1995 LAND ROVER DISCOVERY fuel

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
OVERHAUL3
All engines
13.Check that timing mark on camshaft pulley is
aligned with mark on timing belt rear cover and
the crankshaft Woodruff key is aligned with the
arrow cast on the rear cover.
14.Remove crankshaft pulley bolt.
15.Insert timing pinLRT-12-045into fuel injection
pump gear hub plate and injection pump hub.
16.Slacken but do not remove centre bolt securing
camshaft drive gear to camshaft.
17.If timing belt is to be refitted, mark direction of
rotation on outside surface of belt with chalk or
similar soft material.
18.Slacken but do not remove bolt securing timing
belt tensioner pulley, move pulley until tension
is removed from belt.
19.Remove nut and washer securing idler pulley.
20.Release idler pulley from timing belt, remove
pulley.
21.Release timing belt from gears, discard belt.

ENGINE
OVERHAUL5
6.Remove 3 bolts securing fuel injection pump
gear and hub plate to pump hub.
CAUTION: Do not remove nut securing
hub to fuel injection pump.
7.Remove timing pinLRT-12-045.
8.Remove fuel injection pump gear and hub
plate.Inspecting components
1.Check timing gear teeth for burrs.
2.Remove all traces of gasket from timing belt
front and rear covers using suitable gasket
removal spray and a plastic scraper.

ENGINE
6
OVERHAUL Timing belt tensioner and gears - refit
1.Smear a new 'O' ring with engine oil and fit to
crankshaft.
2.Fit Woodruff key in slot in crankshaft.
3.Fit crankshaft gear on to crankshaft and using
a soft mallet, tap gear fully home.
4.Position camshaft timing gear and hub plate to
camshaft, fit bolt and washer, finger tighten
bolt. Do not tighten bolt at this stage.
NOTE: Later engines are fitted with a
flange head bolt.
5.Position fuel injection pump gear and hub plate
to fuel injection pump hub ensuring that cut-out
in hub plate is aligned with timing pin hole in
pump hub.
6.Fit 3 bolts, position slots in gear mid-way under
bolt heads, lightly tighten bolts.
CAUTION: Do not fit bolts through
elongated slots in hub plate. Ensure gear
does not move as bolts are tightened.
7.Insert timing pinLRT-12-045in hub plate and
injection pump hub. If timing pin cannot be
inserted, slacken bolts and rotate gear until pin
can be fitted, lightly tighten bolts.

ENGINE
8
OVERHAUL Timing belt - refit and adjust tension
Refit
1.Using the fingers only, fit a new timing belt to
timing gears keeping slack portion of belt on
idler pulley side of belt. If necessary, rotate fuel
injection pump gear anti-clockwise to align
gear teeth with those of timing belt.
CAUTION: If original timing belt is to be
refitted, ensure direction of rotation mark
is facing correct way.
2.Fit idler pulley.
3.Fit idler pulley nut and tighten to 45 Nm.
4.Ensure that timing belt is correctly located on
timing gears.
5.Check that tensioner pulley bolt is finger tight.
6.Temporarily fit crankshaft pulley bolt to
crankshaft.Adjust tension
1.Ensure toolsLRT-12-044andLRT-12-045
are still fitted.2.Position a dial type torque wrench and suitable
extension to hole in tensioner bracket keeping
the torque wrench positioned vertically.
3.Tension timing belt to :
Used belt - 12 Nm
New belt - 15 Nm
4.Keeping timing belt at the correct tension,
tighten tensioner bolt to 45 Nm.

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
18
OVERHAUL CYLINDER HEAD
Remove
1.Remove rocker shaft.
2.Remove fuel injectors.
3.Remove glow plugs.
4.Using sequence shown, progressively slacken
then remove and discard 18 bolts securing
cylinder head.
5.Using assistance, remove cylinder head.
NOTE: Dowel located.
6.Remove cylinder head gasket.
CAUTION: Identify cylinder head gasket
thickness by the number of holes in the
edge of the gasket between numbers 3
and 4 injector ports. Replacement gasket must
be of the same thickness as the original unless a
replacement cylinder head, crankshaft and/or
pistons are fitted.
- See Cylinder head gasket
selection.
7.Discard cylinder head gasket.
8.Remove 2 bolts securing coolant outlet elbow.
9.Remove coolant outlet elbow.
10.Remove thermostat from housing.
11.Remove 4 bolts securing thermostat housing to
cylinder head, remove housing.
12.Remove and discard gasket.
13.Remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.