1995 LAND ROVER DISCOVERY belt

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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

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23
REPAIR VACUUM PUMP
Service repair no - 70.50.19
Remove
NOTE: To ease pump removal set engine
to T.D.C. on No.1 cylinder.
1.Disconnect battery negative lead.
2.Detach servo hose from vacuum pump.
3.Remove six bolts securing vacuum pump.
4.Detach pump complete with harness bracket.
Note location of bracket for refitting.
Refit
5.Clean mating faces of pump and block.
6.Loosely assemble pump to block with a new
gasket and with harness bracket located under
head of bolt noted during removal.
7.Evenly tighten bolts, to depress pump plunger,
finally tightening to
25 Nm.
8.Connect vacuum hose and secure with clip.
9.Reconnect battery negative lead.GENERATOR
Service repair no - 86.10.02
Remove
1.Disconnect battery negative lead.
2.Remove drive belt.
See Drive Belt Renew
3.Disconnect electrical leads from rear of
generator.
4.Remove securing bolt from bottom of generator.
5.Remove long through bolt from top fixing and
withdraw generator.
Refit
6.Reverse removal procedure.

12ENGINE
2
SPECIFICATIONS, TORQUECylinder head
Cylinder head to cylinder block See repair section......................................................
Stub pipe heater feed 22.................................................................................
Water temperature sensor 14.........................................................................
Blanking plug cylinder head 14.......................................................................
Engine lifting brackets 25................................................................................
Electrical harness clip bracket 25...................................................................
Exhaust manifold stud 10................................................................................
Exhaust manifold nut 45.................................................................................
Inlet manifold stud 8.......................................................................................
Inlet manifold nut and bolt 25..........................................................................
Air temperature sensor, inlet manifold 14.......................................................
Blanking plug, inlet manifold 14......................................................................
Heatshield to inlet manifold 6.........................................................................
Glow plug 20...................................................................................................
Glow plug terminal nut 2................................................................................
Injector clamp (stud) 8...................................................................................
Injector clamp (nut) 25....................................................................................
Thermostat housing 25...................................................................................
Water outlet elbow to thermostat housing 25..................................................
Water temperature switch, thermostat housing 11..........................................
Plug thermostat housing 6.............................................................................
Rocker shaft pedestal bolt 5 + 50° .....................................................................
Rocker cover (stud) 8.....................................................................................
Rocker cover (fixing nut) 10............................................................................
Breather cyclone to rocker cover 9................................................................
Tappet adjusting nut 16..................................................................................
Front cover to cylinder block 25......................................................................
Front cover plate to front cover 25..................................................................
Static idler - timing belt (stud) 10.....................................................................
Static idler - timing belt (nut) 45......................................................................
Tensioner (timing belt) 45...............................................................................
Camshaft hub bolt 80......................................................................................
Timing pulley to camshaft hub 25...................................................................
Fuel injection pump (stud) 8...........................................................................
Fuel injection pump (nut) 25...........................................................................
Abutment bracket to injection pump 25...........................................................
Support bracket injection pump to cylinder block 25.......................................
Fuel injection pump access plte to front cover plate 25..................................
Timing pulley to injection pump hub 25...........................................................
TV Damper pulley bolt to crankshaft 80 + 90° .....................................................
Fan pulley to hub 25.......................................................................................
Fan and viscous coupling to hub 45...............................................................
Auto tensioner, auxiliary drive (stud) 14..........................................................
Auto tensioner, auxiliary drive (nut) 45...........................................................
Auxiliary mounting bracket to cylinder block (stud) 8.....................................
Auxiliary mounting bracket to cylinder block (bolt and nut) 25........................
Water pump to block and mounting plate 25..................................................
Water pump pulley to hub 25..........................................................................

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3
SPECIFICATIONS, TORQUE Turbo charger oil drain adaptor to block 42....................................................
Oil drain pipe to turbocharger 25....................................................................
Turbocharger oil drain pipe to adaptor 38.......................................................
Turbocharger oil feed pipe adaptor to block 25...............................................
Turbocharger oil feed pipe to adaptor 25........................................................
Oil feed pipe to turbocharger 19.....................................................................
Turbocharger to cylinder head (stud) 10.........................................................
Turbocharger to cylinder head (nut) 45...........................................................
Turbocharger to blanking plate 25..................................................................
Turbocharger to EGR valve 25.......................................................................
EGR delivery tube to valve 25........................................................................
EGR delivery tube to mixing tube 25..............................................................
Fuel lift pump to filter (union) 15.....................................................................
Fuel filter from lift pump (banjo bolt) 33...........................................................
Fuel filter to fuel injection pump (banjo bolt) 33..............................................
Fuel injection pump from fuel filter (banjo bolt) 25..........................................
Injector pipes to injectors and fuel injection pump 29.....................................
Spill rail to injectors (banjo bolt) 10.................................................................
Spill rail to injection pump (banjo bolt) 25.......................................................
Boost pipe injection pump (banjo bolt) 10.......................................................
Plug, rear of injection pump 29.......................................................................
PAS pump to mounting plate 25.....................................................................
PAS pump mounting plate to auxiliaries mounting bracket 25........................
PAS pump pulley to hub 25............................................................................
Generator to auxiliaries mounting bracket 25.................................................
Starter motor (bolt and nut) 45........................................................................
Tachometer electrical connection 4...............................................................
Air conditioning compressor
Compressor mounting bracket to front cover 45.............................................
Compressor to mounting bracket (stud) 8......................................................
Compressor to mounting bracket (nut) 25......................................................
Belt tensioner pulley to tensioner arm 45........................................................
Belt tensioner assembly to front cover plate 25..............................................
Idler pulley to front cover plate 45...................................................................
Compressor belt guard (nut) 25......................................................................
Sensors to water outlet elbow (air/con) 25......................................................
Blanking plug, water outlet elbow (air/con) 25................................................
Generator mounting bracket to front cover 45................................................
Generator to mounting bracket 85..................................................................
Generator pulley to hub 95.............................................................................
Generator belt guard 25..................................................................................

