1995 LAND ROVER DISCOVERY engine

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
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
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
10
OVERHAUL
22.Tighten bolts in sequence shown to 25 Nm.
23.Lightly oil crankshaft spigot, fit Woodruff key
and crankshaft pulley.
24.Position toolLRT-12-080to crankshaft pulley,
retain tool using 4 bolts.
25.Fit crankshaft pulley flange head bolt.
26.Restrain crankshaft and tighten bolt to 80
Nm,then further 90.°
27.Remove toolLRT-12-080.

ENGINE
OVERHAUL11
ROCKER SHAFT
Remove
1.Disconnect breather hoses from crankcase
breather cyclone unit.
2.Remove bolt securing cyclone unit to rocker
cover.
3.Remove cyclone unit, remove and discard 'O'
ring.
4.Disconnect breather hoses from cylinder block
and rocker cover.
5.Remove 3 flange nuts securing rocker cover,
recover sealing washers.
6.Remove rocker cover, remove and discard
gasket.
7.Slacken locknut on each tappet adjusting
screw, slacken adjusting screws until they are
clear of push rods.
8.Working from the centre outwards,
progressively slacken then remove 3 nuts and
2 bolts securing rocker shaft pedestals to
cylinder head.
CAUTION: Insert a slave bolt into
pedestals 1 and 5 to prevent components
sliding off shaft.
9.Remove rocker shaft assembly.

ENGINE
12
OVERHAUL
10.Withdraw push rods.
11.Remove valve caps.
CAUTION: Keep push rods and valve caps
in their fitted order.Rocker shaft - dismantling
1.Suitably identify each component to its fitted
position.
2.Remove locknut and tappet adjusting screw
from each rocker.
3.Remove slave bolt and pedestal from end of
rocker shaft.
4.Remove washer, rocker arm and spacer
followed by second rocker arm, spacer and
pedestal.
5.Repeat above procedures until all components
are removed.