belt LAND ROVER DISCOVERY 1995 User Guide

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REPAIR DRIVE BELT INFORMATION
A single 'serpentine drive belt' drives all the
ancilliaries bar the air conditioning compressor, which
has a separate drive belt. It is essential that the belts
are fitted exactly as shown. It should also be noted
that the water pump/viscous fan is driven in a
clockwise direction.
A drive belt tensioner automatically tensions the drive
belt, eliminating the need for tensioning individual
drive belts. Turning the tensioner pulley in a clockwise
direction will release drive belt tension.
Under normal highway use the belt must be changed
at 160,000 kilometres, 96,000 miles or eight years
whichever occurs first.
The drive belt must be examined at every service and
replaced if necessary.Off road driving
Regular examination of the drive belt is essential if the
vehicle is used off road. The vehicle driver should be
requested to identify the type of mileage the vehicle
has covered.
After every off road session the owner should inspect
the belt for cuts and possible damage caused by
stones. If belt has jumped, reposition belt correctly. A
new belt must be fitted at the next service or before,
dependant on the type of damage sustained.
Fan cowl
To ensure easy access to the drive belt the top portion
of the fan cowl is detachable.
Check condition
Check condition of drive belt. Renew a belt that shows
signs of wear, splitting or oil contamination.

12ENGINE
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REPAIR DRIVE BELT RENEW
Service repair no - 86.10.03
NOTE: If cast lines on tensioner arm and
tensioner spring case are aligned, a new
drive belt must be fitted.
Remove
1.Remove fan cowl upper.
2.Apply ring spanner to tensioner pulley retaining
bolt.
3.Turn spanner to release pulley tension from belt.
4.Detach belt from pulley.
5.Release tensioner.
6.Complete removal of belt. Mark direction on belt
if refitting.
Refit
7.Reverse removal procedure.COMPRESSOR DRIVE BELT
Service repair no - 86.10.02
Remove
1.Remove auxiliary drive belt.
See Drive Belt
Renew
2.Remove compressor shield.
3.Loosen tensioner retaining bolts.
4.Remove compressor drive belt. Mark direction
on belt if refitting.
Refit
5.Fit compressor drive belt.
6.Fit torque meter to centre of tensioner and apply
and hold a torque of
35 Nm.Tighten 3 tensioner
retaining bolts.
7.Rotate crankshaft 2 full turns.
8.Reapply and hold a torque of
35 Nmto
tensioner, then fully loosen and retighten 3
tensioner retaining screws to
25 Nm.

12ENGINE
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REPAIR CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1.Disconnect battery negative lead.
2.Drain coolant.
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous fan and coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
6.Remove fan cowl.
7.Remove drive belt.
See Drive Belt Renew
8.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts.
9.Remove crankshaft pulley retaining bolt using
socket and suitable long bar.
10.Remove pulley retainer.
11.Remove pulley, if necessary using extractor
LRT-12-049 with thrust pad from LRT-12-031.Refit
12.Refit in reverse order, lightly greasing pulley
spigot. Tighten to
80 Nm + 90°.

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REPAIR FRONT COVER PLATE
Service repair no - 12.65.01
Remove
1.Disconnect battery negative lead.
2.Drain coolant.
3.Remove top hose from radiator.
4.Remove inter-cooler to induction manifold hose.
5.Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
6.Remove fan cowl.
7.Remove drive belt.
See Drive Belt Renew
8.Remove crankshaft pulley.See Crankshaft
Pulley
9.Remove 14 bolts securing front cover plate,
noting top two bolts also retain thermostat hose
clips.
10.Remove cover plate complete with gasket.
11.Remove small gasket from centre bolt boss.
Seal replacement
12.Remove worn seal from cover and clean recess.
13.Support cover and fit new seal, open side fitted
into recess, using special tool LRT-12-077.
Refit
14.Refit in reverse order to removal using new
gaskets, fitting the securing bolts as shown in
illustration ST3475. Tighten to
25 Nm.

12ENGINE
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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.

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REPAIR Belt tensioner
NOTE: The belt tensioner need only be
removed if it is being replaced or for
access purposes to remove front cover.
11.Remove securing bolt and withdraw tensioner
complete with spacer.
Crankshaft gear/front cover oil seal
12.If the crankshaft gear cannot be removed by
hand, use special tool LRT-12-078 with main
body and thrust button from special tool
LRT-12-031 as illustrated ST3478M. Withdraw
gear complete with 'O' ring seal.
13.If necessary prise out oil seal from front cover.
14.Lubricate a new crankshaft oil seal with clean
engine oil.
15.With lip side leading, drive-in seal squarely using
special tool LRT-12-079.
16.Lubricate new 'O' ring seal with petroleum jelly
and slide onto shaft, taking care not to damage
seal on the woodruff keys.
17.Fit crankshaft gear, tap fully home ensuring 'O'
ring seal is properly seated.
CAMSHAFT GEAR/FRONT COVER OIL SEAL
Service repair no - 12.13.05
18.Remove centre bolt from camshaft gear and
withdraw gear.
19.Remove existing oil seal from front cover using
special tool LRT-12-038.
20.Lubricate a new camshaft oil seal with clean
engine oil.

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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

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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

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REPAIR VACUUM PUMP
Service repair no - 70.50.19
Remove
NOTE: To ease pump removal set engine
to T.D.C. on No.1 cylinder.
1.Disconnect battery negative lead.
2.Detach servo hose from vacuum pump.
3.Remove six bolts securing vacuum pump.
4.Detach pump complete with harness bracket.
Note location of bracket for refitting.
Refit
5.Clean mating faces of pump and block.
6.Loosely assemble pump to block with a new
gasket and with harness bracket located under
head of bolt noted during removal.
7.Evenly tighten bolts, to depress pump plunger,
finally tightening to
25 Nm.
8.Connect vacuum hose and secure with clip.
9.Reconnect battery negative lead.GENERATOR
Service repair no - 86.10.02
Remove
1.Disconnect battery negative lead.
2.Remove drive belt.
See Drive Belt Renew
3.Disconnect electrical leads from rear of
generator.
4.Remove securing bolt from bottom of generator.
5.Remove long through bolt from top fixing and
withdraw generator.
Refit
6.Reverse removal procedure.

12ENGINE
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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..........................................................................