timing belt LAND ROVER DISCOVERY 1995 Service Repair Manual

04GENERAL SPECIFICATION DATA
22
INFORMATION ENGINE - Mpi - 2.0 LITRE
Type 20 T4 - 16 valve twin overhead camshaft.................................................................................
Cylinder arrangement 4 in line.......................................................
Bore 84.45 mm.................................................................................
3.325 in
Stroke 89.00 mm...............................................................................
3.504 in
Capacity 1994 cm
3...........................................................................
121.68 in3
Firing order 1-3-4-2.......................................................................
Compression ratio 10 : 1............................................................
Oil pump
Outer rotor to body clearance 0.05 to 0.10 mm..........................................
Inner rotor tip clearance 0.025 to 0.12 mm...................................................
Outer rotor end float 0.03 to 0.08 mm.........................................................
Oil pressure relief valve
Spring free length 42.0 mm.............................................................
Cooling system
Starts to open 82 to 86°C ...................................................................
Thermostat fully open 88°C .......................................................
Open travel A 9 mm...................................................................
Camshaft
Camshaft end-float 0.06 to 0.25 mm...........................................................
Bearing clearance 0.060 to 0.094 mm............................................................
Service limit 0.15 mm.............................................................
Timing belt tensioner
Spring free length 57.5 to 58.5 mm.............................................................
Cylinder head
Longitudinal warp - maximum 0.1 mm.................................
Transverse warp - maximum 0.1 mm...................................
Diagonal warp - maximum 0.1 mm......................................
Cylinder head height 135.0 to 135.1 mm...............................................
Valve springs
Free length 46.25 mm.......................................................................
Fitted length 37.0 mm.....................................................................
Load at fitted length 255±12 N ..........................................................
Load at valve open length 560±22.5 N ................................................

MAINTENANCE
11
MAINTENANCE
CHECK/ADJUST ENGINE IDLE SPEED - Tdi
For idle speed.See ENGINE TUNING DATA,
Information, 300 Tdi Engine
CHECK ENGINE IDLE SPEED - Mpi
For idle speed.See ENGINE TUNING DATA,
Information, Engine - Mpi - 2.0 Litre
CHECK/ADJUST STEERING BOX V8i - Tdi - Mpi
Check steering box for fluid leaks.
Check that there is no backlash in steering box in
straight ahead position. Adjust steering box if
necessary.
See STEERING, Adjustment, Power
Steering Box
CLEAN BATTERY CONNECTIONS
NOTE: Some 96 models are fitted with
battery backed-up sounder
See
ELECTRICAL, Repair, Battery
Remove battery terminals, clean and coat with
petroleum jelly.
A low maintenance battery is installed in vehicle.
Dependent upon climate conditions electrolyte levels
should be checked as follows:
Temperate climates every three years.
Hot climates every year.
RENEW CAMSHAFT DRIVE BELT - Tdi
Renew camshaft drive belt.See ENGINE, Repair,
Camshaft Drive Belt and Gears
The engine timing gears are driven by a flexible
rubber belt which must be renewed at intervals
determined by the severity of operating conditions.
In reasonable, temperate climate operation, renew the
belt every 120,000 km (72,000 miles) or every 6 years
whichever occurs earlier.
In adverse operating conditions such as work in dusty
atmospheres, high ambient temperatures and desert
and tropical zones, renew the belt every 60,000 km
(36,000 miles) or every 3 years whichever occurs
earlier.
CAUTION: If the drive belt is not renewed
at the correct interval, it could fail,
resulting in serious damage.
RENEW CAMSHAFT DRIVE BELT - Mpi
Renew every 160,000 km (96,000 miles) or every 6
years. In adverse conditions every 80,000 km (48,000
miles).
For details of renewing camshaft drive belt.
See
ENGINE, Repair, Camshaft Drive Belt - Mpi
CHECK CAMSHAFT DRIVE BELT - Mpi
For details of checking camshaft drive belt.See
ENGINE, Repair, Check Camshaft Drive Belt - Mpi

