1995 LAND ROVER DISCOVERY wheel

86ELECTRICAL
46
REPAIR STARTER MOTOR - 4.0 V8
Service repair no - 86.60.01
Remove
1.Disconnect battery negative lead.
2.Raise vehicle on ramp.
3.Remove heated oxygen sensor from RH front
exhaust pipe.
See EMISSION CONTROL,
Repair, Heated Oxygen Sensor (HO2S) - 4.0
V8
4.Mark front propeller shaft and drive flanges for
assembly reference.
5.Remove 4 nuts and bolts securing propeller
shaft flange.
NOTE: Raise 1 front road wheel and rotate
propeller shaft to gain access to all
fixings.
6.Tie propeller shaft aside.
7.Position starter motor heat shield above motor.
See Starter Motor Heat Shield - 4.0 V8
8.Disconnect Lucar from solenoid.
9.Remove nut securing feed wires to starter
solenoid and disconnect from terminal.

ENGINE
DESCRIPTION AND OPERATION15
OPERATION
The 300 TDi is a 4 cylinder, water cooled,
turbocharged diesel engine with a capacity of 2.5
litres.
The cast iron cylinder block is integral with the
crankcase and incorporates direct bored cylinders.
The crankshaft is carried in 5 main bearings,
end-float being controlled by thrust washers which
are positioned on both sides of the centre main
bearing.
The flywheel/drive plate housing is an aluminium
alloy casting secured to the rear of the cylinder
block, it also forms the mounting for the starter
motor. A plugged aperture in the housing allows
access for the insertion of the timing pin.
The aluminium alloy cylinder head carries a
conventional rocker shaft and rockers, operating 2
valves per cylinder via camshaft followers and push
rods from a single camshaft, supported in the
cylinder block by 4 bearings and driven by a gear
and toothed belt from the crankshaft. A lobe formed
between the 2 inner bearing journals provides drive
for the fuel lift pump and another lobe, between the 2
drive end journals provides drive for the brake servo
pump. Camshaft end-float is controlled by a thrust
plate bolted to the cylinder block.
Graphite coated, aluminium alloy pistons are fitted
with 2 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. A swirl chamber is incorporated in
the piston crown to facilitate combustion.
The timing case consists of cast aluminium alloy
front and rear covers which house the oil pump,
crankshaft and camshaft front oil seals and which
also carry the fuel injection pump and drive belt idler
pulley. Housed within the timing case housing is the
crankshaft gear which provides drive for the
camshaft and fuel injection pump gears via a rubber
toothed belt.

ENGINE
2
OVERHAUL
6.Remove timing belt front cover.
7.Remove and discard gasket.
8.Remove and discard crankshaft front oil seal
from timing belt front cover.
9.Temporarily fit crankshaft pulley bolt to
crankshaft.
Manual gearbox
10.Remove plug from bottom of flywheel housing.
11.Rotate crankshaft clockwise using crankshaft
pulley bolt until toolLRT-12-044can be
located in slot in flywheel.
CAUTION: Do not rotate crankshaft
anti-clockwise and do not use camshaft or
fuel injection pump gear bolts to rotate
crankshaft.
Automatic gearbox
12.Rotate crankshaft clockwise using crankshaft
pulley bolt until toolLRT-12-044can be
inserted through hole in engine plate and into
slot in drive plate.
CAUTION: Do not rotate crankshaft
anti-clockwise and do not use camshaft or
fuel injection pump gear bolts to rotate
crankshaft.

