LAND ROVER DISCOVERY 1995 Service Repair Manual

ENGINE
46
OVERHAUL Oil pick-up and drain pipes - refit
1.Clean oil pick-up and drain pipes and strainer,
remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
2.Ensure bolt holes in timing belt rear cover,
cylinder block and main bearing cap bolts are
clean and dry and that all traces of Loctite are
removed from holes in main bearing cap bolts.
CAUTION: Do not use a tap to remove
Loctite from bolt holes.
3.Lubricate a new 'O' ring with engine oil and fit
to oil pick-up pipe.
4.Position a new gasket to cylinder block.
5.Position oil pick-up pipe to timing belt rear
cover and drain pipe to cylinder block.
6.Apply Loctite 242E to threads of oil pick-up
pipe to main bearing cap bolts, fit bolts and
tighten to 9 Nm.
7.Fit bolts securing oil pick-up and drain pipes to
cylinder block and timing belt rear cover,
tighten to 25 Nm.

ENGINE
OVERHAUL47
Sump - refit
1.Clean sump and remove all traces of sealant
using solvent from kit GUG 705548GM.
2.Apply a 2 mm bead of Hylomar Instant Gasket
302 (black) to sump flange ensuring that
sealant is applied inboard of bolt holes.
3.Position sump to cylinder block.
CAUTION: Sump must be fitted within 30
minutes of applying sealant.
4.Fit 22 sump bolts and tighten in sequence
shown to 25 Nm.
5.Check that sump drain plug is tightened to 35
Nm.FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
1.Screw 2 slave 8 mm bolts into flywheel.

ENGINE
48
OVERHAUL
2.Temporarily fit crankshaft pulley.
3.Position toolLRT-12-080to crankshaft pulley,
secure with 4 bolts.
4.Restrain crankshaft pulley using tool
LRT-12-080and remove 8 bolts securing
flywheel; discard locking plate - if fitted.
5.Using assistance, remove flywheel using 2
slave bolts.
NOTE: Dowel located.

ENGINE
OVERHAUL49
Inspecting components
1.Check clutch face of flywheel for scoring or
signs of overheating ( blueing ), if deep scoring
or signs of overheating exist, flywheel must be
replaced.
2.Check teeth of starter ring gear for chipping
and wear, replace ring gear as necessary.Starter ring gear - replace
1.Drill a 3 mm diameter hole to the depth of the
ring gear at the root of 2 teeth.
CAUTION: Ensure drill does not contact
flywheel.
2.Using a cold chisel, split ring gear.
WARNING: Wear suitable eye protection
and cover flywheel with cloth to protect
against flying fragments.
3.Remove ring gear from flywheel.
4.Heat replacement ring gear uniformly to 250
°C.

ENGINE
50
OVERHAUL
5.Position ring gear to flywheel with square edge
of teeth towards flywheel flange.
6.Press ring gear on to flywheel, allow to air cool.Flywheel - refit
1.Ensure bolt holes in crankshaft are clean and
dry.
2.Ensure 2 slave 8 mm bolts are screwed fully
into flywheel.
3.Using assistance, position flywheel on
crankshaft.
NOTE: Dowel located.
4.Fit and finger tighten 8 bolts.
5.Restrain crankshaft using toolLRT-12-080
and tighten flywheel bolts by diagonal selection
to 146 Nm.
6.Remove toolLRT-12-080and crankshaft
pulley.
7.Remove slave bolts from flywheel.

ENGINE
OVERHAUL51
DRIVE PLATE
Remove
1.Temporarily fit crankshaft pulley - if removed.
2.Position toolLRT-12-080to crankshaft pulley,
secure using 4 bolts.
3.Restrain crankshaft using toolLRT-12-080
and remove 8 bolts securing drive plate,
discard locking plate - if fitted.
4.Remove drive plate, recover spacer and shims.
NOTE: Dowel located.

ENGINE
52
OVERHAUL Inspecting components
1.Check starter ring gear teeth for chipping or
wear, replace ring gear if necessary.
2.Check drive plate for visible signs of damage
or distortion, replace drive plate if necessary.Drive plate - refit
1.Check that bolt holes in crankshaft are clean
and dry.
2.Position spacer, less original shims to
crankshaft.
3.Position a straight edge across spacer.
4.Measure and record distance between gearbox
mating flange of drive plate housing and
straight edge.
5.Repeat procedure on opposite side of spacer.
6.Add the 2 measurements obtained together
and calculate the average.
7.Calculate the difference between the average
figure obtained and 12.4 mm.
8.Select shims from the range available which
equal the final figure obtained.
NOTE: Shims are available rising in
increments of 0.1 mm from 1.0 mm to 2.1
mm in thickness.

ENGINE
OVERHAUL53
9.Position selected shims, spacer and drive plate
to crankshaft.
NOTE: Dowel located.
10.Fit and finger tighten 8 bolts.
NOTE: Locking plate is no longer required.
11.Restrain crankshaft using toolLRT-12-080
and tighten drive plate bolts to 146 Nm.
12.Remove toolLRT-12-080and crankshaft
pulley.FLYWHEEL/DRIVE PLATE HOUSING
Remove
1.Remove flywheel/drive plate.
NOTE: Flywheel housing illustrated.
2.Remove 2 bolts securing top of housing to
cylinder block.
3.Remove 4 bolts securing housing to engine
mountings.
4.Progressively slacken then remove 6 bolts
securing housing to cylinder block.
5.Remove housing.

ENGINE
54
OVERHAUL Refit
1.Remove all traces of sealant from mating faces
of housing and cylinder block using solvent
from kit GUG 705548GM.
2.Apply a bead of sealant from kit to cylinder
block.
3.Position housing to cylinder block.
4.Fit and finger tighten bolts.
5.Using sequence shown, tighten bolts to 45 Nm.
NOTE: If engine mounting bolts were not
fitted, omit bolts 8, 10, 11 and 12 from
tightening sequence and re-number
accordingly.
6.Fit flywheel/drive plate.

ENGINE
OVERHAUL55
CRANKSHAFT, CAMSHAFT, PISTONS AND
CYLINDER BLOCK
1.Remove timing belt rear cover.
2.Remove flywheel/drive plate housing.
3.Remove fuel lift pump.
4.Remove cylinder head.
5.Remove sump, oil pick-up and drain pipes.
6.Remove oil filter head.
7.Remove brake servo vacuum pump.Crankshaft rear oil seal - remove
1.Remove 5 bolts securing rear oil seal housing
to cylinder block.
2.Remove and discard oil seal and housing.
3.
Early engines:Remove and discard 'O' ring.
4.Remove and discard gasket.