engine LAND ROVER DISCOVERY 1995 Service Repair Manual

ENGINE
OVERHAUL31
TIMING BELT REAR COVER AND OIL PUMP
Timing belt rear cover - remove
1.Remove timing belt, tensioner and gears.
2.Remove fuel injection pump.
3.Remove sump and oil pick-up pipe.
4.Using sequence shown, progressively slacken
then remove bolts securing timing belt rear
cover; remove cover.
5.Remove and discard gasket.
6.Remove and discard camshaft and crankshaft
front oil seals.Oil pump and oil pressure relief valve - remove
Oil pump
1.Make suitable alignment marks between oil
pump and timing belt rear cover.
2.Progressively slacken then remove 7 screws
securing oil pump cover.
3.Remove oil pump cover.
4.Make suitable alignment marks between oil
pump inner and outer rotors and outer rotor
and timing belt rear cover.

ENGINE
32
OVERHAUL Oil pressure relief valve
1.Remove plug retaining oil pressure relief valve.
2.Withdraw spring and plunger.Inspecting components
1.Check rotor clearances.
A- Outer rotor to housing = 0.025 to 0.075 mm
B- Inner rotor to outer rotor = 0.025 to 0.075
mm
C- Rotor end-float = 0.026 to 0.135 mm
2.Remove inner and outer rotors.
3.Check rotors for damage, wear and scoring.
4.Check oil pump cover for wear and scoring.
5.Check oil pressure relief valve spring free
length is 68.0 mm.
6.Check plunger and relief valve bore for wear
and scoring.
7.Clean all traces of sealant from oil pump cover
using solvent from kit GUG 705548GM.
8.Remove all traces of sealant from relief valve
plug threads in oil pump body.
CAUTION: Do not use a tap.

ENGINE
OVERHAUL33
Oil pump and oil pressure relief valve - refit
Oil pump
1.Thoroughly clean timing belt rear cover,
remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
Remove all traces of sealant using solvent
from kit GUG 705548GM.
2.Ensure oil pump cover screw holes are clean
and dry.
3.Clean oil pump rotors and recess, lubricate
rotors and recess with engine oil.
CAUTION: Ensure alignment marks made
during dismantling are not erased.
4.Position inner and outer rotors in housing
ensuring that reference marks are aligned.
5.Apply bead of sealant from kit to outer edge of
oil pump cover, fit cover to housing ensuring
that reference marks are aligned.
6.Fit oil pump cover, fit and progressively tighten
7 screws.
7.Check that pump rotates freely.Oil pressure relief valve
1.Thoroughly clean oil pressure relief valve
plunger, spring and relief valve bore then
lubricate components with engine oil.
2.Insert plunger and spring into bore.
3.Smear threads of relief valve plug with Loctite
577.
4.Fit plug and tighten to 17 Nm.

ENGINE
34
OVERHAUL Timing belt rear cover - refit
1.Remove all traces of gasket material from
cylinder block using suitable gasket removal
spray and a plastic scraper.
2.Screw 2 slave guide studs into cylinder block.
3.Fit new gasket over guide studs.
4.Note position of oil pump drive flats on
crankshaft.
5.Rotate oil pump inner rotor to align with drive
flats on crankshaft and position timing belt rear
cover on guide studs.
6.Fit timing belt rear cover.
CAUTION: Do not remove guide studs at
this stage.
7.Fit 8 bolts of the correct length in positions
shown, remove guide studs and fit remaining 2
bolts.

ENGINE
OVERHAUL35
8.Using sequence shown, tighten bolts to 25 Nm.
9.Fit oil pick-up pipe and sump.
10.Lubricate a new crankshaft front oil seal with
engine oil.
11.Fit oil seal using toolLRT-12-079.
12.Lubricate a new camshaft oil seal with engine
oil.
13.Fit oil seal using toolLRT-12-082.
14.Fit fuel injection pump.
15.Fit timing belt, tensioner and gears.

