1995 LAND ROVER DISCOVERY clock

86ELECTRICAL
30
REPAIR INSTRUMENT ILLUMINATION AND WARNING
LIGHT BULBS
Service repair no - 86.45.48 - Instrument
Service repair no - 86.45.61 - Warning light
Remove
1.Remove binnacle.
See Instrument binnacle
2.Identify bulb to be replaced.
NOTE: If faulty bulb is not accessible,
remove screws securing circuit board and
carefully ease circuit board aside.
3.Rotate bulb holder anti-clockwise, withdraw bulb
holder and remove bulb.Refit
4.Fit new bulb to holder.
CAUTION: Ensure bulb of correct wattage
and type is fitted.
5.Reverse removal procedure.

ELECTRICAL
49
REPAIR Refit
8.Fit bulb to lens.
9.Secure bulb retaining clip.
10.Connect 2 Lucars to bulb.
11.Position lamp lens to shroud.
12.Position lamp to bracket and secure fog lamp
adjustment ball joint to bracket.
13.Position spacers, align lamp to bracket and
secure with Torx screws.
14.Fit front fog lamp.
See fog lamp - front; Refit
CLOCK
Service repair no - 88.15.07
Remove
1.Remove drinks tray.
See CHASSIS AND
BODY, Repair, drinks tray
2.Release 4 clock panel securing tags.
3.Release clock panel from louvre panel.
4.Disconnect 2 multiplugs from clock.
5.Remove clock.
Refit
6.Position clock.
7.Connect multiplugs to clock and secure clock to
louvre panel.
8.Fit drinks tray.
See CHASSIS AND BODY,
Repair, drinks tray; Refit
REAR SPEAKER
Service repair no - 88.15.12
Remove
1.Remove 4 screws securing speaker.
2.Release speaker and disconnect 2 Lucars.
3.Remove speaker.
Refit
4.Position speaker, connect Lucars and secure
with screws.

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
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
OVERHAUL17
VALVE CLEARANCES - ADJUST
CAUTION: To prevent possibility of
damage to cam follower seatings, it is
essential that ball ends of tappet adjusting
screws are seated in recess in push rods and
that ball end of each push rod is correctly
located in cam follower slide.
1.Rotate crankshaft by means of crankshaft
pulley bolt in a clockwise direction until number
8 valve ( counting from front of engine ) is fully
open.
2.Using feeler gauges and a screwdriver, adjust
clearance of number 1 valve.
Valve clearance - all valves = 0.20 mm
3.Tighten tappet adjusting screw locknut when
clearance is correct.
4.Adjust the remaining valve clearances in the
following sequence:
Adjust number 3 clearance with number 6
valve fully open
Adjust number 5 clearance with number 4
valve fully open
Adjust number 2 clearance with number 7
valve fully open
Adjust number 8 clearance with number 1
valve fully open
Adjust number 6 clearance with number 3
valve fully open
Adjust number 4 clearance with number 5
valve fully open
Adjust number 7 clearance with number 2
valve fully open
5.Upon completion, re-check all clearances and
adjust as necessary.

ENGINE
OVERHAUL27
Valves and springs - refit
1.Lubricate valve stems, guides, spring seats,
valve springs, spring cups and collets with
engine oil.
2.Lubricate new valve stem oil seals with engine
oil and fit to valve guides.
3.Fit spring seat, insert valve into its respective
guide, fit valve spring and spring cup.
4.Compress valve spring using toolLRT-12-034
and fit collets.
5.Remove toolLRT-12-034.
6.Tap spring cup with a soft mallet to ensure that
collets are correctly seated.
7.Repeat above procedures for remaining
valves.Cylinder head gasket selection
CAUTION: New cylinder head gasket
should be same thickness as the original.
If, however, cylinder head, pistons or
crankshaft have been replaced, it will be
necessary to check piston stand proud in order
to determine the correct thickness of gasket.
1.Position a magnetic base DTI to cylinder block
top face adjacent to number 1 cylinder bore.
2.Position stylus of gauge to cylinder block top
face on edge of number 1 cylinder bore; zero
gauge.
3.Rotate crankshaft in a clockwise direction until
numbers 1 and 4 pistons are at TDC.
4.Position stylus of DTI gauge near edge of
piston crown, measure and record number 1
piston stand proud. Measurement must be
taken at front and rear of piston and highest
protrusion figure recorded.
5.Repeat above procedures for remaining
pistons.