width LAND ROVER DISCOVERY 1995 Service Repair Manual

04GENERAL SPECIFICATION DATA
2
INFORMATION Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin 0,018-0,041 mm...................................
Piston rings
Number of compression rings 2..........................................
Number of control rings 1....................................................
No 1 compression ring Molybdenum barrel faced.....................................................
No 2 compression ring Tapered and marked 'T' or 'TOP'.....................................................
Width of compression rings 1,478-1,49 mm..............................................
Compression ring gap 0,40-0,65 mm......................................................
Oil control ring width 3,0 mm.........................................................
Oil control ring rail gap 0,38-1,40 mm.....................................................
Camshaft
Location Central...........................................................................
Bearings Tin - aluminium...........................................................................
Number of bearings 5..........................................................
Drive Chain 9,52 mm pitch x 54 pitches..................................................................................
TappetsHydraulic-self-adjusting ...........................................................................
Valves
Length: Inlet 116,59-117,35 mm..................................
Exhaust 116,59-117,35 mm...........................
Seat angle: Inlet 45°to 45 1/2° ..................................
Exhaust 45°to 45 1/2° ...........................
Head diameter: Inlet 39,75-40,00 mm..................................
Exhaust 34,226-34,480 mm...........................
Stem diameter: Inlet 8,664-8,679 mm..................................
Exhaust 8,651-8,666 mm...........................
Stem to guide clearance: Inlet 0,025-0,066 mm..................................
Exhaust 0,038-0,078 mm...........................
Valve lift (Inlet and Exhaust) 9,49 mm............................................
Valve spring length fitted 40,4 mm at pressure of 29,5 kg..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Eccentric rotor...................................................................
Oil pressure 2.75 bar (40 lb/in
2) at 2500 rev/min with engine at ......................................................................
running temperature
Oil filter-internal Wire screen, pump intake filter.................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................

04GENERAL SPECIFICATION DATA
4
INFORMATION Piston rings
Number of compression rings 2..........................................
Number of control rings 1....................................................
No 1 compression ring Nitrided steel barrel faced.....................................................
No 2 compression ring Tapered spherical barrel marked 'TOP'.....................................................
Width of compression rings 1.478 - 1.49 mm.............................................. 0.0582 - 0.0587 in
(Top) 1.21 - 1.23 mm................................ 0.0476 - 0.0484 in
Compression ring gap 0.40-0.65 mm...................................................... 0.0157 - 0.0256 in
(Top) 0.3 - 0.5 mm................................ 0.0118 - 0.0197 in
Oil control ring type Aclonoform..........................................................
Oil control ring width 3.0 mm......................................................... 0.1181 in
Oil control ring rail gap 0.38-1.40 mm..................................................... 0.0150 - 0.0551 in
Camshaft
Location Central...........................................................................
Bearings Non serviceable...........................................................................
Number of bearings 5..........................................................
Drive Chain 9.52 mm pitch x 54 pitches..................................................................................
Camshaft End Float 0.076 - 0.355 mm......................................................... 0.003 - 0.014 in
TappetsHydraulic self-adjusting ...........................................................................
Valves
Length: Inlet 116.59 - 117.35 mm.................................. 4.590 - 4.620 in
Exhaust 116.59 - 117.35 mm........................... 4.590 - 4.620 in
Seat angle: Inlet 46°-46°25' ..................................
Exhaust 46°-46°25' ...........................
Head diameter: Inlet 39.75 - 40.00 mm.................................. 1.565 - 1.575 in
Exhaust 34.227 - 34.48 mm........................... 1.3475 - 1.3575 in
Stem diameter: Inlet 8.664 - 8.679 mm.................................. 0.3411 - 0.3417 in
Exhaust 8.651 - 8.666 mm........................... 0.3406 - 0.3412 in
Stem to guide clearance: Inlet 0.025 - 0.066 mm.................................. 0.0010 - 0.0026 in
Exhaust 0.038 - 0.078 mm........................... 0.0015 - 0.0031 in
Valve lift (Inlet and Exhaust) 9.94 mm............................................ 0.3913 in
Valve spring length fitted 40.4 mm (1.59 in) at pressure of 29.5 kg (65 lb)..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Rotor...................................................................
Oil pressure 2.11 to 2.81 kg/cm
2(30 to 40 psi) at 2400 rev/min with ......................................................................
engine warm
Oil filter-internal Wire screen, pump intake filter in sump................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................