ENGINE
36
OVERHAUL OIL FILTER HEAD
Remove
1.Remove and discard oil filter element.
2.Remove 4 bolts securing filter head to cylinder
block.
3.Remove filter head, remove and discard
gasket.Thermostatic valve - remove
1.Secure oil filter head in a soft-jawed vice with
thermostatic valve vertically upwards.
2.Remove 2 bolts securing thermostatic valve
extension housing to oil filter head.
3.Remove extension housing, remove and
discard 'O' ring.
4.Withdraw thermostatic valve and spring.
CAUTION: Do not separate valve from
spring.

ENGINE
OVERHAUL37
Inspecting components
1.Check thermostatic valve spring for distortion
and corrosion.
CAUTION: Do not separate valve from
spring.
2.Check valve for corrosion, seating faces of
valve and extension housing for damage and
pitting; replace valve as an assembly.
3.Check valve bore for corrosion. Light corrosion
must be removed from valve bore using grade
600 emery cloth soaked in oil.
4.Check oil passages in oil filter head are clear.Thermostatic valve - refit
1.Secure oil filter head in a soft-jawed vice with
thermostatic valve bore vertically upwards.
2.Lubricate a new 'O' ring with engine oil and fit
to thermostatic valve extension housing.
3.Lubricate thermostatic valve and bore with
engine oil.
4.Fit thermostatic valve and spring.
5.Position extension housing to oil filter head
ensuring that thermostatic valve is positioned
centrally in housing.
6.Fit and progressively finger tighten 2 bolts
ensuring that thermostatic valve remains
correctly positioned in extension housing.
7.Tighten bolts to 9 Nm.

ENGINE
38
OVERHAUL Oil filter head - refit
1.Remove all traces of gasket from oil filter head
and cylinder block using suitable gasket
removal spray and a plastic scraper.
2.Smear a new gasket with engine oil and
position on oil filter head.
3.Fit oil filter head, fit 4 bolts and tighten to 45
Nm.
4.Smear sealing ring of new oil filter element with
engine oil and fit to oil filter head.
5.Plug open pipe connections to prevent ingress
of dirt.FUEL INJECTION PUMP
Remove
1.Remove timing belt.
2.Remove fuel pipes from pump and injectors.3.Ensure that timing pinLRT-12-045is inserted
in injection pump gear hub plate and injection
pump hub.
4.Remove 3 bolts securing hub and injection
pump gear to injection pump, remove timing
pinLRT-12-045and gear.
CAUTION: Do not remove nut securing
hub to pump.

ENGINE
OVERHAUL39
5.Remove 3 bolts securing mounting bracket and
baffle plate to cylinder block.
6.Remove 2 bolts securing mounting bracket to
injection pump, remove bracket.
7.Remove banjo bolt securing fuel spill return
pipe to injection pump, discard sealing
washers.
CAUTION: Plug open connections to
prevent ingress of dirt.
8.Remove 3 nuts securing injection pump to
timing belt rear cover, remove injection pump.

ENGINE
40
OVERHAUL Refit
1.Position injection pump to timing belt rear
cover, fit nuts and tighten to 25 Nm.
2.Fit fuel spill return pipe, fit banjo bolt and 2 new
sealing washers.
3.Tighten banjo bolt to 25 Nm.
4.Position mounting bracket to injection pump
and cylinder block, fit and finger tighten bolts.
5.Tighten mounting bracket bolts to 25 Nm in the
following order:
Mounting bracket to cylinder block
Mounting bracket to injection pump
6.Fit fuel pipes.
7.Position injection pump gear and hub plate to
injection pump hub ensuring that cut-out in hub
plate is aligned with timing pin hole in pump
hub.
8.Fit 3 bolts, position slot in gear mid-way under
bolt heads, lightly tighten bolts.
NOTE: Do not fit bolts through elongated
slots in hub plate. Bolts are fully tightened
after timing belt has been adjusted.
9.Insert timing pinLRT-12-045in hub plate and
injection pump hub.
10.Fit and tension timing belt.FUEL LIFT PUMP
Remove
1.Disconnect fuel delivery pipe from fuel lift
pump, discard sealing washers.
CAUTION: Plug open connections to
prevent ingress of dirt.