wheel bolt torque LAND ROVER DISCOVERY 1995 Workshop Manual

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
16
REPAIR 8.Ensure housing seal is correctly seated in its
groove in new housing and seal assembly.
9.Fit new assembly, with former/guide in-situ, over
crankshaft flange, this action will eject
former/guide.
10.Secure assembly to cylinder block with five bolts
tightened to correct torque, removing slave studs
individually and inserting bolts.
11.Refit flywheel.
See Flywheel
12.Refit clutch.See CLUTCH, Repair, Clutch
Assembly
13.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
14.Reconnect battery negative lead.CRANKSHAFT BEARING BUSH
Service repair no - 12.21.45
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Remove flywheel.See Flywheel
5.Remove bearing bush.
NOTE: The bearing bush can be removed
by using one of the following methods.
Method 1.
Obtain a short length of steel rod of a diameter having
a good slide fit in the bore of the bush. Pack the bore
with grease and insert the steel rod into the end of the
bore, give a sharp blow with a hammer and the
grease should drive out the bush. It is recommended
that the bush and rod be covered by a suitable cloth
or rag to prevent grease from splashing.

Tdi
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine block
Bearing cap 133...............................................................................................
Blanking plug, oil gallery, rear 37....................................................................
Oil squirt jet assembly 17................................................................................
Drain plug, cylinder block 25...........................................................................
Oil squirt jet, vacuum pump cam 7.................................................................
Connecting rod to cap 59................................................................................
Oil pick up assembly to bearing cap 9...........................................................
Oil pick up assembly to front cover 25............................................................
Camshaft thrust plate 9..................................................................................
Oil drain pipe to block (internal) 25.................................................................
Oil drain pipe to block (external) 25................................................................
Sump to cylinder block and front cover 25......................................................
Drain plug, oil sump 35...................................................................................
Tappet guide 14..............................................................................................
Breather side cover assembly 25....................................................................
Baffle plate to breather side cover 4..............................................................
Vacuum pump 25............................................................................................
Fuel lift pump 25.............................................................................................
Flywheel housing 45.......................................................................................
Flywheel housing clutch cover stud 10...........................................................
Plug, flywheel housing 12...............................................................................
Rear oil seal assembly 25...............................................................................
Oil filter adaptor 45..........................................................................................
Waxstat adaptor to oil filter adaptor 9............................................................
Oil pressure switch 17.....................................................................................
Oil filter, spin on 13.........................................................................................
Oil cooler unions to filter adaptor 45...............................................................
Oil level tube 25..............................................................................................
Engine mounting foot to cylinder block 85......................................................
Engine mounting foot to flywheel housing 45.................................................
Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................
Flywheel to crankshaft 146..............................................................................
Clutch cover plate to flywheel 34....................................................................
Flex drive plate to crankshaft (auto) 146..........................................................
Flex drive plate to ring gear (auto) 25.............................................................
Flex drive plate to torque converter (auto) 45.................................................

V8i
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine
Adaptor plate to crankshaft 84........................................................................
Generator and power steering mounting bracket to cylinder head 30............
Cylinder head:
Stage 1: 20.............................................................................................
Stage 2: - Further 180°±5°
Drive plate to converter 39..............................................................................
Engine mountings to engine and chassis 55..................................................
Engine mounting rubbers to brackets 30........................................................
Flexible drive plate to crankshaft adaptor plate 41.......................................... **
Flywheel to crankshaft bolts 78....................................................................... **
Lifting eye to cylinder heads 39......................................................................
Main bearing cap rear bolts 92....................................................................... *
Oil sump drain plug 40....................................................................................
Oil sump to cylinder block 18..........................................................................
Rocker cover to cylinder head 9....................................................................
Rocker shaft bracket to cylinder head 38........................................................
Spark plug 21..................................................................................................
Starter motor attachment 44...........................................................................
* These bolts must have threads coated in lubricant EXP16A before assembly.
** These bolts must have threads coated in sealant Loctite 270
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................
NOTE: Torque values above are for all screws and bolts used except for those specified.

