engine LAND ROVER DISCOVERY 1995 Service Repair Manual

ENGINE
OVERHAUL1
TIMING BELT, TENSIONER AND GEARS
Timing belt - remove
1.Position toolLRT-12-080to crankshaft pulley,
retain with 4 bolts.
2.Restrain crankshaft using toolLRT-12-080
and remove crankshaft pulley flange head bolt.
NOTE: Bolt and washer fitted to early
engines.
3.Remove toolLRT-12-080 .
4.Position toolLRT-12-049and thrust button,
part of toolLRT-12-031to crankshaft pulley,
remove pulley, recover Woodruff key.
5.Using sequence shown, progressively slacken
then remove 14 bolts securing timing belt front
cover.

ENGINE
2
OVERHAUL
6.Remove timing belt front cover.
7.Remove and discard gasket.
8.Remove and discard crankshaft front oil seal
from timing belt front cover.
9.Temporarily fit crankshaft pulley bolt to
crankshaft.
Manual gearbox
10.Remove plug from bottom of flywheel housing.
11.Rotate crankshaft clockwise using crankshaft
pulley bolt until toolLRT-12-044can be
located in slot in flywheel.
CAUTION: Do not rotate crankshaft
anti-clockwise and do not use camshaft or
fuel injection pump gear bolts to rotate
crankshaft.
Automatic gearbox
12.Rotate crankshaft clockwise using crankshaft
pulley bolt until toolLRT-12-044can be
inserted through hole in engine plate and into
slot in drive plate.
CAUTION: Do not rotate crankshaft
anti-clockwise and do not use camshaft or
fuel injection pump gear bolts to rotate
crankshaft.

ENGINE
OVERHAUL3
All engines
13.Check that timing mark on camshaft pulley is
aligned with mark on timing belt rear cover and
the crankshaft Woodruff key is aligned with the
arrow cast on the rear cover.
14.Remove crankshaft pulley bolt.
15.Insert timing pinLRT-12-045into fuel injection
pump gear hub plate and injection pump hub.
16.Slacken but do not remove centre bolt securing
camshaft drive gear to camshaft.
17.If timing belt is to be refitted, mark direction of
rotation on outside surface of belt with chalk or
similar soft material.
18.Slacken but do not remove bolt securing timing
belt tensioner pulley, move pulley until tension
is removed from belt.
19.Remove nut and washer securing idler pulley.
20.Release idler pulley from timing belt, remove
pulley.
21.Release timing belt from gears, discard belt.

ENGINE
4
OVERHAUL Timing belt tensioner and timing gears - remove
1.Remove crankshaft gear using tools
LRT-12-031andLRT-12-078,recover
Woodruff key from crankshaft.
2.Remove and discard 'O' ring.
3.Remove bolt and slotted washer securing
timing belt tensioner pulley, remove pulley
together with tensioner bracket.
4.Recover flanged spacer from idler pulley stud.
5.Remove centre bolt and washer securing
camshaft timing gear, remove gear and hub
plate as an assembly.
NOTE: Later engines are fitted with a
flange head bolt.
CAUTION: Do not remove 3 bolts securing
hub plate to gear.

ENGINE
OVERHAUL5
6.Remove 3 bolts securing fuel injection pump
gear and hub plate to pump hub.
CAUTION: Do not remove nut securing
hub to fuel injection pump.
7.Remove timing pinLRT-12-045.
8.Remove fuel injection pump gear and hub
plate.Inspecting components
1.Check timing gear teeth for burrs.
2.Remove all traces of gasket from timing belt
front and rear covers using suitable gasket
removal spray and a plastic scraper.

ENGINE
6
OVERHAUL Timing belt tensioner and gears - refit
1.Smear a new 'O' ring with engine oil and fit to
crankshaft.
2.Fit Woodruff key in slot in crankshaft.
3.Fit crankshaft gear on to crankshaft and using
a soft mallet, tap gear fully home.
4.Position camshaft timing gear and hub plate to
camshaft, fit bolt and washer, finger tighten
bolt. Do not tighten bolt at this stage.
NOTE: Later engines are fitted with a
flange head bolt.
5.Position fuel injection pump gear and hub plate
to fuel injection pump hub ensuring that cut-out
in hub plate is aligned with timing pin hole in
pump hub.
6.Fit 3 bolts, position slots in gear mid-way under
bolt heads, lightly tighten bolts.
CAUTION: Do not fit bolts through
elongated slots in hub plate. Ensure gear
does not move as bolts are tightened.
7.Insert timing pinLRT-12-045in hub plate and
injection pump hub. If timing pin cannot be
inserted, slacken bolts and rotate gear until pin
can be fitted, lightly tighten bolts.