GENERAL SPECIFICATION DATA
23
INFORMATION Valves
Valve stem diameter:
Inlet 7.09 to 7.10 mm.........................................................................
Exhaust 7.07 to 7.09 mm...................................................................
Valve head diameter:
Inlet 31.7 to 31.95 mm.........................................................................
Exhaust 29.2 to 29.43 mm...................................................................
Valve installed height - maximum 43.4 mm....................................
Valve stem to guide clearance:
Inlet 0.04 to 0.06 mm.........................................................................
Service limit 0.09 mm.............................................................
Exhaust 0.06 to 0.07 mm...................................................................
Service limit 0.10 mm.............................................................
Valve guides
Internal diameter - Inlet and Exhaust 7.137 to 7.162 mm...............................
Overall length:
Inlet 48.5 mm.........................................................................
Exhaust 52.9 mm...................................................................
Valve seats
Valve seat angle - Inlet and Exhaust 45° ................................
Valve seat width - Inlet and Exhaust 1.5 to 2.0 mm................................
Valve face angle:
Inlet and Exhaust 45°to 45°15' .............................................................
Crankshaft
End-float 0.03 to 0.2 mm...........................................................................
Thrust washer halves thickness 2.31 to 2.36 mm.......................................
Main journal diameter 54.005 to 54.026 mm.......................................................
Maximum out of round 0.010 mm............................................
Main bearing diametric clearance 0.03 to 0.07 mm....................................
Big-end journal diameter 47.648 to 47.661 mm..................................................
Maximum out of round 0.010 mm............................................
Big-end bearing diametric clearance 0.04 to 0.08 mm................................
Piston rings
New ring to groove clearance:
Top compression 0.06 to 0.09 mm.............................................................
2nd compression 0.05 to 0.07 mm..............................................................
Oil control rails - expander fitted 0.03 to 0.05 mm......................................
Ring fitted gap:
Top compression 0.25 to 0.35 mm.............................................................
2nd compression 0.3 to 0.5 mm..............................................................
Oil control rails 0.38 to 1.14 mm.................................................................
Pistons
Piston diameter:
Grade A 84.409 to 84.422 mm...................................................................
Grade B 84.423 to 84.436 mm...................................................................
Clearance in bore 0.01 to 0.03 mm.............................................................
Cylinder bore
Grade A 84.442 to 84.455 mm...................................................................
Grade B 84.456 to 84.469 mm...................................................................

GENERAL SPECIFICATION DATA
25
INFORMATION VEHICLE DIMENSIONS
Dimensions
Overall length (including spare wheel) 4538 mm.............................
Overall length (including tow hitch) 4581 mm..................................
Overall width 2189 mm....................................................................
Overall height 1914 mm...................................................................
Wheelbase 2540 mm.......................................................................
Track front/rear 1486 mm.................................................................
Width between wheel boxes 1080 mm............................................
Seating capacity 5 to 7...............................................................
Performance
Tyre size fitted 205 R16 radial..................................................................
Tyre size fitted 235/70 R16 radial..................................................................
Max. gradient (EEC kerb weight) 45° .....................................
Approach angle (EEC kerb weight) 35° ..................................
Departure angle with tow hitch (EEC kerb weight) 20° ...........
Departure angle without tow hitch
(EEC kerb weight) 29° ............................................................
Ramp break over angle 33° ....................................................
Min. ground clearance (unladen) 204 mm.....................................
Wading depth 500 mm...................................................................
Towing weights
On road Off road
Unbraked trailers 750 kg.............................................................. 500 kg
Trailers with overrun brakes - Mpi 2750 kg.................................... 1000 kg
Trailers with overrun brakes - V8i & Tdi 3500 kg........................... 1000 kg
4 wheel trailers with coupled brakes
(FULLY BRAKED)* 4000 kg.......................................................... 1000 kg
NOTE: * Only applies to vehicles modified to accept coupled brakes.
NOTE: All weight figures are subject to local restrictions.

