Timing belt failure - misalignment

TIMING BELT FAILURE - MISALIGNMENT

Model

Discovery, Defender and Range Rover Classic

Affected vehicles

All 300 TDi prior to VINs: Discovery - WA748935 Defender - VA129096 Classic - MA664120 Refer to PARTS INFORMATION for specific VIN change points.

Date

1998-03-25

Reference

L8424BU

Bulletin text

Discovery, Defender and Range Rover Classic

AFFECTED RANGE:

All 300 TDi prior to VINs:

Discovery - WA748935 Defender - VA129096 Classic - MA664120

Refer to PARTS INFORMATION for specific VIN change points.

PROBLEM:

TIMING BELT FAILURE - MISALIGNMENT

CAUSE:

Premature wear of timing belt due to misalignment of belt and pulleys.

ACTION:

This Bulletin replaces Technical Information Bulletins 12/13/96 and 12/10/94. Please cancel your existing copies and replace with this information.

This Bulletin is also supplementary to Service Action Bulletin A/D482 and should be used for first time failures which are outside the parameters of the Service Action.

PLEASE NOTE THAT NORMAL WARRANTY POLICY AND PROCEDURES APPLY.

Where timing belt failure is confirmed, the timing belt and associated parts should be replaced as detailed in the following, having first carried out the additional engine condition checks to determine the extent of any consequential damage.

Check VIN of failed vehicle against change point details in PARTS INFORMATION to determine which Option Kit is required and whether a crankshaft front seal will also be required.

Refer to Workshop Manual Section 12 for repair procedure, observing the additional requirements of this Bulletin.

Bull. N o : 0008 CDS: L8424bu 1 25.03.98

Remove the rocker cover and inspect for broken rocker arms and bent • pushrods. Should a rocker arm be broken the cylinder head must be removed and inspection of all valves carried out to ensure they are not damaged, i.e. tightness in a valve guide would signify a bent valve. Replace any damaged components.

If a cylinder head is removed, on completion of repair, refer to bulletin 10/02/94 • for coolant refill procedure.

Before fitting the new idler pulley • stud to either the new front cover, or the original cover where this is retained, ensure that the stud hole in the front cover has a 2 mm x 45º chamfer as shown, (illustration A). If no chamfer is evident, produce one using an appropriate countersink tool.

When fitting the new idler pulley, do • not refit the original spacer washer. This is not required with the new design and must be discarded.

When fitting the new tensioner, do • not attempt to re-use the original slotted washer and flange These must be discarded as the slotted washer is incorporated into the bearing and the flange bolt is replaced by the new cap head bolt.

The new crankshaft gear has a flange added on each side. Before fitting, • ensure that these flanges have not suffered handling damage.

The timing belt tension has changed from that published in the Workshop • Manual. The new method is as follows, it is essential that this procedure is adhered to precisely:

a) Ensure that the timing marks are aligned and appropriate timing pins are used as described in the Workshop Manual.

b) Fit idler pulley and tensioner assembly and tighten the idler securing nut to 45 Nm.

c) Loosen the three injection pump pulley fixings.

d) Locate timing belt onto pulleys.

bolt.

e) Lightly tighten the tensioner locking screw then back off one full turn. Ensure tensioner is free to move.

f) Using a dial type torque meter with a maximum length of 250 mm apply a torque of 11 Nm with the torque meter positioned vertically as shown, (illustration B).

g) Tighten the tensioner locking bolt to 45 Nm.

h) Tighten the injection pump pulley fixings to 25 Nm.

i) Remove timing pins.

It is no longer a requirement to rotate the engine and repeat the tensioning procedure.

j) On later vehicles, fit a new crankshaft front seal to the front cover plate (see NOTE in PARTS INFORMATION for definition of specific vehicles), refit cover plate and remaining covers and ancillaries as detailed in the Workshop Manual.

k) Apply a dab of yellow paint at least 2 cm square in the position arrowed in the illustration to indicate that one of the Parts Option Kits has been fitted.

PARTS INFORMATION:

STC4095K Timing belt repair kit - Option 1 - containing front cover, timing belt, crankshaft gear, tensioner, idler, FIE pump bracket, side cover, gaskets, dowels and fasteners.

STC4096K Timing belt repair kit - Option 2 - containing timing belt, crankshaft gear, tensioner, idler, gaskets and fasteners.

( NOTE: This seal is not included in the kits. ERR7143 Seal - crankshaft front ( Refer to Option 2 VIN details which follow to ( determine correct applications.

STC4095K Kit - Option 1 is to be fitted to vehicles in the following VIN ranges:

Discovery:

MA 081991 to TA 200000 MA 939976 to VA 101256 MA 500000 to VA 542370 TA 700000 to VA 711273

STC4096K Kit - Option 2 is to be fitted to vehicles in the following VIN ranges:

Discovery:

VA 542371 to VA 558898 VA 101257 to VA 129096 VA 711274 to WA 748935

ERR7143 Seal - crankshaft front is to be fitted to vehicles in the following VIN ranges when fitting STC4096K Kit - Option 2:

Discovery:

VA 548520 to VA558898 VA 107351 to VA 129096 VA 716697 to WA748935

Defender: Range Rover Classic:

MA 647645 to MA 664120

Defender: Range Rover Classic:

Not applicable

Defender: Range Rover Classic:

Not applicable

WARRANTY CLAIMS:

Use Complaint Code: 2G8D

Use S.R.O.: 12.65.09 Fit kit - Option 1 Time allowance: 5.95 Hrs

Use S.R.O.: 12.65.09/20 Fit kit - Option 1 (vehicle fitted with air conditioning) Time allowance: 6.45 Hrs

Use S.R.O.: 12.65.89/29 Fit kit - Option 2 Time allowance: 3.50 Hrs

Use S.R.O.: 12.65.89/32 Fit kit - Option 2 (vehicle fitted with air conditioning) Time allowance: 3.70 Hrs

These times are applicable to Discovery, Defender and Classic.

Where additional repairs have been carried out, refer to ROT Manuals for the relevant SRO details. Times claimed should reflect any reduced work content from the standard SRO. For example, where rocker arms are replaced, the full rocker shaft overhaul time is not acceptable.