1995 LAND ROVER DISCOVERY timing belt

ENGINE
DESCRIPTION AND OPERATION5
CRANKSHAFT, SUMP AND OIL PUMP
1.Crankshaft
2.Woodruff key
3.Main bearing shell
4.Main bearing cap - front
5.Main bearing cap bolt
6.'O' ring - oil pick-up pipe
7.Oil pick-up pipe and strainer
8.Sump bolt
9.Oil drain pipe
10.Sump
11.Gasket - oil drain pipe
12.Main bearing cap - rear
13.Rear main bearing cap oil seal14.Crankshaft thrust washers
15.Main bearing cap - centre
16.Big-end bearing cap
17.Big-end bearing cap nut
18.Big-end bearing shell
19.Oil jet tube banjo bolt
20.Oil jet tube
21.Oil pump
22.Timing belt rear cover
23.Plug
24.Oil pressure relief valve spring
25.Oil pressure relief valve plunger

ENGINE
DESCRIPTION AND OPERATION11
TIMING BELT REAR COVER AND GEARS
1.Camshaft oil seal
2.Gasket
3.Crankshaft front oil seal
4.Timing belt rear cover
5.Injection pump drive gear
6.Hub plate
7.Nut - injection pump hub
8.Bolt - injection pump hub plate
9.Camshaft drive gear
10.Washer - camshaft drive gear11.Bolt - camshaft drive gear
12.Idler pulley
13.Retaining nut
14.Crankshaft gear
15.Bolt - timing belt tensioner pulley
16.Spacer - timing belt tensioner pulley bolt
17.Timing belt tensioner pulley and tensioner
bracket
18.Flanged spacer - idler pulley
19.'O' ring

ENGINE
DESCRIPTION AND OPERATION13
TIMING BELT AND FRONT COVER
1.Timing belt
2.Gasket
3.Access plate
4.Bolt - access plate
5.Timing belt front cover6.Bolts - timing belt front cover
7.Wading plug
8.Oil seal
9.Crankshaft pulley
10.Pulley bolt

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
OVERHAUL1
TIMING BELT, TENSIONER AND GEARS
Timing belt - remove
1.Position toolLRT-12-080to crankshaft pulley,
retain with 4 bolts.
2.Restrain crankshaft using toolLRT-12-080
and remove crankshaft pulley flange head bolt.
NOTE: Bolt and washer fitted to early
engines.
3.Remove toolLRT-12-080 .
4.Position toolLRT-12-049and thrust button,
part of toolLRT-12-031to crankshaft pulley,
remove pulley, recover Woodruff key.
5.Using sequence shown, progressively slacken
then remove 14 bolts securing timing belt front
cover.

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
4
OVERHAUL Timing belt tensioner and timing gears - remove
1.Remove crankshaft gear using tools
LRT-12-031andLRT-12-078,recover
Woodruff key from crankshaft.
2.Remove and discard 'O' ring.
3.Remove bolt and slotted washer securing
timing belt tensioner pulley, remove pulley
together with tensioner bracket.
4.Recover flanged spacer from idler pulley stud.
5.Remove centre bolt and washer securing
camshaft timing gear, remove gear and hub
plate as an assembly.
NOTE: Later engines are fitted with a
flange head bolt.
CAUTION: Do not remove 3 bolts securing
hub plate to gear.