service LAND ROVER DISCOVERY 1995 Owner's Manual

12ENGINE
2
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.

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3
REPAIR ENGINE
Service repair no - 12.41.01
Remove
CAUTION: Seal all exposed pipe ends
against ingress of dirt after disconnection.
1.Park vehicle on level ground and apply park
brake.
2.Disconnect battery negative lead.
3.Remove bonnet [hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.If air conditioning is fitted, remove RH footwell
side trim panel and disconnect harness multiplug
from relay.
5.Disconnect the two engine harness multiplugs
on LH side of footwell.
6.Remove engine harness grommet from
bulkhead and move harness into engine bay.
7.Release battery positive lead from retaining clip
at base of suspension turret.
8.Remove Radiator Assembly.
See COOLING
SYSTEM, Repair, Radiator
9.Discharge air conditioning system.See AIR
CONDITIONING, Adjustment, Refrigerant
Recovery Recycling Recharging
Remove retaining bolts and disconnect both pipe
adaptors from rear of compressor.
10.Remove rocker cover insulation.
11.Disconnect cyclone hose from air cleaner hose.
12.Remove air cleaner hose from turbocharger.
13.Remove feed pipe/hose from turbocharger and
intercooler.
14.Disconnect heater hoses from cylinder head and
heater rails.
15.Remove bolt securing transmission breather
pipe clip to cylinder head; move breather pipes
aside.
16.Disconnect inlet and outlet hoses from power
steering pump.
17.Disconnect bypass hose from thermostat
housing.
18.Release bypass hose from retaining clips on
front timing cover.
19.Remove split pin securing inner throttle cable to
injector pump.
20.Depress tags on outer cable adjusting nut,
remove cable from mounting bracket, and move
aside.
21.If automatic transmission is fitted, release
kickdown cable from injector pump and mounting
bracket.

12ENGINE
6
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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7
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
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.

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9
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.

12ENGINE
10
REPAIR
21.With lip side leading, drive-in seal squarely using
special tool LRT-12-082.
22.Refit gear.
FUEL INJECTION PUMP GEAR
Service repair no - 19.30.06
Remove
23.Slacken the three bolts on front of gear.
CAUTION: It is important to ensure that
when the injection pump is locked no
attempt must be made to rotate it. Take
care not to allow the crankshaft to be turned.24.Remove special tool pin from gear.
25.Remove three bolts and withdraw plate and
gear.
Refit
26.Fit gear and plate and secure with three bolts.
27.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.

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

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13
REPAIR OIL SUMP
Service repair no - 12.60.44
Remove
1.Disconnect battery negative lead.
2.Drain engine oil.
3.Slacken sump securing bolts and, using a sharp
knife, break sealant around sump flange.
4.Remove bolts and withdraw sump.
Refit
5.Clean mating faces of sump, timing gear housing
and cylinder block.
6.Apply a 2,0 mm bead of 'Hylosil RTV102' to the
sump flange, ensuring bead is applied inboard of
the bolt holes.
7.Secure sump to block with bolts. Tighten to
25
Nm.
8.Refill engine oil.See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
9.Reconnect battery negative lead.OIL PICK-UP STRAINER
Service repair no - 12.60.20
Remove
1.Disconnect battery negative lead.
2.Drain engine oil.
3.Remove engine oil sump.
See Oil Sump
4.Remove bolts securing pipe support bracket.
5.Remove bolts from pipe flanges.
6.Withdraw pick-up strainer assembly.
Refit
7.Refit pick-up strainer assembly, fitting a new 'O'
ring seal at oil pump connection.
8.Apply Loctite 242E to the two screws at the
bearing cap. Tighten to
9 Nm.
9.Fit bolts to pipe flanges. Tighten to25 Nm.
10.Refit engine oil sump.See Oil Sump
11.Reconnect battery negative lead.

12ENGINE
14
REPAIR FLYWHEEL
Service repair no - 12.53.07
Remove
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Fit two long 8mm bolts into the clutch bolt holes,
diametrically opposite, to use as handles when
lifting the flywheel off the crankshaft.
5.Remove fan cowl
6.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts, to restrain crankshaft
while removing flywheel retaining bolts.
7.Remove the bolts and lift off flywheel.
NOTE: To prevent excessive flywheel
run-out, ensure that the mating faces of
the flywheel and crankshaft are clean.Refit
8.Locate the flywheel on the crankshaft and
secure with new patched retaining bolts,
progressively tighten to
147 Nm.
9.Check the flywheel for possible run-out by
mounting a dial test indicator with the stylus in a
loaded condition resting on the flywheel face at a
radius of 114mm from the centre.
10.Turn the flywheel and check that run-out does
not exceed 0,05 to 0,07mm. Should run-out be
excessive, remove the flywheel and check again
for irregularities on the crankshaft and flywheel
mating faces and the dowel.
11.Reverse removal procedure. 1 to 6.