Mpi
9
DESCRIPTION AND OPERATION SYSTEM OPERATION
Ignition on
When the ignition is switched on, voltage is applied to
ECM pin 11. The ECM then switches on the main
relay by supplying an earth path at pin 4. This allows
battery voltage to pass to ECM pin 28, to the four
injectors and through the ignition coil to ECM pin 25.
In addition, the fuel pump relay is switched on by the
ECM supplying an earth path on pin 20. Voltage is
applied through the inertia switch to the fuel pump.
The pump runs for a short period to pressurise the
fuel rail. The fuel pressure regulator will open at its
maximum setting and excess fuel is spill returned to
the tank.
The ECM determines the amount of stepper motor
movement from the following signals:
·Engine coolant temperature data at pin 33.
·Inlet air temperature data at pin 16.
·Throttle potentiometer data at pin 8.
·Engine speed data at pins 31 and 32.
·Manifold absolute pressure data (via pipe from
manifold).
·Battery voltage at pin 28.
·Ignition signal at pin 11.
If one or more of the following inputs fail, the ECM will
substitute the back-up values shown to maintain
driveability.
Input Back-up value
Coolant temperature Idle Speed controlled until
engine is fully warm. 60°Cat
speeds above idle.
Inlet air temperature Derived from engine speed and
engine load.
Manifold absolute Derived from engine speed and
pressure throttle position.
Starter operation
Whilst the starter relay is energised, battery voltage is
applied to the starter motor solenoid. The solenoid
also energises and supplies battery voltage directly to
the starter motor.
Ignition is controlled by the ECM switching the low
tension circuit via pin 25.
The ECM provides an earth signal on pins 24, 23, 26
and 1 for the period the injectors are required to be
open, the injector solenoids are energised
(simultaneously on naturally aspirated models) and
fuel is sprayed into the manifold onto the back of the
inlet valves. The ECM carefully meters the amount of
fuel injected by adjusting the injector opening period
(pulse width). During cranking, when the engine
speed is below approx. 400 rev/min, the ECM
increases the injector pulse width to aid starting. The
amount of increase depends upon coolant
temperature. To prevent flooding, injector pulses are
intermittent i.e. 24 on then 8 pulses off.
Idling
After start enrichment is provided at all temperatures
immediately cranking ceases. The ECM controls the
enrichment by increasing injector pulse width. The
enrichment decays in relation to the rising coolant
temperature.
Provided the ECM is receiving a signal that the engine
speed is close to the idle speed set point, the ECM
will implement idle speed control.
The ECM activates a unipolar stepper motor acting
directly on the throttle lever. Idle speed response is
improved by the ignition system advancing or
retarding the timing when load is placed on, or
removed from the engine.
If, during engine idle, the load on the engine is
increased sufficiently to cause engine speed to fall,
the ECM will sense this via the crankshaft sensor and
instantly advance the ignition timing to increase idle
speed and then energise the stepper motor to open
the throttle disc thus maintaining the idle speed.
Finally the ignition timing is retarded to its nominal
value.
The ECM monitors battery voltage and, if voltage falls
sufficiently to cause fluctuations in injector pulse
widths, it increases the injector pulse widths to
compensate.
On return to idle, the ECM will implement a slightly
higher idle speed to prevent the engine stalling.

19FUEL SYSTEM
10
DESCRIPTION AND OPERATION
Driving
When the throttle pedal is depressed, the ECM
implements the cruise air/fuel ratio map. During
driving the ECM continually monitors inlet air
temperature and engine speed and load for it's air
flow calculations, together with coolant temperature
for any temperature corrections. Additional inputs are
throttle potentiometer for acceleration and throttle
pedal switch for cruise/idle fuel map selection and
over-run fuel cut-off.
Acceleration enrichment
When the throttle pedal is depressed, the ECM
receives a rising voltage from the throttle
potentiometer and detects a rise in manifold pressure
from the manifold absolute pressure sensor. The ECM
provides additional fuel by increasing the normal
injector pulse width and also provides a small number
of extra injector pulses on rapid throttle openings.
Over-run fuel cut-off
The ECM implements over-run fuel cut-off when the
following signals are received.
·Throttle disc closed.
·Engine speed is above 2000 rev/min - engine at
normal operating temperature.
Fuel is reinstated progressively when any of the
above signals cease.
Over-speed fuel cut-off
To prevent damage at high engine speeds the ECM
inhibits the earth path for the injectors, cutting off
injection. As engine speed falls, injection is reinstated.
Ignition switch off
When the ignition is switched off, the ECM will keep
the main relay energised for approx. 30 seconds while
it drives the stepper motor to the 35 step position for
the next engine start.

WHEELS AND TYRES
1
REPAIR GENERAL INFORMATION
WARNING: This is a multi- purpose vehicle
with wheels and tyres designed for both
on and off road usage. Only use wheels
and tyres specified for use on the vehicle.
The vehicle is equipped with tubeless 'S','T' or 'H'
rated radial ply tyres as standard equipment. The
tyres are of European metric size and must not be
confused with the "P" size metric tyres available in
North America.
Vehicle wheel sets, including spare wheel, must be
fitted with the same make and type of tyre to the
correct specification and tread pattern. Under no
circumstances must cross-ply or bias-belted tyres be
used.
For tyre specification and pressures.
See GENERAL
SPECIFICATION DATA, Information, Wheels and
Tyres
Alloy Wheels
Tubeless tyres are mounted on 7.0 inch wide by 16
inch diameter cast aluminium alloy wheels.The
surface has a paint finish covered with a clear
polyurethane lacquer. Care must be taken when
handling the wheel to avoid scratching or chipping the
finish.
The alloy wheel rim is of the asymmetric hump
type incorporating a safety hump to improve
location of the tyre bead in its seat. If difficulty is
experienced in fitting tyres to this type of rim.
See
Tyre Fitting
WARNING: Do not fit an inner tube to an
alloy wheel.
Steel wheels
Tubeless tyres are mounted on 7.0 inch wide by 16
inch diameter steel wheels.TYRE INSPECTION
Inspect tyres at weekly intervals to obtain maximum
tyre life and performance and to ensure compliance
with legal requirements. Check for signs of incorrect
inflation and uneven wear, which may indicate a need
for balancing or front wheel alignment.
See Fault
diagnosis, Tyre Wear Chart
if the tyres have
abnormal or uneven wear patterns.
Check tyres at least weekly for cuts, abrasions, bulges
and for objects embedded in the tread. More frequent
inspections are recommended when the vehicle is
regularly used in off road conditions.
To assist tyre inspection, tread wear indicators are
moulded into the bottom of the tread grooves, as
shown in the illustration below.
When the tread has worn to a remaining depth of 1.6
mm the indicators appear at the surface as bars which
connect the tread pattern across the width of the tread
as shown in the illustration below.

