1995 LAND ROVER DISCOVERY Workshop Manual

12ENGINE
8
REPAIR CAMSHAFT DRIVE BELT AND GEARS
Service repair no - 12.65.18
TIMING BELT
Remove
1.Remove front cover plate.
See Front Cover
Plate
2.Position engine at TDC on No. 1 cylinder.
3.If manual gearbox: Remove blanking plug from
flywheel housing and insert timing tool
LRT-12-044. If EDC - timing tool LRT-12-085
must be used.
If automatic gearbox:Sited to the rear of the
engine sump on engine backplate is a blanking
plate. Remove 2 blanking plate bolts and insert
timing tool LRT-12-044 into the larger bolt hole.
4.Engage timing tool pin with slot in flywheel.
5.Check correct alignment of timing mark on
camshaft gear and that crankshaft key aligns
with cast arrow on housing.
6.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.
NOTE: If the camshaft gear is to be
removed during these operations its
retaining bolt should be slackened before
the timing belt is removed.
7.Slacken belt tensioner bolt.
8.Remove idler pulley.
9.Remove timing belt.
NOTE: During use, a belt develops a wear
pattern relative to its running direction, if
the original belt is to be re-used it must be
refitted so that it rotates in the original direction.
CAUTION: Belts must be stored on edge
on a clean surface and in such a manner
that bends are not less than 50 mm radius.
Do not bend belts at an acute angle or radius of
less than 50 mm, otherwise premature failure
could result.
10.Mark belt direction of rotation, using soft chalk,
to ensure correct refitment.

Tdi
9
REPAIR Belt tensioner
NOTE: The belt tensioner need only be
removed if it is being replaced or for
access purposes to remove front cover.
11.Remove securing bolt and withdraw tensioner
complete with spacer.
Crankshaft gear/front cover oil seal
12.If the crankshaft gear cannot be removed by
hand, use special tool LRT-12-078 with main
body and thrust button from special tool
LRT-12-031 as illustrated ST3478M. Withdraw
gear complete with 'O' ring seal.
13.If necessary prise out oil seal from front cover.
14.Lubricate a new crankshaft oil seal with clean
engine oil.
15.With lip side leading, drive-in seal squarely using
special tool LRT-12-079.
16.Lubricate new 'O' ring seal with petroleum jelly
and slide onto shaft, taking care not to damage
seal on the woodruff keys.
17.Fit crankshaft gear, tap fully home ensuring 'O'
ring seal is properly seated.
CAMSHAFT GEAR/FRONT COVER OIL SEAL
Service repair no - 12.13.05
18.Remove centre bolt from camshaft gear and
withdraw gear.
19.Remove existing oil seal from front cover using
special tool LRT-12-038.
20.Lubricate a new camshaft oil seal with clean
engine oil.

12ENGINE
10
REPAIR
21.With lip side leading, drive-in seal squarely using
special tool LRT-12-082.
22.Refit gear.
FUEL INJECTION PUMP GEAR
Service repair no - 19.30.06
Remove
23.Slacken the three bolts on front of gear.
CAUTION: It is important to ensure that
when the injection pump is locked no
attempt must be made to rotate it. Take
care not to allow the crankshaft to be turned.24.Remove special tool pin from gear.
25.Remove three bolts and withdraw plate and
gear.
Refit
26.Fit gear and plate and secure with three bolts.
27.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.

Tdi
11
REPAIR Timing belt fitting and tensioning
NOTE: It is important that belt tensioning
is carried out carefully and accurately. The
following procedure involves tensioning
the belt twice to ensure that it is equally tensioned
between each gear. New and original belts are
tensioned to different figures.
28.Ensure timing marks are correctly aligned, pin
from special tool LRT-12-045 is correctly
inserted in injection pump gear and timing tool
LRT-12-044 (LRT-12-085 if EDC) is fitted to
flywheel housing with pin located in flywheel slot.
Or if automatic: Timing tool LRT-12-044 is fitted
to engine backplate and pin located in ring gear.
29.Fit belt observing rotational marks made during
removal. Feed belt over gears keeping it tight on
drive side.
30.Fit idler pulley.
31.Slacken injection pump gear retaining bolts.
32.Adjust belt to correctly sit in gears.
33.Slacken belt tensioner securing bolt to finger
tight.
34.Insert 13 mm square drive extension bar in
tensioner plate.
NOTE: Belt tensioning should be carried
out using a dial type torque meter having a
range not exceeding
60 Nm.The torque
meter should be used in the almost vertical
position.
35.Apply a tension of
14 to 16 Nmfor a new belt or
11 to 13 Nmfor an original belt. When tension
is correct tighten clamp bolt.
36.Tighten injection pump gear bolts.
37.Remove pin from injection pump gear.
38.Disengage timing pin from timing slot in flywheel
or ring gear.
39.Rotate crankshaft one and three quarter turns in
a clockwise direction; then continue rotation until
timing pin in timing tool can be engaged with slot
in flywheel or ring gear.
40.Disengage timing pin.
41.Insert pin from special tool LRT-12-045 in
injection pump gear and through into pump
flange.
42.Slacken injection pump gear retaining bolts.
43.Slacken tensioner and retension belt.
44.Tighten injection pump gear retaining bolts.
45.Remove pin from injection pump gear.
46.Remove timing tool and refit plug.
47.Fit front cover plate using new gaskets.
See
Front Cover Plate

