1995 LAND ROVER DISCOVERY fuel

ENGINE
30
OVERHAUL
10.Assemble degree plateLRT-12-007to a
torque wrench or extension bar.
11.Make a suitable pointer from welding rod and
attach it to the rocker shaft pedestal bolt hole
adjacent to number 1 cylinder head bolt.
12.Using sequence shown, tighten cylinder head
bolts a further 60°.
NOTE: Re-position the pointer as
necessary to enable degree of tightening
to be measured.
13.Using sequence shown, tighten each bolt a
further 60°.
CAUTION: Bolts must be tightened in
sequence 60°at a time - never 120°in one
operation.
14.Using sequence shown, tighten bolts numbers
1, 2, 7, 8, 9, 10, 15, 16, 17 and 18 a further
20°.
15.Remove pointer.
16.Position a new thermostat housing gasket to
cylinder head.
17.Fit thermostat housing, fit bolts and tighten to
25 Nm.
18.Position thermostat in housing.
19.Fit coolant outlet elbow, fit bolts and tighten to
25 Nm.
20.Position engine front lifting bracket to cylinder
head, fit 2 bolts and tighten to 25 Nm.
21.Fit fuel injectors.
22.Fit glow plugs.
23.Fit rocker shaft assembly.

ENGINE
OVERHAUL31
TIMING BELT REAR COVER AND OIL PUMP
Timing belt rear cover - remove
1.Remove timing belt, tensioner and gears.
2.Remove fuel injection pump.
3.Remove sump and oil pick-up pipe.
4.Using sequence shown, progressively slacken
then remove bolts securing timing belt rear
cover; remove cover.
5.Remove and discard gasket.
6.Remove and discard camshaft and crankshaft
front oil seals.Oil pump and oil pressure relief valve - remove
Oil pump
1.Make suitable alignment marks between oil
pump and timing belt rear cover.
2.Progressively slacken then remove 7 screws
securing oil pump cover.
3.Remove oil pump cover.
4.Make suitable alignment marks between oil
pump inner and outer rotors and outer rotor
and timing belt rear cover.

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
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
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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.

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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.

ENGINE
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OVERHAUL FUEL INJECTORS
Remove
1.Disconnect each pair of fuel pipes from fuel
injection pump and injectors.
2.Remove banjo bolt securing fuel spill return
pipes to injector, remove and discard 2 sealing
washers.
CAUTION: Plug broken connections to
prevent ingress of dirt.
3.Remove nut securing injector clamp, remove
clamp.
4.Remove injector, remove and discard sealing
washer.
WARNING: Do not attempt to remove
injectors using engine compression,
either use an open ended spanner on
injector body and rotate injector until it is
released or use a slide hammer and suitable
adaptor.
5.Repeat above procedures to remove remaining
injectors.