAMSHAFT SPROCKET - ERR5086 CRANK SPROCKET - 90602372 V8 PISTON, COMPLETE WITH PIN & RINGS ORDER ON:01522 568000 / www.rimmerbros.co.uk PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. 3 - P11 - 18 21/6/07 13:38 Page 5
DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. Engine & Gearbox Mountings Engine mounting rubber; Td5 (2)KKB102602 V8 (2)KKB102450 Screw - mounting rubber - Td5 (4)FS112281L Nut - engine mounting rubber; Td5 (6)FX110047L V8 (4)FX112041L Heatshield - LH mounting - V8 (1)KKJ100100 Bracket - engine mounting; Td5 rh (1)KKU000740 lh (1)ANR6623 V8 rh (1)KKU106200 lh (1)ANR6338Screw - engine mounting bracket; Td5 (8)FS110301L V8 large (4)ANR3329 small (2)ANR3589Gearbox mounting rubber; rh (1)KQB100140 lh (1)KQB100150 Screw - gearbox mounting rubber; rh (1)FS112251L lh (1)FS112201L Nut - gearbox mounting rubber (2)FX110047L Bracket - gearbox mounting - Td5 & V8; rh (1)ANR5636 lh manual (1)KKU000710 automatic (1)ANR5639 CLUTCH & FLYWHEEL - ENGINE & GEARBOX MOUNTINGS Flywheel & Driveplate Flywheel; Td5 manual (1)PSD103470 automatic (1)TKB100010 V8 (manual) (1)PSD103340 Ring gear - flywheel; Td5 (1)PSF100140 V8 (1)PSF000030 Driveplate (automatic); Td5 (1)FTC4713 V8 (1)TPD000040 Ring gear - driveplate - V8 (1)PSF000030 Clutch Components Clutch kit;Includes clutch cover, plate and release bearing.Td5 (1)LL1082 V8 (1)RD1193 Clutch cover; Td5 (1)FTC4630 V8 (1)FTC5301 Clutch plate; Td5 (1)UQB000120 V8 (1)8510309 Release bearing (all models) (1)FTC5200 Clutch Master Cylinder Master cylinder - clutch; Td5 (1)STC000280 V8 (1)STC100390 Flexi clutch pipe; Master to slave cylinder.Td5 (1)STG101032 V8 (1)STG101043 Switch assembly - clutch (Td5) (1)AHU700160 Switch only - clutch (Td5) (1)MSK100070 Slave Cylinder & Clutch Release Components Slave cylinder - clutch all models(1)FTC5202 Repair kit - slave cylinder (1)STC2818 Pushrod - slave cylinder (1)FTC5199 Clip - pushrod (1)576723 Release lever - clutch (1)576137 Cap - pivot pin (1)571161 Clip - release lever to pivot pin (1)571163 V8 & Td5.Screw - release lever clip (1)FS106101LV8 &Td5. M6 x 10mm. Clutch Fluid Clutch/brake fluid; Dot 3 - 1 litre (a/r)GBF103 Dot 4 - 1 litre (a/r)SIJ000030 silicone fluid Replaces conventional clutch/brake fluid. Doesn’t absorb water - doesn’t degrade. Will not harm paintwork if spilt. 0.5 litre (a/r)RX1327 1 litre (a/r)RX1326 Pedal Rubber - Clutch Pedal rubber - clutch (1)575818 17ORDER ON:01522 568000 / www.rimmerbros.co.uk PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. CLUTCH KIT RD1193 TD5 ENGINE MOUNTING RUBBER KKB102602 GEARBOX MOUNTING RUBBERS KQB100140 & KKB100150 CLUTCH MASTER CYLINDER STC00280 CLUTCH PEDAL RUBBER 575818 4 - 19 to 26 21/6/07 13:58 Page 1
