ECU LAND ROVER DISCOVERY 1995 Workshop Manual

30MANIFOLD AND EXHAUST SYSTEM
6
REPAIR 10.Release clip and disconnect breather hose from
manifold.
11.Release 2 bolts securing cam cover brackets to
manifold.
12.Remove 3 bolts securing engine harness to
manifold.
13.Disconnect 3 vacuum hoses from manifold.
14.Release clip and disconnect fuel hose from
pressure regulator.
CAUTION: Plug the connections.
15.Disconnect intake air temperature sensor
multiplug.
16.Disconnect fuel injector harness multiplug.
17.Remove 2 nuts and 7 bolts securing manifold to
cylinder head
18.Remove manifold assembly and collect gaskets.

MANIFOLD AND EXHAUST SYSTEM
7
REPAIR Refit
19.Ensure mating faces of inlet manifold and
cylinder head are clean.
20.Fit a new gasket, position inlet manifold to
cylinder head.
21.Fit nuts and bolts, tighten in the order shown to
the correct torque
25Nm
22.Position engine breather hose to manifold and
secure with bolts.
23.Connect fuel injector harness and intake air
temperature sensor multiplug.
24.Connect fuel hose to pressure regulator and
secure with clip.
25.Fit fuel pipe to fuel rail, tighten union to
10Nm
26.Connect vacuum hoses to manifold.
27.Position engine harness and cam cover brackets
to manifold, secure with bolts.
28.Connect breather hose and brake servo hose to
manifold, secure with clips.
29.Connect multiplug to fuel temperature sensor.
30.Connect breather hose to throttle housing and
secure with clip.
31.Connect throttle cable to cam and secure to
abutment bracket.
32.Connect coolant bypass hose to throttle housing.
33.Connect stepper motor and throttle
potentiometer multiplugs.
34.Connect air cleaner hose to throttle housing and
secure with clip.
35.Connect battery negative lead.
36.Adjust throttle cable.EXHAUST MANIFOLD GASKET - Mpi
Service repair no - 30.15.12
Remove
1.Raise vehicle.
2.Loosen 2 nuts securing downpipe to silencer
box.
3.Remove 4 nuts securing downpipe to exhaust
manifold.
4.Release downpipe from exhaust manifold.
5.Discard gasket.

30MANIFOLD AND EXHAUST SYSTEM
8
REPAIR 6.Disconnect oxygen sensor multiplug.
7.Release multiplug from bracket on thermostat
housing.
8.Release harness from cable tie.
9.Remove drive belt.
10.Remove 2 front bolts securing generator to
mounting bracket.
11.Remove 2 rear bolts securing generator to
mounting bracket.
12.Move generator from mounting bracket and
place aside.
13.Remove exhaust manifold heat shield.
14.Remove dipstick and bolt securing dipstick tube
to coolant rail.
15.Remove dipstick tube from cylinder block.16.Remove 3 bolts and 2 nuts securing exhaust
manifold to cylinder head.
17.Release coolant rail bracket from manifold studs.
18.Remove exhaust manifold and discard gasket.
Refit
NOTE: For torque values.See
Specifications, torque, Torque Values
19.Clean mating faces of exhaust manifold and
cylinder head.
20.Fit new manifold gasket and align exhaust
manifold to cylinder head.
21.Position coolant rail bracket to manifold studs.
22.Fit manifold nuts and bolts, tighten to the correct
torque in the order shown.
23.Secure oxygen sensor multiplug to bracket.
24.Connect oxygen sensor multiplug.
25.Fit new manifold flange gasket and align exhaust
front pipe to manifold.
26.Fit nuts and tighten diagonally to the correct
torque.
27.Tighten exhaust downpipe to silencer box nuts
to the correct torque.
28.Position generator to mounting bracket.
29.Fit and tighten 4 generator securing bolts.
30.Refit drive belt.