ENGINE
OVERHAUL7
8.Position flanged spacer on idler pulley stud.
9.Fit timing belt tensioner pulley and bracket
ensuring that hole in tensioner bracket is
located on flanged spacer.
10.Fit slotted washer with the slot vertical and fit
bolt, finger tight.
11.Temporarily fit crankshaft pulley bolt to
crankshaft.
NOTE: Flywheel illustrated
12.
Manual gearbox:Rotate crankshaft clockwise
using crankshaft pulley bolt until tool
LRT-12-044can be inserted in slot in flywheel.
13.
Automatic gearbox:Rotate crankshaft
clockwise using crankshaft pulley bolt until tool
LRT-12-044can be inserted in slot in drive
plate.
14.Check that crankshaft Woodruff key is aligned
with arrow on timing belt rear cover.
15.If necessary, rotate camshaft timing gear using
the centre bolt until timing mark on gear is
aligned with timing mark on timing belt rear
cover.
16.Remove crankshaft pulley bolt.

ENGINE
OVERHAUL9
5.Check that timing pinLRT-12-045moves
freely in and out of injection pump hub, if pin
does not move freely, slacken 3 bolts, move
gear slightly and re-check.
6.When timing pin moves freely, tighten 3 bolts
to 25 Nm.
7.Remove timing pinLRT-12-045and
flywheel/drive plate locking toolLRT-12-044.
8.Rotate crankshaft twice in a clockwise direction
using crankshaft pulley bolt until flywheel/drive
plate locking toolLRT-12-044can be refitted.
9.Slacken timing belt tensioner securing bolt and
re-tension timing belt.
10.Tighten tensioner bolt to 45 Nm.
11.Fit timing pinLRT-12-045into fuel injection
pump gear hub plate and pump hub. If timing
pin cannot be inserted, slacken injection pump
gear bolts, rotate pump shaft using shaft nut
until pin slides easily into pump hub, Tighten
bolts to 25 Nm.
12.Tighten camshaft gear bolt to 80 Nm.
13.Remove timing pin and flywheel/drive plate
locking tools.
14.Fit plug to flywheel housing, tighten to 12 Nm.
15.Remove crankshaft pulley bolt.
16.Support timing belt front cover on suitable
blocks of wood.
17.Smear a new crankshaft oil seal with engine
oil.
18.Using toolLRT-12-077,fit oil seal from inside
face of front cover.
19.Fit a dry, new gasket to timing belt rear cover.
20.Position timing belt front cover to rear cover.
21.Fit bolts of the correct length in positions
shown.

ENGINE
OVERHAUL47
Sump - refit
1.Clean sump and remove all traces of sealant
using solvent from kit GUG 705548GM.
2.Apply a 2 mm bead of Hylomar Instant Gasket
302 (black) to sump flange ensuring that
sealant is applied inboard of bolt holes.
3.Position sump to cylinder block.
CAUTION: Sump must be fitted within 30
minutes of applying sealant.
4.Fit 22 sump bolts and tighten in sequence
shown to 25 Nm.
5.Check that sump drain plug is tightened to 35
Nm.FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
1.Screw 2 slave 8 mm bolts into flywheel.

ENGINE
48
OVERHAUL
2.Temporarily fit crankshaft pulley.
3.Position toolLRT-12-080to crankshaft pulley,
secure with 4 bolts.
4.Restrain crankshaft pulley using tool
LRT-12-080and remove 8 bolts securing
flywheel; discard locking plate - if fitted.
5.Using assistance, remove flywheel using 2
slave bolts.
NOTE: Dowel located.

ENGINE
OVERHAUL49
Inspecting components
1.Check clutch face of flywheel for scoring or
signs of overheating ( blueing ), if deep scoring
or signs of overheating exist, flywheel must be
replaced.
2.Check teeth of starter ring gear for chipping
and wear, replace ring gear as necessary.Starter ring gear - replace
1.Drill a 3 mm diameter hole to the depth of the
ring gear at the root of 2 teeth.
CAUTION: Ensure drill does not contact
flywheel.
2.Using a cold chisel, split ring gear.
WARNING: Wear suitable eye protection
and cover flywheel with cloth to protect
against flying fragments.
3.Remove ring gear from flywheel.
4.Heat replacement ring gear uniformly to 250
°C.