12ENGINE
2
FAULT DIAGNOSIS ENGINE NOISES
Excessive or obtrusive noise from the engine
compartment originates from three main sources:
A. The exhaust system, which makes an
unmistakable and easy to diagnose noise.
B. External components emit the greatest variety of
noises, but are also easy to diagnose by simply
removing the drive belt.
C. Engine internal mechanical noises which can
vary in volume and pitch and may be a
combination of, tapping - knocking or rumbling,
are the most difficult to diagnose. The following
is therefore a guide to diagnosis of engine
internal mechanical noises only.
Engine internal mechanical noises.
Single or multiple, light tapping noise, particularly
when engine is cold.
See Description and
operation, Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Suspect valve operating mechanism.
3.To confirm diagnosis, remove the rocker covers
and with the engine idling, insert a feeler gauge
of 0,015mm between each rocker and valve
stem. A faulty valve operating mechanism will
emit a different noise when the feeler gauge is
inserted.
See Repair, Rocker Shaft Renew
Heavy knocking noise (particularly on load and
when engine is hot).
See Description and
operation, Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Drain engine oil and filter, and examine
for metallic contamination.
3.Is the oil contaminated with metal particles?
YES - Suspect faulty big end bearings. To
confirm diagnosis, short out the ignition to
each spark plug in turn. The noise will
disappear or be reduced when the
cylinder with the faulty big end is shorted
out.
4.If noise is not conclusively diagnosed, check the
security of the flywheel and crankshaft front
pulley. Temporarily release the drive belt to
reduce general noise level and use a
stethoscope to locate source of noise.
Heavy rumbling noise (particularly during hard
acceleration).
See Description and operation,
Description
1.Is engine oil level correct?
NO - Top up to correct level.
See
LUBRICANTS, FLUIDS AND
CAPACITIES, Information,
Recommended Lubricants and Fluids
YES - Continue.
2.Is the lubricating pressure correct?
NO -
See Engine Oil Pressure Test
YES - Drain engine oil and filter, and examine
for metallic contamination.
3.Is the oil contaminated with metal particles?
YES - Suspect faulty main bearings. If noise is
not conclusively diagnosed, check the
security of the flywheel and crankshaft
front pulley. Temporarily release the drive
belt to reduce general noise level and use
a stethoscope to locate source of noise.

V8i
1
REPAIR DRIVE BELT
A single 'serpentine drive belt' is introduced for 1995
model year. This belt drives the water pump and all
the ancilliaries. It is essential that the belt is fitted
exactly as shown in illustrations RR3956 and RR3957.
It should also be noted that the water pump/viscous
fan is driven in a counter clockwise direction.
A drive belt tensioner automatically tensions the drive
belt, eliminating the need for tensioning individual
drive belts. Turning the tensioner pulley in a clockwise
direction will release drive belt tension.
Under normal highway use the belt must be changed
at 120,000 kilometres, 75,000 miles or five years
whichever occurs first.
The drive belt must be examined at every service and
replaced if necessary.
Off road driving
Regular examination of the drive belt is essential if the
vehicle is used off road. The vehicle driver should be
requested to identify the type of mileage the vehicle
has covered.
After every off road session the owner should inspect
the belt for cuts and possible damage caused by
stones. If belt has jumped, reposition belt correctly. A
new belt must be fitted at the next service or before,
dependant on the type of damage sustained.
Fan cowl
To ensure easy access to the drive belt the top portion
of the fan cowl is detachable.
Check condition
Check condition of drive belt. Renew a belt that shows
signs of wear, splitting or oil contamination.DRIVE BELT RENEW
Service repair no - 86.10.03
Air conditioning
Non air conditioning

12ENGINE
2
REPAIR Remove
1.Remove fan cowl upper.
2.Release drive belt tension by turning tensioner
clockwise.
3.With tension released, remove belt from
generator pulley.
4.Release tensioner pulley.
5.Remove drive belt. Mark direction of rotation on
belt if refitting
Refit
6.Clean drive belt pulley grooves and ensure
grooves are not damaged.
7.Position belt correctly around all pulleys except
generator. Illustrations RR3956 and RR3957
show correct drive belt run.
8.Turn drive belt tensioner clockwise.
9.Locate drive belt on generator pulley.
10.Ensure drive belt is squarely located on pulleys
with all grooves engaged.
11.Release tensioner to tension drive belt.
12.Fit upper fan cowl section.DRIVE BELT - CHECK TENSION
As the drive belt is automatically tensioned, no tension
check or adjustment should be necessary. If the drive
belt is believed to be slack carry out the following
checks:
1.Visually check drive belt tension.
2.Watch movement of tensioner with engine
running, 5 mm 'bounce' is normal. If tensioner
movement is 12 mm or more, fit a new tensioner.
See Drive Belt Tensioner
3.Inspect tensioner. Is the tensioner arm and
spring case in contact? If so fit a new tensioner.
4.Using a recognised drive belt tensioning gauge,
check belt tension several times, running engine
between checks. The checks should be made at
the same point on the belt, away from the
tensioner.
Drive belt tension, with used tensioner and used drive
belt should be more than:-
270N. Non air conditioning or
295N with air conditioning.