12ENGINE
8
REPAIR CAMSHAFT DRIVE BELT AND GEARS
Service repair no - 12.65.18
TIMING BELT
Remove
1.Remove front cover plate.
See Front Cover
Plate
2.Position engine at TDC on No. 1 cylinder.
3.If manual gearbox: Remove blanking plug from
flywheel housing and insert timing tool
LRT-12-044. If EDC - timing tool LRT-12-085
must be used.
If automatic gearbox:Sited to the rear of the
engine sump on engine backplate is a blanking
plate. Remove 2 blanking plate bolts and insert
timing tool LRT-12-044 into the larger bolt hole.
4.Engage timing tool pin with slot in flywheel.
5.Check correct alignment of timing mark on
camshaft gear and that crankshaft key aligns
with cast arrow on housing.
6.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.
NOTE: If the camshaft gear is to be
removed during these operations its
retaining bolt should be slackened before
the timing belt is removed.
7.Slacken belt tensioner bolt.
8.Remove idler pulley.
9.Remove timing belt.
NOTE: During use, a belt develops a wear
pattern relative to its running direction, if
the original belt is to be re-used it must be
refitted so that it rotates in the original direction.
CAUTION: Belts must be stored on edge
on a clean surface and in such a manner
that bends are not less than 50 mm radius.
Do not bend belts at an acute angle or radius of
less than 50 mm, otherwise premature failure
could result.
10.Mark belt direction of rotation, using soft chalk,
to ensure correct refitment.

Tdi
11
REPAIR Timing belt fitting and tensioning
NOTE: It is important that belt tensioning
is carried out carefully and accurately. The
following procedure involves tensioning
the belt twice to ensure that it is equally tensioned
between each gear. New and original belts are
tensioned to different figures.
28.Ensure timing marks are correctly aligned, pin
from special tool LRT-12-045 is correctly
inserted in injection pump gear and timing tool
LRT-12-044 (LRT-12-085 if EDC) is fitted to
flywheel housing with pin located in flywheel slot.
Or if automatic: Timing tool LRT-12-044 is fitted
to engine backplate and pin located in ring gear.
29.Fit belt observing rotational marks made during
removal. Feed belt over gears keeping it tight on
drive side.
30.Fit idler pulley.
31.Slacken injection pump gear retaining bolts.
32.Adjust belt to correctly sit in gears.
33.Slacken belt tensioner securing bolt to finger
tight.
34.Insert 13 mm square drive extension bar in
tensioner plate.
NOTE: Belt tensioning should be carried
out using a dial type torque meter having a
range not exceeding
60 Nm.The torque
meter should be used in the almost vertical
position.
35.Apply a tension of
14 to 16 Nmfor a new belt or
11 to 13 Nmfor an original belt. When tension
is correct tighten clamp bolt.
36.Tighten injection pump gear bolts.
37.Remove pin from injection pump gear.
38.Disengage timing pin from timing slot in flywheel
or ring gear.
39.Rotate crankshaft one and three quarter turns in
a clockwise direction; then continue rotation until
timing pin in timing tool can be engaged with slot
in flywheel or ring gear.
40.Disengage timing pin.
41.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.
42.Slacken injection pump gear retaining bolts.
43.Slacken tensioner and retension belt.
44.Tighten injection pump gear retaining bolts.
45.Remove pin from injection pump gear.
46.Remove timing tool and refit plug.
47.Fit front cover plate using new gaskets.
See
Front Cover Plate

12ENGINE
12
REPAIR FRONT COVER/TIMING GEAR HOUSING GASKET
Service repair no - 12.65.10
Remove
1.Remove timing belt and gears.
See Camshaft
Drive Belt and Gears
2.Remove fuel injection pump.See FUEL
SYSTEM, Repair, Fuel Injection Pump and
Timing
3.Remove engine oil sump.See Oil Sump
4.Remove oil pick up strainer.See Oil Pick-Up
Strainer
5.Remove bolts securing timing gear housing to
block.
6.Withdraw timing gear housing complete with
gasket.
7.Clean all gasket material from mating faces.
Refit
8.Fit slave guide studs to locate gasket.
9.Fit new gasket, over slave studs, to cylinder
block.
10.Align flats on oil pump with flats on crankshaft.
11.Fit front cover to block taking care not to damage
oil seal.
12.Secure with bolts of correct length in locations
where slave studs are not fitted (ST3482).
13.Remove slave studs and fit correct length bolts.
14.Tighten to
25 Nm.
15.Fit oil pick-up strainer.See Oil Pick-Up
Strainer
16.Fit oil sump.See Oil Sump
17.Refit fuel injection pump.See FUEL SYSTEM,
Repair, Fuel Injection Pump and Timing