12ENGINE
12
REPAIR FRONT COVER/TIMING GEAR HOUSING GASKET
Service repair no - 12.65.10
Remove
1.Remove timing belt and gears.
See Camshaft
Drive Belt and Gears
2.Remove fuel injection pump.See FUEL
SYSTEM, Repair, Fuel Injection Pump and
Timing
3.Remove engine oil sump.See Oil Sump
4.Remove oil pick up strainer.See Oil Pick-Up
Strainer
5.Remove bolts securing timing gear housing to
block.
6.Withdraw timing gear housing complete with
gasket.
7.Clean all gasket material from mating faces.
Refit
8.Fit slave guide studs to locate gasket.
9.Fit new gasket, over slave studs, to cylinder
block.
10.Align flats on oil pump with flats on crankshaft.
11.Fit front cover to block taking care not to damage
oil seal.
12.Secure with bolts of correct length in locations
where slave studs are not fitted (ST3482).
13.Remove slave studs and fit correct length bolts.
14.Tighten to
25 Nm.
15.Fit oil pick-up strainer.See Oil Pick-Up
Strainer
16.Fit oil sump.See Oil Sump
17.Refit fuel injection pump.See FUEL SYSTEM,
Repair, Fuel Injection Pump and Timing

Tdi
13
REPAIR OIL SUMP
Service repair no - 12.60.44
Remove
1.Disconnect battery negative lead.
2.Drain engine oil.
3.Slacken sump securing bolts and, using a sharp
knife, break sealant around sump flange.
4.Remove bolts and withdraw sump.
Refit
5.Clean mating faces of sump, timing gear housing
and cylinder block.
6.Apply a 2,0 mm bead of 'Hylosil RTV102' to the
sump flange, ensuring bead is applied inboard of
the bolt holes.
7.Secure sump to block with bolts. Tighten to
25
Nm.
8.Refill engine oil.See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
9.Reconnect battery negative lead.OIL PICK-UP STRAINER
Service repair no - 12.60.20
Remove
1.Disconnect battery negative lead.
2.Drain engine oil.
3.Remove engine oil sump.
See Oil Sump
4.Remove bolts securing pipe support bracket.
5.Remove bolts from pipe flanges.
6.Withdraw pick-up strainer assembly.
Refit
7.Refit pick-up strainer assembly, fitting a new 'O'
ring seal at oil pump connection.
8.Apply Loctite 242E to the two screws at the
bearing cap. Tighten to
9 Nm.
9.Fit bolts to pipe flanges. Tighten to25 Nm.
10.Refit engine oil sump.See Oil Sump
11.Reconnect battery negative lead.

12ENGINE
14
REPAIR FLYWHEEL
Service repair no - 12.53.07
Remove
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Fit two long 8mm bolts into the clutch bolt holes,
diametrically opposite, to use as handles when
lifting the flywheel off the crankshaft.
5.Remove fan cowl
6.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts, to restrain crankshaft
while removing flywheel retaining bolts.
7.Remove the bolts and lift off flywheel.
NOTE: To prevent excessive flywheel
run-out, ensure that the mating faces of
the flywheel and crankshaft are clean.Refit
8.Locate the flywheel on the crankshaft and
secure with new patched retaining bolts,
progressively tighten to
147 Nm.
9.Check the flywheel for possible run-out by
mounting a dial test indicator with the stylus in a
loaded condition resting on the flywheel face at a
radius of 114mm from the centre.
10.Turn the flywheel and check that run-out does
not exceed 0,05 to 0,07mm. Should run-out be
excessive, remove the flywheel and check again
for irregularities on the crankshaft and flywheel
mating faces and the dowel.
11.Reverse removal procedure. 1 to 6.

Tdi
15
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing the housing and seal
assembly (1) must be renewed complete with the
housing seal (3). Housing and seal assemblies are
supplied with their own former/seal guide (2)
already fitted. This former must not be removed
before fitting the assembly to the engine. If a seal
and housing assembly is received without a
former/guide fitted it must be returned to the
supplier. Used formers/guides must be discarded
immediately after use, under no circumstances
should they be reused on other assemblies.
1.Disconnect battery negative lead.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
Assembly
4.Remove flywheel.See Flywheel
5.Remove five bolts and withdraw seal housing
and seal assembly complete with gasket.
Refit
6.Insert slave studs to seal housing mounting face.
7.Position new seal housing gasket over slave
studs and crankshaft flange onto cylinder block.