COOLING & HEATING SYSTEMDESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. 18ORDER ON:01522 568000 / www.rimmerbros.co.uk PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. Water Pump Water pump; Td5 (1)PEM500040 V8 (1)STC4378 Seal - water pump - Td5; ‘D’-ring seals (Set of 3 ) (1)PFQ10001L water pump to PAS bracket (1)ERR6711 Gasket - water pump - V8 (1)ERR4077 Cover - water pump - Td5 (1)ERR7047 Drive Belts Drivebelt - ancillary components; Td5 with ACE* air con (1)PQS101510 non air con (1)PQS101520 without ACE* air con (1)PQS101500 non air con (1)PQS101490 V8 (serpentine belt) with ACE* air con (1)ERR6896 non air con (1)ERR6897 without ACE* air con (1)ERR6898 non air con (1)ERR6899 Tensioner - drivebelt; Td5 (all models) (1)ERR6951 V8 (all models) (1)ERR6439 (*ACE = Active Cornering Enhancement) Expansion Tank Expansion tank - cooling system; Td5 (1)PCF101420 V8 (1)ESR2935 Pressure cap - expansion tank (1)PCD000070 Td5 & V8. Radiator & Oil Cooler Radiator; Td5 up to VIN 1A736339 (1)PCC000640 VIN 2A736340 on (1)PDK000080 V8 (1)PCC000650 Mounting rubber - radiator (2)ESR3586 Td5 & V8.Oil cooler; Td5 - transmission auto (1)PFZ100020 manual (1)PFZ100000 V8 engine (2)ESR3592 transmission (1)PFZ100010 Switch - oil temperature (1)UBI100030 Td5 & V8, oil cooler. Intercooler - Diesel Intercooler - Td5; standard (1)PCM100220 uprated (1)PCM100220UR Larger capacity performance intercoolers are designed to offer an improvement in power & torque over the standard factory item. The larger swept volume of this unit allows a cooler and denser charge of air into the engine, which in turn produces a more efficient combustion, resulting in more torque and power than with the standard factory item. NB., when fitting an uprated intercooler to Td5 engines, it is essential to fit a modified performance engine management unit, such as the Rimmer Bros Powerbox. See Accessoriessection. Intercooler hoses; Td5 intercooler to inlet manifold(1)ESR4640 intercooler to rigid pipe (1)PNH102101 turbo to rigid pipe (1)PNH102101 Clip for intercooler hoses - Td5; intercooler to rigid pipe (a/r)CN100908 rigid pipe to turbo (a/r)PYC102340 Intercooler to inlet manifold intercooler end (1)PYC102350 inlet manifold end (1)PYC102360 Radiator Hoses Top hose - radiator; Td5 (1)PEH101080 V8 Hose set, includes T-piece and thermostat hoses plus clips. up to VIN YA241594 (1)PCH115360 VIN YA241595 (1)PCH000460 Bleed screw - top hose (1)PYP10008L Td5 & V8.Bottom hose - radiator;To thermostat.Td5 (1)PEH101120 V8 (1)PCH119020 Other coolant hoses; Td5 thermostat to rigid coolant pipe large bore (1)PEH101110 small bore (1)PEH101070 coolant pipe to water pump (1)PEH101660 V8 thermostat to water pump (1)PEH000080 thermostat to T-piece usePCH000460 engine to T-pieceusePCH000460 T-piece - V8usePCH000460 Coolant pipe - rigid - Td5 (1)PFV100120 Thermostat to water pump.Heater hoses - see Heater Components,next page. Hose Clips Spring band clips - coolant hoses; Td5 top hose to radiator (1)PYC102100 to engine (1)PYC102110 bottom hose to radiator (1)PYC102110 to thermostat (1)PYC102100 thermostat to large rigid pipe (1)PYC102100 to small rigid pipe (2)PYC102090 V8 top hose to radiator (1)PYC102100 to T-piece (1)PYC102210 bottom hose - both (2)PYC102100 thermostat to large hose (1)PYC102100 to small hose (1)PYC102090 hose to water pump (1)PYC101900 T-piece (3)PYC102210 small clips 22mm (a/r)PYC102190 23mm (a/r)PYC102010 UPRATED INTERCOOLER RA1466 TD5 EXPANSION TANK PCF101420 AND PRESSURE CAP PCD000070 TD5 WATER PUMP PEM500040 TD5 RADIATOR PCC000640 4 - 19 to 26 21/6/07 13:58 Page 2