12ENGINE
2
SPECIFICATIONS, TORQUECylinder head
Cylinder head to cylinder block See repair section......................................................
Stub pipe heater feed 22.................................................................................
Water temperature sensor 14.........................................................................
Blanking plug cylinder head 14.......................................................................
Engine lifting brackets 25................................................................................
Electrical harness clip bracket 25...................................................................
Exhaust manifold stud 10................................................................................
Exhaust manifold nut 45.................................................................................
Inlet manifold stud 8.......................................................................................
Inlet manifold nut and bolt 25..........................................................................
Air temperature sensor, inlet manifold 14.......................................................
Blanking plug, inlet manifold 14......................................................................
Heatshield to inlet manifold 6.........................................................................
Glow plug 20...................................................................................................
Glow plug terminal nut 2................................................................................
Injector clamp (stud) 8...................................................................................
Injector clamp (nut) 25....................................................................................
Thermostat housing 25...................................................................................
Water outlet elbow to thermostat housing 25..................................................
Water temperature switch, thermostat housing 11..........................................
Plug thermostat housing 6.............................................................................
Rocker shaft pedestal bolt 5 + 50° .....................................................................
Rocker cover (stud) 8.....................................................................................
Rocker cover (fixing nut) 10............................................................................
Breather cyclone to rocker cover 9................................................................
Tappet adjusting nut 16..................................................................................
Front cover to cylinder block 25......................................................................
Front cover plate to front cover 25..................................................................
Static idler - timing belt (stud) 10.....................................................................
Static idler - timing belt (nut) 45......................................................................
Tensioner (timing belt) 45...............................................................................
Camshaft hub bolt 80......................................................................................
Timing pulley to camshaft hub 25...................................................................
Fuel injection pump (stud) 8...........................................................................
Fuel injection pump (nut) 25...........................................................................
Abutment bracket to injection pump 25...........................................................
Support bracket injection pump to cylinder block 25.......................................
Fuel injection pump access plte to front cover plate 25..................................
Timing pulley to injection pump hub 25...........................................................
TV Damper pulley bolt to crankshaft 80 + 90° .....................................................
Fan pulley to hub 25.......................................................................................
Fan and viscous coupling to hub 45...............................................................
Auto tensioner, auxiliary drive (stud) 14..........................................................
Auto tensioner, auxiliary drive (nut) 45...........................................................
Auxiliary mounting bracket to cylinder block (stud) 8.....................................
Auxiliary mounting bracket to cylinder block (bolt and nut) 25........................
Water pump to block and mounting plate 25..................................................
Water pump pulley to hub 25..........................................................................

