1995 LAND ROVER DISCOVERY Service Repair Manual

ENGINE
34
OVERHAUL Timing belt rear cover - refit
1.Remove all traces of gasket material from
cylinder block using suitable gasket removal
spray and a plastic scraper.
2.Screw 2 slave guide studs into cylinder block.
3.Fit new gasket over guide studs.
4.Note position of oil pump drive flats on
crankshaft.
5.Rotate oil pump inner rotor to align with drive
flats on crankshaft and position timing belt rear
cover on guide studs.
6.Fit timing belt rear cover.
CAUTION: Do not remove guide studs at
this stage.
7.Fit 8 bolts of the correct length in positions
shown, remove guide studs and fit remaining 2
bolts.

ENGINE
OVERHAUL35
8.Using sequence shown, tighten bolts to 25 Nm.
9.Fit oil pick-up pipe and sump.
10.Lubricate a new crankshaft front oil seal with
engine oil.
11.Fit oil seal using toolLRT-12-079.
12.Lubricate a new camshaft oil seal with engine
oil.
13.Fit oil seal using toolLRT-12-082.
14.Fit fuel injection pump.
15.Fit timing belt, tensioner and gears.

ENGINE
36
OVERHAUL OIL FILTER HEAD
Remove
1.Remove and discard oil filter element.
2.Remove 4 bolts securing filter head to cylinder
block.
3.Remove filter head, remove and discard
gasket.Thermostatic valve - remove
1.Secure oil filter head in a soft-jawed vice with
thermostatic valve vertically upwards.
2.Remove 2 bolts securing thermostatic valve
extension housing to oil filter head.
3.Remove extension housing, remove and
discard 'O' ring.
4.Withdraw thermostatic valve and spring.
CAUTION: Do not separate valve from
spring.

ENGINE
OVERHAUL37
Inspecting components
1.Check thermostatic valve spring for distortion
and corrosion.
CAUTION: Do not separate valve from
spring.
2.Check valve for corrosion, seating faces of
valve and extension housing for damage and
pitting; replace valve as an assembly.
3.Check valve bore for corrosion. Light corrosion
must be removed from valve bore using grade
600 emery cloth soaked in oil.
4.Check oil passages in oil filter head are clear.Thermostatic valve - refit
1.Secure oil filter head in a soft-jawed vice with
thermostatic valve bore vertically upwards.
2.Lubricate a new 'O' ring with engine oil and fit
to thermostatic valve extension housing.
3.Lubricate thermostatic valve and bore with
engine oil.
4.Fit thermostatic valve and spring.
5.Position extension housing to oil filter head
ensuring that thermostatic valve is positioned
centrally in housing.
6.Fit and progressively finger tighten 2 bolts
ensuring that thermostatic valve remains
correctly positioned in extension housing.
7.Tighten bolts to 9 Nm.

ENGINE
38
OVERHAUL Oil filter head - refit
1.Remove all traces of gasket from oil filter head
and cylinder block using suitable gasket
removal spray and a plastic scraper.
2.Smear a new gasket with engine oil and
position on oil filter head.
3.Fit oil filter head, fit 4 bolts and tighten to 45
Nm.
4.Smear sealing ring of new oil filter element with
engine oil and fit to oil filter head.
5.Plug open pipe connections to prevent ingress
of dirt.FUEL INJECTION PUMP
Remove
1.Remove timing belt.
2.Remove fuel pipes from pump and injectors.3.Ensure that timing pinLRT-12-045is inserted
in injection pump gear hub plate and injection
pump hub.
4.Remove 3 bolts securing hub and injection
pump gear to injection pump, remove timing
pinLRT-12-045and gear.
CAUTION: Do not remove nut securing
hub to pump.

ENGINE
OVERHAUL39
5.Remove 3 bolts securing mounting bracket and
baffle plate to cylinder block.
6.Remove 2 bolts securing mounting bracket to
injection pump, remove bracket.
7.Remove banjo bolt securing fuel spill return
pipe to injection pump, discard sealing
washers.
CAUTION: Plug open connections to
prevent ingress of dirt.
8.Remove 3 nuts securing injection pump to
timing belt rear cover, remove injection pump.

ENGINE
40
OVERHAUL Refit
1.Position injection pump to timing belt rear
cover, fit nuts and tighten to 25 Nm.
2.Fit fuel spill return pipe, fit banjo bolt and 2 new
sealing washers.
3.Tighten banjo bolt to 25 Nm.
4.Position mounting bracket to injection pump
and cylinder block, fit and finger tighten bolts.
5.Tighten mounting bracket bolts to 25 Nm in the
following order:
Mounting bracket to cylinder block
Mounting bracket to injection pump
6.Fit fuel pipes.
7.Position injection pump gear and hub plate to
injection pump hub ensuring that cut-out in hub
plate is aligned with timing pin hole in pump
hub.
8.Fit 3 bolts, position slot in gear mid-way under
bolt heads, lightly tighten bolts.
NOTE: Do not fit bolts through elongated
slots in hub plate. Bolts are fully tightened
after timing belt has been adjusted.
9.Insert timing pinLRT-12-045in hub plate and
injection pump hub.
10.Fit and tension timing belt.FUEL LIFT PUMP
Remove
1.Disconnect fuel delivery pipe from fuel lift
pump, discard sealing washers.
CAUTION: Plug open connections to
prevent ingress of dirt.

ENGINE
OVERHAUL41
2.Remove 2 bolts securing fuel lift pump to
cylinder block, remove pump, gasket, spacer
and 2nd gasket.
3.Discard gaskets.Refit
1.Remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
2.Position new gaskets and spacer to fuel lift
pump.
3.Fit fuel lift pump ensuring that operating lever
is correctly positioned on camshaft.
4.Fit bolts and tighten to 25 Nm.
5.Position fuel delivery pipe to fuel lift pump, fit
banjo bolt and 2 new sealing washers.
CAUTION: Do not fully tighten banjo bolt
until pipe is connected to fuel filter.