COOLING & HEATING SYSTEMDESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No.DESCRIPTION QTY REQ. PART No. Thermostat Thermostat - all models (1)PEM100990 Cooling Fan Cooling fan; Td5 (1)PGG101050 V8 (1)ERR4959 Viscous coupling - V8 (1)ERR4995 Heater Components Heater assemblyFor price & availability of complete heater assemblies, please contact our sales department. Heater core kit - all vehicles (1)STC3135 Blend motor assembly; RH lower (1)JWO100000 RH upper (1)JWO100020 LH (1)JWO100010 Blower motor - please contact our sales department.Control assembly - heater (1)AWR7155 Slider knob - heater control (1)BTR6494 Rotary knob - heater (3)BTR8930 Switch - push/push (1)STC1863 Bulb - switch illumination (a/r)JWH100070 Heater hoses; Td5 inlet (to matrix) (1)JHB000060 outlet (from matrix) (1)JHC100460 V8 - inlet/outlet combined (1)PCH500040 Clips - heater hoses; TD5 white (2)JYC100860 blue (2)PYC102030 V8 white (2)JYC100860 green (2)JYC100870 Air Conditioning Components Listed below are the principle air conditioning components. If the part you require is not listed, please contact our sales department, remembering to have details of your VIN/chassis number to hand. Compressor - air condtioning (1)JPB101330Td5 & V8 models.‘O’-ring seal - compressor connections; suction (1)STC3176 discharge (1)STC3177 Condenser assembly (1)JRB100840 Includes condenser, receiver dryer (R134a refrigerant) and fan. Condenser only (1)JRB100790 Receiver drier (1)JRJ100550 Fan - air conditioning (1)JRP100060 Pressure switch (1)JRY100000 Thermistor - evaporator (1)JOF100020 Ambient sensor - airbox - Td5 (1)MHK100600 AIr conditioning.Ambient sensor - front of car (1)JTF100160 Sensor - in-car temperature (1)JTF100290 Solar sensor - dashboard (1)JTF100190 Control assembly - air conditioning(1)JTF500040 Bulb - control illumination (a/r)JWH100060 Bulb & holder; orange (a/r)STC1877 green (a/r)STC1878 Antifreeze Antifreeze; all engines exceptTd5 1 litre (1)GAC2018 5 litres (1)GAC2019 Td5 only 1 litre (1)STC50529 5 litres (1)STC50530 Miscellaneous Gasket - coolant elbow (1)LVJ000010 Temperature sensor - elbow (1)ERR2081 Washer - temperature sensor (1)ERR6192 19ORDER ON:01522 568000 / www.rimmerbros.co.uk PART NUMBERS: A ‘P’ suffix in the Price Guide denotes “Aftermarket”. RADIATOR RELIEF COOLING SYSTEM ADDITIVE Radiator relief allows your radiator to transfer heat more efficiently, reducing your engines operating temperature (which is obviously controlled by the thermostat) by up to 30 • •F. Y o u therefore have ‘a little bit in hand’ for those hot days stuck in traffic. This proven coolant additive will also cut engine warm-up time in half which will reduce engine wear which is most extreme when the engine is cold. Fully compatible with water and anti-freeze and is safe with cast iron and all alloys. ●30 • •F lower operating temperature ●50% quicker warm up time ●Safe with water/antifreeze mixture ●Safe with cast iron, alloy engines and heads ●Increased engine life! ●100% biodegradable, non corrosive, non toxic ●For use in all water cooled engines RADIATOR RELIEF (946ml) (1) RX1461 Treats 1 engine. A MUST FOR ALL OWNERS 4 - 19 to 26 21/6/07 13:58 Page 3