ENGINE
26
OVERHAUL Lapping-in valves
1.Lap each valve to its seat using grinding paste.
2.Apply Prussian Blue to valve seat insert. Insert
valve into guide and press it firmly, without
rotating on to seat.
3.Remove valve and check that a continuous,
even line of Prussian Blue has been
transferred to valve face, continue lapping-in
valve as necessary.
NOTE: Line does not have to be across
whole width of valve face.
4.Remove all traces of grinding paste on
completion.
5.Check valve head stand down of each valve.Valve head stand down - checking
1.Insert each valve into its respective guide.
2.Using a straight edge and feeler gauges, check
and record stand down of each valve head.
3.Compare figures obtained with those given
below. If any valve head has a stand down
outside that specified, valve and/or seat insert
must be replaced.
Valve head stand down:
Inlet valveA= 0.81 to 1.09 mm
Exhaust valveB= 0.86 to 1.14 mm

ENGINE
60
OVERHAUL Main bearing clearance - checking
CAUTION: If crankshaft has been
reground, oversize main bearing shells
must be fitted.
1.Degrease new main bearing shells and ensure
all traces of oil are removed from crankshaft
journals.
2.Fit new main bearing shells to saddles and
main bearing caps ensuring that tags are
located in recesses in saddles and bearing
caps.
NOTE: Number 5 main bearing shells are
wider than numbers 1 to 4.
3.Using assistance, fit crankshaft.
4.Place a piece of Plastigage across width of
each main journal.
5.Fit main bearing caps to their correct location
ensuring that direction marks are facing the
correct way; fit each pair of main bearing cap
bolts and tighten to 133 Nm.
CAUTION: Do not rotate crankshaft.
6.Remove main bearing caps and bearing shells.
CAUTION: Retain main bearing shells and
cap bolts with their respective main
bearing caps.
7.Measure widest portion of Plastigage on each
main bearing journal using the scale supplied;
the graduation that corresponds to the widest
portion of Plastigage indicates main bearing
clearance.
Main bearing clearance = 0.031 to 0.079 mm8.If main bearing clearances are incorrect, use a
combination of standard and oversize main
bearing shells and re-check clearances.
CAUTION: Keep main bearing shells
selected in their fitted order.
9.Remove all traces of Plastigage using an oily
rag.
10.Using assistance, remove crankshaft.
11.Remove upper main bearing shells and keep in
their fitted order.

ENGINE
62
OVERHAUL Big-end bearing clearance - checking
1.Fit pistons and connecting rods.
2.Degrease new big-end bearing shells.
3.Fit big-end bearing shells to connecting rods
ensuring that tag is located in recess in
connecting rod.
4.Fit big-end bearing shells to bearing caps
ensuring that tag is located in recess in cap.
5.Temporarily fit crankshaft pulley bolt and rotate
crankshaft to bring numbers 1 and 4 journals to
BDC.
6.Remove all traces of oil from crankshaft
journals.
7.Pull numbers 1 and 4 connecting rods on to
crankshaft journals, remove plastic tubing from
connecting rod bolts.
8.Place a strip of Plastigage across width of
numbers 1 and 4 big-end journals.
9.Fit bearing caps and shells to connecting rods
ensuring that reference marks on caps and
rods are aligned.
10.Fit big-end bearing cap nuts and tighten to 59
Nm.
CAUTION: Do not rotate crankshaft.
11.Remove big-end bearing caps and shells.
12.Measure widest portion of Plastigage on
crankshaft journals using the scale supplied;
the graduation that corresponds to the widest
portion of Plastigage indicates big-end bearing
clearance.
Big-end bearing clearance = 0.025 to 0.075
mm13.If big-end bearing clearances are incorrect, use
a combination of standard and oversize
bearing shells and re-check clearance.
CAUTION: Retain selected shells with their
respective connecting rods and caps.
14.Remove all traces of Plastigage using an oily
rag.
15.Repeat above procedures for numbers 2 and 3
big-end bearings.