Mpi
3
REPAIR
For torque values.See Specifications, torque,
Torque Values
3.Fit timing belt upper backplate and tighten bolts
to the correct torque.
4.Fit camshaft gears noting the 'IN' and
'EXHAUST' identifying marks.
5.Fit, but do not tighten, camshaft gear centre
bolts.
6.Ensure timing marks are aligned.
7.Fit camshaft locking tool LRT-12-060.
8.Tighten camshaft gear bolts to the correct
torque.
9.Fit timing belt.
See Camshaft Drive Belt
10.Adjust timing belt tension.
11.Remove tool LRT-12-058 from flywheel.
12.Fit timing belt centre cover and tighten bolts to
correct torque.
13.Fit timing belt upper cover and tighten bolts to
correct torque.
14.Fit drive belt.
See SECTION 10, Maintenance,
Under Bonnet [Hood] Maintenance
15.Reconnect battery negative lead.INLET - EXHAUST CAMSHAFT REAR OIL PLUG
Remove
1.Remove cylinder head.
2.Lever out, camshaft rear oil seal plug.
Refit
1.Clean plug housing.
2.Fit new plug applying force to outer edge only.
3.Refit cylinder head.

Mpi
5
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
1.Remove gearbox.
2.Remove clutch assembly.
3.Remove flywheel.
4.Drain engine oil.
5.Fit sump plug, replacing sealing washer if
damaged and tighten to the correct torque.
6.Loosen 15 sump bolts by approximately 3 turns,
allowing sump to drop away from rear oil seal
housing. Do not loosen 3 boltsAaround oil
pump housing.
7.Remove bolts securing oil seal housing, remove
seal and housing assembly.
Refit
1.Clean seal seating area of block and accessible
area of sump gasket. Sump gasket must be
replaced if damaged.
2.Lubricate oil seal sealing surfaces with engine
oil.
3.Fit tool LRT-12-061 over crankshaft boss and fit
oil seal and housing assembly.
4.Remove tool.
5.Fit and tighten seal housing bolts to correct
torque in sequence shown.
10Nm
6.Tighten sump bolts to correct torque and in the
correct sequence.
See Engine Sump Gasket
7.Fit flywheel.
8.Fit clutch assembly.
9.Fit gearbox.

12ENGINE
22
REPAIR
CAUTION: Ease timing belt off gears using
fingers only. Metal levers may damage the
belt and gears. Do not rotate engine with
timing belt removed and cylinder head fitted.
Timing belts must be stored and handled with
care. Always store a timing belt on its edge with a
bend radius greater than 50 mm. Do not use a
timing belt which has been twisted or bent double
as this can fracture reinforcing fibres. Do not use
an oil contaminated timing belt. Although the belt
has a service life of 96,000 miles, 160,000 km, an
existing belt should only be refitted if it has
completed less than 48,000 miles, 80,000 km.
Refit
NOTE: For torque values.See
Specifications, torque, Torque values
1.Clean timing belt gears and pulleys.
2.Clean crankshaft pulley.
CAUTION: If original belt is to be refitted,
ensure direction of rotation mark is facing
correct way.
3.Fit timing belt to gears, starting at the crankshaft
gear and working in an anti-clockwise direction.
CAUTION: Ensure the belt run between the
crankshaft and exhaust camshaft gear is
kept taut during the fitting procedure.
4.Fit timing belt lower cover, tighten 3 bolts to the
correct torque.
5.Fit crankshaft pulley to crankshaft timing gear.
6.Fit tool LRT-12-059 to crankshaft pulley, fit 2
bolts to retain tool.
7.Fit crankshaft pulley centre bolt, and using tool
LRT-12-059 to restrain pulley, tighten bolt to the
correct torque.
8.Remove tool LRT-12-059
9.Fit bolts securing crankshaft pulley to timing
gear, tighten bolts to the correct torque.
10.Remove tool LRT-12-060.Tension belt
1.Loosen timing belt tensioner pulley bolt.
2.Apply
40Nmanti-clockwise torque to inlet cam
pulley bolt and release.
3.Tighten tensioner pulley bolt to the correct
torque.
4.Remove tool LRT-12-058 from flywheel.
5.Fit timing belt centre cover, tighten 5 bolts to the
correct torque.
6.Fit timing belt upper cover, tighten 5 bolts to the
correct torque.
7.Fit drive belt.