V8i
9
REPAIR FRONT COVER GASKET
Service repair no - 12.65.04
1.Remove crankshaft pulley.
See Crankshaft
Pulley Assembly. Do not remove pulleys
2.Remove water pump pulley.
3.Release distributor cap clips.
4.Release plug leads from plugs and clips.
5.Place cap and leads to one side.
6.Turn engine until No. 1 piston is at T.D.C.
7.Check position of rotor arm.
8.Remove fixings securing power steering pump
bracket to water pump bracket.
9.Remove power steering pump bracket from
water pump.
10.Remove clips securing wiring to generator
tensioner.
11.Disconnect distributor feed wire.
12.Pivot power steering pump away from front
cover, tighten pivot to retain in position.
13.Disconnect vacuum pipe from distributor.
14.Remove water pump bottom hose.
15.Disconnect oil pressure switch.
16.Disconnect heater hose at water pump.
17.Remove generator tensioner from water pump,
move tensioner aside.
18.Mark distributor position to front cover.
19.Remove distributor clamp, remove distributor.
See ELECTRICAL, Repair, Distributor - V8i
20.Remove fixings sump to front cover.
21.Loosen four adjacent sump fixings.
22.Remove generator support strut from front cover,
move strut aside.
23.Loosen remaining front cover fixings and remove
front cover.
24.Remove front cover gasket.Refit
25.Clean timing cover, clean block face.
26.Lightly grease gasket faces.
27.Fit new gasket to block face.
28.Apply hylosil to sump gasket.
29.Clean threads of cover fixing bolts, apply Loctite
372 to threads.
30.Fit timing cover, fit fixing bolts. Tighten to
28
Nm.
31.Fit generator support strut to front cover.
32.Tighten sump to timing cover fixings to
10 Nm.
33.Tighten sump fixings to10 Nm.
34.Lubricate distributor O ring.
35.Fit distributor in position marked.
36.Align oil pump drive, if distributor does not seat
correctly.
37.Fit distributor clamp. Tighten to
20 Nm.
38.Locate generator tensioner on water pump
bracket.
39.Connect heater hose, tighten clip.
40.Connect oil pressure switch.
41.Connect bottom hose, tighten clip.
42.Connect vacuum pipe to distributor.
43.Loosen power steering pump pivot, lower pump.
44.Connect distributor feed wire.
45.Connect wire ties to generator tensioner.
46.Fit power steering pump bracket to water pump.
Tighten to
28 Nm.
47.Fit power steering pump to bracket.
48.Position distributor cap. Fit plug leads to plugs
and clips.
49.Clip distributor cap in position.
50.Fit water pump pulley. Tighten to
10 Nm.
51.Fit crankshaft pulley.See Crankshaft Pulley
Assembly
52.Tension drive belts correctly.
53.Check ignition timing.
54.Refill cooling system.

Mpi
1
DESCRIPTION AND OPERATION DESCRIPTION
The 'T' Series engine is a four cylinder, water cooled
unit comprising a cast iron cylinder block, aluminium
alloy cylinder head and twin aluminium alloy camshaft
carriers.
The cylinder block incorporates direct bored,
siamesed cylinder bores which provide good structural
rigidity. The crankshaft is carried in five main
bearings, end-float being controlled by thrust washers
positioned each side of the centre main bearing.The main bearing caps are located to the cylinder
block by dowels; the bearing shells fitted to Nos. 1, 3
and 5 bearings are fully grooved whilst those fitted to
Nos. 2 and 4 bearings are plain.
The cylinder head carries twin camshafts operating
four valves per cylinder via hydraulic tappets. Both
camshafts are driven by the timing belt and run
directly in journals line bored in the cylinder head and
camshaft carriers. The plastic camshaft covers are
bolted to the camshaft carriers.

12ENGINE
2
DESCRIPTION AND OPERATION The aluminium alloy, tin coated pistons have two
compression and an oil control ring and are secured
to the connecting rods by semi-floating gudgeon pins
which are an interference fit in the small-end bush.
Gudgeon pins are offset towards the thrust side of the
pistons to reduce frictional drag.
Plain, big-end bearing shells are fitted to each
connecting rod.The internally toothed timing belt is driven from a gear
which is keyed to the crankshaft, belt tension being
controlled by a semi-automatic tensioner.
The trochoidal type oil pump is mounted on the front
of the engine and carries the crankshaft front oil seal.
Drive to the pump is via a Woodruff key inserted in the
crankshaft.

12ENGINE
8
DESCRIPTION AND OPERATION TIMING BELT COMPONENTS
1. Bolt - timing belt upper cover
2. Timing belt upper cover
3. Bolt - camshaft timing gear
4. Plain washer
5. Timing belt
6. Inlet camshaft timing gear
7. Exhaust camshaft timing gear
8. Bolt - upper timing cover backplate
9. Upper timing cover backplate
10. Lower timing cover backplate
11. Tensioner spring sleeve
12. Anchorage bolt13. Tensioner spring
14. Tensioner pulley
15. Tensioner clamp bolt
16. Crankshaft timing gear
17. Timing belt lower cover
18. Bolt - timing belt lower cover
19. Timing belt centre cover
20. Crankshaft pulley
21. Crankshaft pulley/timing gear bolt
22. Crankshaft pulley bolt