Hello All,"I had previously searched the forum before posting, and the purpose of this post is to hopefully assist those who are having difficulty sourcing parts. While I understand there may be better solutions to resolve my issue with the Discovery, I have chosen this method because it works best for me given the time constraints I have.

Why did I opt to rebuild the pulley instead of purchasing new parts?

1. I reside in Edmonton, Alberta, Canada, where Land Rover parts are scarce, often taking 2-2.5 weeks to obtain. Additionally, dealer parts are expensive and still require a waiting period.
2. This Discovery 2 serves as a project car, and I'm not looking to invest a significant amount of money into it at the moment.

Total Time invested: 4 hours

• 30 minutes for research and contacting suppliers (Alco Industries at 11650 156 Street, Edmonton, AB, 780-442-3380)
• 30 minutes to pick up the bearing
• 30 minutes to remove 3 pulleys
• 1.5 hours to rebuild 3 pulleys
• 1 hour to install and inspect

Parts Purchased for the Rebuild: $18.90

• Quantity 2: $7 CAD each - bearing number 6203 (a commonly available bearing) with dimensions 17x40x12mm (bore hole); one for the belt tensioner pulley and the other for the 70mm idle pulley
• Quantity 1: $11 CAD - bearing number 6304 (15x52x20 bore hole)

Procedure:

• Mark the engine side and washer of the 70mm Idle pulley (Bearing 6203) and remove it from the car. On a bench vise, use a socket close to the OD (I used a 22mm socket) to knock the bearing out of the pulley from the engine side toward the washer side. Install the new bearing by carefully using a rubber mallet until it bottoms out.
• For the belt tensioner bearing, as the pulley does not have a stop, you can hit it on any side. Use the same method as above to seat the new bearing into place.
• For the 80mm Idle pulley (bearing 6304), remove the snap ring holding the bearing in place, tap the old bearing out, and install the new one using the same method.

Background: I am a new owner of a 2001 LR Discovery 2 with 225KM mileage. I purchased it with known issues of leaking coolant, a broken belt, and it wouldn't start. According to the previous owner, the Discovery leaked coolant and the belt broke when the temperature dropped to -40C (-40F) the previous week. Upon bringing the Discovery home and beginning work on it, I first addressed a broken top radiator hose/hard plastic pipe under the radiator cover. After replacing the belt and starting the Discovery, it began to squeak and smoke. Upon inspection, I discovered that the belt tension pulley had seized, and the bearings in the 70mm and 80mm idle pulleys were making noise. Thus, I decided to rebuild all three of them."

 

Thanks for the info.
As far as shipping times go, I live in Kelowna. I usually order parts from Paddock Spares or LR Direct in England. I usually get parts in less than a week, and both companies have an option to prepay Canadian duties, so you never get those surprise huge brokerage fees.

 

Thank you for taking the time to post this and include the part numbers! Just ordered bearings and going to do this while I have it apart!

 

Dandy post!! For an unknown D2, these idler pulleys are the very first thing to check. And replace! I have lost count of the number of people who feel a freely-spinning bearing is "good to go". Rather, they are completely dry.... and ready to fail.
I will add that I have one supplier (Worldpac) who still carry an impressive number of D2 parts, with reasonable prices.... and usually an OEM AND chinese option for the part. PM me if you'd like more details....

 

Great info. Lots of cheaper priced (but unknown quality) available on Amazon. I used the part # info above and did some local research on trusted Timken bearings. Pricing is in CAN$.