1995 LAND ROVER DISCOVERY timing belt

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
OVERHAUL39
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.

ENGINE
OVERHAUL45
SUMP, OIL PICK-UP AND DRAIN PIPES
Sump - remove
1.Using sequence shown, progressively slacken,
then remove 22 bolts securing sump to cylinder
block.
2.Remove sumpOil pick-up and drain pipes - remove1.Remove bolt securing oil pick-up pipe flange to
timing belt rear cover.
2.Remove 4 bolts securing oil pick-up and drain
pipes to cylinder block and main bearing cap
bolts.
3.Remove oil pick-up and drain pipes.
4.Remove and discard 'O' ring and gasket.

ENGINE
46
OVERHAUL Oil pick-up and drain pipes - refit
1.Clean oil pick-up and drain pipes and strainer,
remove all traces of gasket using suitable
gasket removal spray and a plastic scraper.
2.Ensure bolt holes in timing belt rear cover,
cylinder block and main bearing cap bolts are
clean and dry and that all traces of Loctite are
removed from holes in main bearing cap bolts.
CAUTION: Do not use a tap to remove
Loctite from bolt holes.
3.Lubricate a new 'O' ring with engine oil and fit
to oil pick-up pipe.
4.Position a new gasket to cylinder block.
5.Position oil pick-up pipe to timing belt rear
cover and drain pipe to cylinder block.
6.Apply Loctite 242E to threads of oil pick-up
pipe to main bearing cap bolts, fit bolts and
tighten to 9 Nm.
7.Fit bolts securing oil pick-up and drain pipes to
cylinder block and timing belt rear cover,
tighten to 25 Nm.

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
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.