ENGINE
OVERHAUL7
8.Position flanged spacer on idler pulley stud.
9.Fit timing belt tensioner pulley and bracket
ensuring that hole in tensioner bracket is
located on flanged spacer.
10.Fit slotted washer with the slot vertical and fit
bolt, finger tight.
11.Temporarily fit crankshaft pulley bolt to
crankshaft.
NOTE: Flywheel illustrated
12.
Manual gearbox:Rotate crankshaft clockwise
using crankshaft pulley bolt until tool
LRT-12-044can be inserted in slot in flywheel.
13.
Automatic gearbox:Rotate crankshaft
clockwise using crankshaft pulley bolt until tool
LRT-12-044can be inserted in slot in drive
plate.
14.Check that crankshaft Woodruff key is aligned
with arrow on timing belt rear cover.
15.If necessary, rotate camshaft timing gear using
the centre bolt until timing mark on gear is
aligned with timing mark on timing belt rear
cover.
16.Remove crankshaft pulley bolt.

ENGINE
8
OVERHAUL Timing belt - refit and adjust tension
Refit
1.Using the fingers only, fit a new timing belt to
timing gears keeping slack portion of belt on
idler pulley side of belt. If necessary, rotate fuel
injection pump gear anti-clockwise to align
gear teeth with those of timing belt.
CAUTION: If original timing belt is to be
refitted, ensure direction of rotation mark
is facing correct way.
2.Fit idler pulley.
3.Fit idler pulley nut and tighten to 45 Nm.
4.Ensure that timing belt is correctly located on
timing gears.
5.Check that tensioner pulley bolt is finger tight.
6.Temporarily fit crankshaft pulley bolt to
crankshaft.Adjust tension
1.Ensure toolsLRT-12-044andLRT-12-045
are still fitted.2.Position a dial type torque wrench and suitable
extension to hole in tensioner bracket keeping
the torque wrench positioned vertically.
3.Tension timing belt to :
Used belt - 12 Nm
New belt - 15 Nm
4.Keeping timing belt at the correct tension,
tighten tensioner bolt to 45 Nm.

ENGINE
OVERHAUL9
5.Check that timing pinLRT-12-045moves
freely in and out of injection pump hub, if pin
does not move freely, slacken 3 bolts, move
gear slightly and re-check.
6.When timing pin moves freely, tighten 3 bolts
to 25 Nm.
7.Remove timing pinLRT-12-045and
flywheel/drive plate locking toolLRT-12-044.
8.Rotate crankshaft twice in a clockwise direction
using crankshaft pulley bolt until flywheel/drive
plate locking toolLRT-12-044can be refitted.
9.Slacken timing belt tensioner securing bolt and
re-tension timing belt.
10.Tighten tensioner bolt to 45 Nm.
11.Fit timing pinLRT-12-045into fuel injection
pump gear hub plate and pump hub. If timing
pin cannot be inserted, slacken injection pump
gear bolts, rotate pump shaft using shaft nut
until pin slides easily into pump hub, Tighten
bolts to 25 Nm.
12.Tighten camshaft gear bolt to 80 Nm.
13.Remove timing pin and flywheel/drive plate
locking tools.
14.Fit plug to flywheel housing, tighten to 12 Nm.
15.Remove crankshaft pulley bolt.
16.Support timing belt front cover on suitable
blocks of wood.
17.Smear a new crankshaft oil seal with engine
oil.
18.Using toolLRT-12-077,fit oil seal from inside
face of front cover.
19.Fit a dry, new gasket to timing belt rear cover.
20.Position timing belt front cover to rear cover.
21.Fit bolts of the correct length in positions
shown.

ENGINE
10
OVERHAUL
22.Tighten bolts in sequence shown to 25 Nm.
23.Lightly oil crankshaft spigot, fit Woodruff key
and crankshaft pulley.
24.Position toolLRT-12-080to crankshaft pulley,
retain tool using 4 bolts.
25.Fit crankshaft pulley flange head bolt.
26.Restrain crankshaft and tighten bolt to 80
Nm,then further 90.°
27.Remove toolLRT-12-080.