Timing belt and gears (Discovery 1)

Timing belt

Removal

1. Remove the front belt cover.

2. Bring the piston of the first cylinder to TDC.

3. Manual transmission: Remove the plug from the clutch housing and install the LRT-12-044 pin for a mechanical injection pump or LRT-12-085 pin for an electronically controlled injection pump (EDC).

Automatic Transmission: Locate the torque converter clutch access cover at the rear of the engine oil pan. Remove the two cover mounting bolts and install the LRT-12-044 pin into the large bolt hole.



4. Make sure that the mounting pin enters the slot in the flywheel (clutch).

5. Check the alignment of the mark on the camshaft gear and the crankshaft keyway with the reference marks (arrows made in casting).



6. Install the LRT-12-045 pin into the gear wheel and the fuel injection pump flange.

Caution: If the camshaft timing gear is to be removed, loosen the timing gear retaining bolts BEFORE removing the timing belt.

7. Loosen the tensioner bolt



8. Remove the guide roller.

9. Remove the timing belt.

10. If you plan to reinstall the old belt, mark its direction of rotation with chalk.

Attention: do not twist the belt; during storage, the bending radius of the belt should be more than 50 mm.

Belt tensioner

Caution: The tensioner should only be removed when replacing it or to remove the cover housing.

11. Loosen the tensioner mounting bolt, remove the tensioner and spacer.

Crankshaft oil seal

12. Remove the crankshaft timing gear. If you cannot remove it by hand, use the puller LRT-12-03 and LRT-12-078, see the figure.



13. Remove the worn crankshaft oil seal.



14. Apply engine oil to the sealing lip of the new oil seal.

15. Press in the oil seal using the LRT-12-079 mandrel.



16. Lubricate the new sealing ring with grease and place it on the nose of the crankshaft. Be careful not to damage the key.

17. Install the gear wheel, tap it lightly to ensure the sealing ring is seated correctly.

Camshaft oil seal

18. Remove the camshaft timing gear.

19. Using special tool LRT-12-038, remove the worn oil seal.

20. Apply engine oil to the sealing lip of the new oil seal.



21. Press in the oil seal using the LRT-12-082 mandrel.

22. Install the gear wheel in place.

Fuel injection pump gear

Removal

23. Loosen the three gear wheel mounting bolts. Caution: Do not turn the engine and fuel injection pump shafts.



24. Remove the fuel injection pump mounting pin.

25. Unscrew the mounting bolts, remove the washer and gear wheel.

Installation

26. Install the gear wheel and washer, secure them with three bolts.

27. Insert the LRT-12-045 mounting pin into the gear wheel and the fuel injection pump flange.