Tdi
13
REPAIR Refit
21.Remove blanks from pump.
22.Remove special tool pin from pump.
23.Clean mating faces of pump and front cover.
24.Fit pump to cover with a new gasket and secure
with nuts. Tighten to
25 Nm.
25.Attach pump to bracket and finger tighten nuts
and bolts
26.First tighten bolts securing bracket to block and
then bolts securing pump to bracket.
27.Connect spill return, main fuel pipes. Tighten to
25 Nm.
28.Connect boost signal pipe and secure with banjo
bolts. Tighten to
10 Nm.
29.Connect stop control solenoid lead.
30.Connect throttle cable and where applicable
hand throttle cable.
31.Remove special tool LRT-12-045.
32.Fit gear lock plate.
33.Fit pin from special tool LRT-12-045.
34.Secure gear with bolts.
35.Remove special tool pin.
36.Turn crankshaft two complete revolutions, check
timing pin from LRT-12-045 can be fully and
easily inserted into the pump. At the same time
check flywheel timing pin LST-12-044 can also
be inserted in the flywheel slot.
37.If, with the flywheel timing pin located, the timing
pin cannot be inserted cleanly into the injection
pump, carry out the following:
(a) Ensure flywheel timing pin is disengaged
from slot in flywheel.
(b) Turn the crankshaft the small amount
necessary to enable the timing pin to be
inserted into the pump.
(c) Loosen the three pump gear retaining
bolts.
(d) Turn the crankshaft to T.D.C..
(e) Check that the timing pin is an easy fit in
the pump and that the flywheel timing pin
locates.
(f) Tighten the pump gear retaining bolts to
the correct torque.
(g) Remove the timing pin from the pump and
the timing tool from the flywheel housing.
38.Using antisieze compound, fit the blanking plug
to flywheel housing. Tighten to
12 Nm.
39.Fit access plate with gasket to front cover plate.
Tighten to
25 Nm.
40.Refit injector pipes. Tighten to29 Nm.

44AUTOMATIC GEARBOX
6
REPAIR 13.Remove starter.
14.Working through starter aperture note position of
torque converter flexible drive plate to facilitate
refitting.
15.Remove the four torque convertor to flexible
drive securing bolts, rotating engine to gain
access to each individual bolt.
16.Raise vehicle on four post ramp [hoist].
17.Drain lubrication oil from transfer and main
gearboxes.
18.Disconnect speedometer cable from transfer
gearbox and disconnect associated clipping.
19.Remove rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
20.Disconnect front propeller shaft at transfer
gearbox and tie to one side.
21.Remove exhaust front pipe.
22.Remove bolts securing front and centre silencer
mounting brackets and tie silencer to one side.
23.Disconnect oil cooler pipes from gearbox.
24.Blank off pipes and union connections.
25.Remove bolt securing retaining bracket to sump
and move cooler pipes aside.
26.Disconnect selector cable from lever on side of
gearbox.
27.Disconnect inhibitor switch multi-plug.
28.Disconnect park brake cable from linkage to park
brake lever.
29.Disconnect electrical connections from
differential lock switch on transfer gearbox.
30.Remove two lower bolts from transfer gearbox
input bearing support plate.
31.Assemble approved support cradle to
transmission hoist.32.Raise hoist and secure cradle to transfer
gearbox input bearing support plate using bolts
removed.
33.Disconnect gearbox mounting brackets from
chassis cross member.
34.Remove chassis cross member.
35.Lower transmission sufficiently to allow access
to items attached to top of gearbox.
36.Remove left hand gearbox mounting bracket
assembly.
37.Remove ties from breather pipes and harness.
38.Remove nut securing gearbox oil filler/dip stick
tube to bell housing.
39.Release union nut at gearbox sump and remove
filler/dipstick tube. Fit blanking plugs.
40.Support engine using a wooden block with a
suitable ramp [hoist] jack.
41.Remove nut securing kick down cable bracket to
bell housing.
42.Remove two bolts securing top of bell housing to
flywheel housing.
43.Remove nuts securing bell housing to flywheel
housing and withdraw transmission assembly
from engine.
44.Fit a suitable torque converter retaining strap to
the bell housing.
45.Remove hoist and transmission from under
vehicle.
46.Fit lifting eyes to transmission.
47.Using suitable chains and lifting tackle take
weight of transmission assembly.
48.Remove bolts securing transmission cradle to
transfer box and withdraw hoist complete with
cradle.
49.Refit bolts to cover plate.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids