1995 LAND ROVER DISCOVERY fuel

ENGINE
OVERHAUL43
Refit
1.Clean all traces of carbon from injector ports.
2.Fit a new sealing washer to injector, insert
injector into port ensuring that spill return banjo
bolt hole faces away from cylinder head.
3.Position injector clamp to injector and cylinder
head stud ensuring that raised 'pip' on concave
face of clamp faces upwards.
4.Fit and tighten injector clamp nut to 25 Nm.
5.Position spill return pipes to injector, fit banjo
bolt and 2 new sealing washers.
6.Tighten banjo bolt to 10 Nm.
7.Repeat above procedures for remaining
injectors.
8.Position fuel pipes to injector and fuel injection
pump, tighten connections.GLOW PLUGS
Remove
1.Remove nut and washer securing harness to
glow plug, release harness from plug.
2.Remove glow plug.
3.Repeat above procedures for remaining plugs.
Refit
1.Fit glow plug and tighten to 20 Nm.
2.Connect harness to glow plug, fit and tighten
nut.
3.Repeat above procedures for remaining plugs.

ENGINE
OVERHAUL55
CRANKSHAFT, CAMSHAFT, PISTONS AND
CYLINDER BLOCK
1.Remove timing belt rear cover.
2.Remove flywheel/drive plate housing.
3.Remove fuel lift pump.
4.Remove cylinder head.
5.Remove sump, oil pick-up and drain pipes.
6.Remove oil filter head.
7.Remove brake servo vacuum pump.Crankshaft rear oil seal - remove
1.Remove 5 bolts securing rear oil seal housing
to cylinder block.
2.Remove and discard oil seal and housing.
3.
Early engines:Remove and discard 'O' ring.
4.Remove and discard gasket.

ENGINE
76
OVERHAUL
15.Insert each cam follower guide into its original
location in the cylinder block.
16.Fit new retaining bolt, locate end of bolt in cam
follower guide.
17.Tighten bolt to 14 Nm.
18.Fit roller ensuring that reference mark made
during removal is towards front of cylinder
block.
19.Fit cam follower slide ensuring that word
'FRONT' or mark 'F' is towards front of cylinder
block.
20.Repeat above procedures for remaining cam
follower assemblies.
21.Fit a dry, new gasket to baffle plate.
22.Fit baffle plate, fit 3 bolts and finger tighten in
their original locations.
23.Bolts are tightened when fuel injection pump is
fitted.Cylinder block - inspection
1.Thoroughly clean cylinder block, ensure all bolt
holes are clean and dry.
2.Remove all traces of carbon from cylinder head
gasket face.
3.Remove all traces of gaskets using suitable
gasket removal spray and a plastic scraper.
4.Check all studs for damage, replace as
necessary.
5.Check core plugs for corrosion and signs of
leakage, replace as necessary.
6.Using an internal micrometer, take 2
measurements at 90°to each other at top of
bore. The difference between the 2
measurements is the ovality of the bore.
Maximum ovality = 0.127 mm
7.Repeat measurements 50 mm from bottom of
each cylinder bore.
8.Measure from side to side from below wear
ridge at top of bore and above wear ridge at
bottom of bore. The difference between the 2
measurements is the taper.
Maximum taper = 0.254 mm

ENGINE
OVERHAUL77
9.Check cylinder bore overall wear, measure at
several points from side to side, the largest
diameter recorded is the maximum wear.
Cylinder bore - standard = 90.47 mm
1st rebore oversize = 90.73 mm
2nd rebore oversize = 90.98 mm
Maximum wear = 0.177 mm
CAUTION: Do not de-glaze cylinder bores.
10.Cylinder bores which are worn in excess of
0.177 mm over the above bore sizes must be
rebored and the appropriate oversize pistons
and rings fitted.
CAUTION: Cylinder bores must be honed
to finished size.
11.Fit oil pick-up and drain pipes and sump.
12.Fit cylinder head.
13.Fit flywheel/drive plate housing.
14.Fit timing belt rear cover and oil pump.
15.Fit timing belt.
16.Fit fuel injection pump.
17.Fit oil filter head.
18.Fit fuel lift pump.
19.Fit brake servo vacuum pump.

ENGINE
DATA, TORQUE & TOOLS3
TORQUE FIGURES
Timing belt tensioner bolt 45 Nm.....................
Timing belt idler pulley nut 45 Nm.....................
Flywheel/drive plate housing plug 12 Nm...............
Timing belt front cover bolts 25 Nm....................
Crankshaft pulley bolt 80 Nm then further 90° ........................
Rocker shaft nuts and bolts 5 Nm then further 50° ....................
Rocker cover nuts 10 Nm...........................
Crankcase breather cyclone unit bolt 9 Nm............
Rear timing cover bolts 25 Nm.......................
Oil pressure relief valve plug 17 Nm...................
Flywheel bolts 146 Nm..............................
Drive plate bolts 146 Nm.............................
Drive plate to starter ring gear bolts 25 Nm..............
Flywheel/drive plate housing bolts 45 Nm...............
Coolant outlet elbow bolts 9 Nm.....................
Thermostat housing bolts 25 Nm.....................
Oil filter head bolts 45 Nm...........................
Cylinder head bolts:
Stage 1 40 Nm...................................
Stage 2 Further 60° ...................................
Stage 3 Further 60° ...................................
Stage 4 - Bolts 1, 2, 7, 8, 9, 10, 15, 16, 17 and 18
onlyFurther 20°
......................................
Sump drain plug 35 Nm............................
Oil sump bolts 25 Nm..............................
Oil pick-up pipe bolts:
To main bearing cap 9 Nm.........................
To timing belt rear cover 25 Nm......................
Oil drain pipe bolts 25 Nm...........................
Fuel pump timing gear to hub plate bolts 25 Nm..........
Injector clamp nut 25 Nm...........................
Spill return pipe banjo bolts 10 Nm....................
Glow plugs 20 Nm.................................
Brake servo vacuum pump bolts 25 Nm................
Camshaft gear bolt 80 Nm..........................
Spill return pipe to injection pump banjo bolts 25 Nm......
Mounting bracket to fuel injection pump bolts 25 Nm......
Fuel injection pump and baffle plate to cylinder
block bolts25 Nm
.................................
Crankshaft rear oil seal housing bolts 25 Nm............
Camshaft thrust plate bolts 9 Nm....................
Camshaft oil jet tube 17 Nm.........................
Piston oil jet banjo bolts 17 Nm.......................
Cam follower guide bolts 14 Nm......................
Big-end bearing cap nuts 59 Nm......................
Main bearing cap bolts 133 Nm.......................

ENGINE
4
DATA, TORQUE & TOOLS TOOL NUMBERS
LRT-12-007 Degree plate
LRT-12-031 Remover - crankshaft/camshaft gear
LRT-12-035 Seal guide
LRT-12-038 Remover - valve guide
LRT-12-044 Timing pin
LRT-12-045 Fuel injection pump timing pin
LRT-12-046 Replacer - valve guide
LRT-12-049 Remover - crankshaft pulley
LRT-12-077 Replacer - oil seal
LRT-12-078 Gear remover
LRT-12-079 Replacer - oil seal
LRT-12-080 Retainer - crankshaft pulley
LRT-12-082 Replacer - oil seal
LRT-12-501 Handle set
LRT-12-502 Pilot - valve seat cutter
LRT-12-515 Distance piece
MS 621 45°cutter
MS 627 60°cutter