30MANIFOLD AND EXHAUST SYSTEM
10
REPAIR 10.Release clip and disconnect breather hose from
manifold.
11.Release 2 bolts securing camshaft cover
brackets to manifold.
12.Disconnect 4 vacuum hoses from manifold.
13.Remove 6 bolts securing manifold chamber to
lower manifold.
14.Remove manifold chamber and collect gaskets.
Refit
NOTE: For torque values.See
Specifications, torque, Torque Values
15.Ensure mating faces of manifold chamber and
lower manifold are clean.
16.Fit a new gasket, position manifold chamber to
lower manifold.
17.Fit bolts, tighten to the correct torque.
18.Connect vacuum hoses to manifold.
19.Position camshaft cover brackets to manifold,
secure with bolts.
20.Connect breather hose and brake servo hose to
manifold, secure with clips.
21.Connect multiplug to fuel temperature sensor.
22.Connect breather hose to throttle housing and
secure with clip.
23.Connect throttle cable to cam and secure to
abutment bracket.
24.Connect coolant bypass hose to throttle housing.
25.Connect stepper motor and throttle
potentiometer multiplugs.
26.Connect air cleaner hose to throttle housing and
secure with clip.
27.Reconnect battery negative lead.
28.Adjust throttle cable.

CLUTCH
1
DESCRIPTION AND OPERATION DESCRIPTION
The clutch unit fitted with the manual transmission,
comprises a single dry plate friction disc and
diaphragm spring clutch unit, secured to the engine
flywheel.OPERATION
The unit is operated hydraulically by the clutch master
cylinder 12 and a slave cylinder 13 attached to the
transmission bell housing.
1. Crankshaft and flywheel
2. Friction plate
3. Clutch cover
4. Diaphragm spring
5. Pressure plate
6. Fulcrum posts (9) for diaphragm spring
7. Bearing rings (2) for diaphragm spring
8. Retraction links and bolts (3) for pressure plate
9. Release bearing
10. Release lever11. Release lever pivot post
12. Master cylinder
13. Slave cylinder
14. Master cylinder pedal pushrod
15. Primary shaft and taper bearing (in gearbox)
16. Gearbox front cover
17. Primary shaft flywheel bush
18. Pedal pivot and return spring
19. Hydraulic damper (Diesel only)

33CLUTCH
2
FAULT DIAGNOSIS FAULT/SYMPTOM CHART
Symptoms
Slip Spin/Drag Judder/Fierce Fault Item
* * * Worn or oil on clutch linings 2
* * * Mechanical damage45678
* * Distorted clutch plate 2
* Failed or air in hydraulic system 12 13
* * Primary shaft tight fit in crankshaft bush 15 17
* Clutch splines sticking 2 15
* Weak clutch plate springs or insecure/worn
engine/gearbox mountings6
* Insecure/worn propeller shafts
* Insecure/worn suspension components/rubber
bushes
For items refered to in this chart.See Description and operation, Description
CLUTCH NOISE - MECHANICAL FAULTS
Noise from clutch or gearbox in neutral, which
disappears when clutch is depressed.
Suspect gearbox input/primary shaft bearings.
See MANUAL GEARBOX, Fault diagnosis,
Manual Gearbox
- Noise from gearbox in neutral, which
disappears when clutch is depressed
Noise from clutch or gearbox in neutral, which
changes tone or becomes worse when the clutch
is depressed.
Suspect worn release bearing.
Knocking/rattling from clutch or gearbox in
neutral, which is reduced or disappears when the
clutch is depressed.
Suspect worn/weak release lever retainer or
clutch unit.
Noise from clutch or gearbox in neutral, which
disappears when clutch is depressed.
Suspect gearbox fault.
See MANUAL GEARBOX, Fault diagnosis,
Manual Gearbox
- Noise from gearbox in neutral, which
disappears when clutch is depressed.HYDRAULIC FAULTS
Unable to dis-engage clutch, little or no pedal
resistance.
1.Check condition, specification and level of fluid.
2.Check pipes and cylinders for leaks.
3.Check that air vent in reservoir lid is clear.
Suspect faulty master cylinder if no fluid leaks
present.
See Repair, Master Cylinder
Spongy pedal operation
1.Check condition, specification and level of fluid.
2.Check that air vent in reservoir lid is clear.
Suspect air in fluid.
See Repair, Bleed Hydraulic System
Clutch is difficult to dis-engage and/or does not
immediately re-engage when pedal is released.
1.Check condition, specification and level of fluid.
2.Check that air vent in reservoir lid is clear.
Suspect pedal pivot, master cylinder or slave
cylinder seizure.
See Repair, Master Cylinder

CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01
Clutch pressure plate
Renew pressure plate if diaphragm spring fingers are
worn or if pressure plate shows signs of wear, cracks
or burning.
Clutch driven plate
Renew driven plate if centre hub splines are worn or if
lining is contaminated, burned or unevenly worn.
Service tools:
Clutch centralising tool
LRT-12-001 - V8
LRT-12-040 - Tdi
LRT-12-057 - Mpi
Remove
1.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
2.Mark position of clutch cover to flywheel for
reassembly.
3.Remove clutch cover securing bolts, working
evenly and diagonally.
4.Do not disturb three bolts in clutch cover.
5.Remove clutch assembly.
6.Withdraw clutch driven plate.
Refit
NOTE: To prevent clutch plate sticking,
lubricate splines using Rocol MV 3 or
Rocol MTS 1000 grease.
7.Renew/refit clutch driver plate and clutch
assembly using centralising tool, where
applicable, align assembly marks.
8.Secure clutch assembly cover fixings evenly,
working in a diagonal sequence. Tighten to
28
Nm.
9.Fit gearbox to engine.

33CLUTCH
4
REPAIR SLAVE CYLINDER
Service repair no - 33.35.01
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Evacuate clutch system fluid at slave cylinder
bleed valve.
2.Disconnect fluid pipe.
3.Remove two securing bolts and withdraw slave
cylinder and backing plate.
4.If dust cover is not withdrawn with slave cylinder,
withdraw it from bell housing.
Refit
5.Withdraw dust cover and backing plate from
slave cylinder.
6.Coat both sides of backing plate with Hylomar
P232M waterproof jointing compound.
7.Locate backing plate and dust cover in position
on slave cylinder.
8.Fit slave cylinder, engaging push-rod through
centre of dust cover and with bleed screw
uppermost.
9.Reconnect fluid pipe.
10.Replenish and bleed clutch hydraulic system.
11.Check for fluid leaks with pedal depressed and
also with system at rest.

CLUTCH
5
REPAIR RENEWING HYDRAULIC DAMPER - Tdi
Service repair no - 33.15.05
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Remove the pipe between the slave cylinder and
damper.
2.Disconnect the hydraulic hose from the damper.
3.Remove the two bolts securing the damper to
the bracket and remove the damper.
Refit
4.Fit the damper to the bracket and tighten the two
bolts.
5.Connect the flexible hose to the damper.
6.Fit the pipe to the slave cylinder and to the
damper and tighten the unions.
7.Bleed the hydraulic system.

CLUTCH
1
OVERHAUL MASTER CYLINDER
Service repair no - 30.20.07
1.Remove master cylinder.
See Repair, Master
Cylinder
Disassemble
2.Pull back and remove rubber sealing boot from
pushrod.
3.Depress push-rod and extract circlip.
4.Withdraw push-rod assembly.
5.Withdraw piston assembly.
6.Withdraw retainer and spring.
7.Remove two piston seals and piston washer.
Inspecting
8.Clean all components thoroughly using new
hydraulic fluid. Dry, using a lint-free cloth.
9.Examine cylinder bore and piston, ensure they
are smooth to touch with no corrosion, score
marks or ridges. If in doubt, fit new components.
10.Fit new seals and rubber boot. These items are
all included in master cylinder overhaul kit.
11.Ensure that feed and by-pass ports are not
obstructed.
12.Ensure reservoir cap vent is clear.
Assemble
NOTE: Cleanliness is essential, ensure
hands are free of grease or dirt. Lubricate
cylinder bore and rubber seals with new
hydraulic fluid before assembly.
13.Fit a new piston washer and thinner of two piston
seals, lip last, over piston nose, up against
drilled piston head. Fit thicker seal into piston
groove with lip facing towards seal at opposite
end.
14.Insert spring and retainer into master cylinder
bore.
15.Insert piston and seal assembly, ensuring that
seal lips do not bend back.
16.Reverse 3 and 4, correctly locating circlip.
17.Stretch new rubber boot over push-rod, pack
with rubber grease. Fit securely into locating
groove.
18.Operate push-rod several times to ensure free
movement of internal components.
19.Fit master cylinder.