ECU LAND ROVER DISCOVERY 1995 Service Repair Manual

ENGINE
OVERHAUL15
8.Make a suitable pointer from welding rod and
position it to number 1 pedestal stud.
9.Temporarily fit a nut to secure pointer to stud.
10.Assemble degree plateLRT-12-007to a
suitable torque wrench or extension bar.
11.Tighten the centre pedestal nut a further 50°.
12.Tighten 2 pedestal bolts and number 5
pedestal nut a further 50°.
13.Remove pointer and secure it to number 5
pedestal stud.
14.Tighten number 1 pedestal nut a further 50°.
15.Remove pointer.
16.Adjust valve clearances.
17.Thoroughly clean mating faces of rocker cover
and cylinder head, remove all traces of gasket
material using gasket removal spray and a
plastic scraper.

ENGINE
18
OVERHAUL CYLINDER HEAD
Remove
1.Remove rocker shaft.
2.Remove fuel injectors.
3.Remove glow plugs.
4.Using sequence shown, progressively slacken
then remove and discard 18 bolts securing
cylinder head.
5.Using assistance, remove cylinder head.
NOTE: Dowel located.
6.Remove cylinder head gasket.
CAUTION: Identify cylinder head gasket
thickness by the number of holes in the
edge of the gasket between numbers 3
and 4 injector ports. Replacement gasket must
be of the same thickness as the original unless a
replacement cylinder head, crankshaft and/or
pistons are fitted.
- See Cylinder head gasket
selection.
7.Discard cylinder head gasket.
8.Remove 2 bolts securing coolant outlet elbow.
9.Remove coolant outlet elbow.
10.Remove thermostat from housing.
11.Remove 4 bolts securing thermostat housing to
cylinder head, remove housing.
12.Remove and discard gasket.
13.Remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.

ENGINE
OVERHAUL19
14.Remove 2 bolts securing engine front lifting
bracket, remove bracket.Valves and springs - remove
1.Support cylinder head clear of valves, use a
hollow drift and tap each valve spring cap to
free collets.
2.Position cylinder head on its side.
3.Using toolLRT-12-034compress valve spring.
4.Remove 2 collets from valve stem.
5.Remove toolLRT-12-034.

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
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
OVERHAUL41
2.Remove 2 bolts securing fuel lift pump to
cylinder block, remove pump, gasket, spacer
and 2nd gasket.
3.Discard gaskets.Refit
1.Remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
2.Position new gaskets and spacer to fuel lift
pump.
3.Fit fuel lift pump ensuring that operating lever
is correctly positioned on camshaft.
4.Fit bolts and tighten to 25 Nm.
5.Position fuel delivery pipe to fuel lift pump, fit
banjo bolt and 2 new sealing washers.
CAUTION: Do not fully tighten banjo bolt
until pipe is connected to fuel filter.

ENGINE
42
OVERHAUL FUEL INJECTORS
Remove
1.Disconnect each pair of fuel pipes from fuel
injection pump and injectors.
2.Remove banjo bolt securing fuel spill return
pipes to injector, remove and discard 2 sealing
washers.
CAUTION: Plug broken connections to
prevent ingress of dirt.
3.Remove nut securing injector clamp, remove
clamp.
4.Remove injector, remove and discard sealing
washer.
WARNING: Do not attempt to remove
injectors using engine compression,
either use an open ended spanner on
injector body and rotate injector until it is
released or use a slide hammer and suitable
adaptor.
5.Repeat above procedures to remove remaining
injectors.