maintenance LAND ROVER DISCOVERY 1995 User Guide

MAINTENANCE
5
MAINTENANCE 2.Clean or replace spark plugs as applicable.
3.It is essential that correct type of spark plugs are
fitted.
4.Incorrect grade of plugs may lead to piston
overheating and engine failure.
Remove
5.Disconnect battery negative lead. Remove H.T.
leads from spark plugs.
6.Remove plugs and washers.
7.When pushing leads onto plugs, ensure that
shrouds are firmly seated.Fitting H.T. leads
8.Ensure replacement H.T. leads are correctly
refitted as illustrated.
Failure to observe this instruction may result in
cross-firing between two closely fitted leads
which are consecutive in firing order.
3.9 V8
4.0 V8

10MAINTENANCE
6
MAINTENANCE
RENEW SPARK PLUGS - Mpi
Spark plugs - Mpi
Remove
1.Release 4 screws and remove spark plug cover.
2.Disconnect 4 plug leads.
3.Release plug leads from securing clips.
4.Remove spark plugs from cylinder head.
Refit
5.Inspect spark plugs.
6.Set plug gaps.
CAUTION: Use correct type and grade of
plug.
7.Apply anti-seize to plug threads. Fit spark plugs.
8.Connect and route spark plug leads as
illustrated.
9.Refit spark plug cover.

MAINTENANCE
7
MAINTENANCE
CHECK/ADJUST VALVE CLEARANCES. - Tdi
Valve adjustment.See GENERAL SPECIFICATION
DATA, Information, 300 Tdi Engine
RENEW FUEL FILTER ELEMENT - Tdi
Drain off water and sediment
CAUTION: It is essential that any water
and sediment in fuel filter is drained off, as
water in fuel can result in damage to
injection pump.
1.Hold a small receptacle beneath drain cock.
Unscrew the drain cock half a turn.
2.Drain off water and sediment.
3.Tighten the drain cock immediately fuel starts to
flow from drain cock.
NOTE: Any delay in tightening drain cock
when fuel starts to flow could possibly
mean bleeding fuel system.
Renew fuel filter element
1.Clean area around filter, place a container
beneath.
2.Unscrew filter, a quantity of fuel will be released,
and discard filter.
3.Wet seal of new filter with fuel.
4.Screw new filter into position.
5.Ensure that drain cock is secure.
RENEW AIR CLEANER ELEMENT V8i CATALYST
Mpi - Tdi - V8i NON CATALYST
To renew air cleaner element - V8i, Mpi,Tdi
See FUEL SYSTEM, Repair, Air Cleaner

10MAINTENANCE
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MAINTENANCE
CLEAN PLENUM CHAMBER VENTILATION
PASSAGEWAY - V8i
Cleaning plenum chamber ventilation passageway
can be carried out without removing plenum chamber
from ram housing.
CAUTION: Care must be taken to prevent
debris from passageway passing beyond
throttle butterfly disc.
WARNING: Safety glasses must be worn
when performing this operation. Ensure
that debris is not blown into atmosphere
which could be harmful to other persons closeby.
1.Disconnect battery negative lead.
2.Release hose clamp and remove hose from
plenum chamber inlet.
3.Remove crankcase ventilation hose from side of
plenum chamber.
4.Insert a piece of lint free cloth down throttle
butterfly bore to prevent debris passing throttle
butterfly.
5.Place a cloth over tube protruding from side of
plenum from which ventilation hose was
removed to prevent debris from passageway
being blown into atmosphere.
6.Use a compressed air line with a slim bent
nozzle to enable passageway to be cleaned out
from within throttle butterfly bore.
7.Any remaining matter can be dislodged using
soft bent wire or pipe cleaner. Finally blow out
passageway again to remove remaining debris.
8.Remove small 'T' piece between crankcase
ventilation hoses and check it is free from
blockages, clean as necessary.
9.Refit 'T' piece and hoses, tighten hose clamps
securely.
RENEW CHARCOAL CANISTER - V8i- Mpi
Charcoal canister
Remove
1.Disconnect battery negative lead.
2.Pry out purge valve.
3.Disconnect pipe.
4.Loosen bolt.
5.Remove charcoal canister.
Refit
6.Reverse removal procedure.

MAINTENANCE
9
MAINTENANCE
CHECK CONDITION OF DRIVE BELT - V8i - Tdi -
Mpi
RENEW - V8i - Tdi
Renew drive belt V8i.See ENGINE, Repair, Drive
Belt Renew
Renew drive belt Tdi.See ENGINE, Repair, Drive
Belt Renew
RENEW - Mpi
1.Check condition of drive belt, renew a belt that
shows signs of wear, splitting or oil
contamination.
2.Check belt length indicator, belt must be
renewed before indicator reaches R.H. end of
slot.
3.Use 15mm ring wrench on bolt and hold
tensioner pulley fully clockwise.
4.Release drive belt from tensioner pulley and
remove ring wrench.
5.Remove belt from between pulleys.
6.Clean drive belt pulley grooves and ensure
grooves are not damaged.
7.Fit new drive belt around pulley, except
tensioner pulley, ensuring all grooves are
correctly engaged.
8.Hold tensioner pulley fully clockwise and fit drive
centrally around tensioner pulley.
RENEW ANCILLARY DRIVE BELTS
CHECK/TOP UP AUTOMATIC TRANSMISSION
FLUID LEVEL
NOTE: Transmission fluid level is checked
when fluid is cold with engine idling in
neutral.
1.Ensure vehicle is on level ground.
2.Check fluid level registers between MAX and
MIN marking on dipstick.

10MAINTENANCE
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MAINTENANCE
CHECK/TOP UP COOLING SYSTEM
1.To prevent corrosion of aluminium alloy engine
parts it is imperative that cooling system is filled
with a solution of water and phosphate free
anti-freeze, winter or summer. Never fill or top up
with plain water.
WARNING: Do not remove filler cap when
engine is hot because cooling system is
pressurised and personal scalding could
result.
2.When removing filler cap, turn cap slowly
anti-clockwise, pause and allow all pressure to
escape.
3.Continue to turn until cap is removed.
4.When engine is cold expansion tank coolant
should be level with top of indicator post, visible
inside tank through filler hole.
5.If necessary, top up cooling system with
premixed coolant. Use soft water whenever
possible, if local water supply is hard, rainwater
should be used.
6.When replacing filler cap it is important that it is
tightened down fully. Failure to tighten filler cap
properly may result in water loss, with possible
damage to engine
The cooling system should be drained and flushed at
2 year intervals or at onset of second winter. Refer to
Coolant Requirements.
See COOLING SYSTEM,
Adjustment, Coolant RequirementsCHECK/ TOP UP POWER STEERING FLUID
RESERVOIR
1.Remove fluid reservoir cap. Check that fluid is
up to high mark on dipstick.
CHECK/ TOP UP CLUTCH AND BRAKE FLUID
RESERVOIRS
CAUTION: Brake fluid can damage
paintwork. If spillage occurs, wash
affected area IMMEDIATELY with a large
quantity of water.
CHECK/TOP UP WASHER RESERVOIR
Top up washer reservoir to within 25 mm of filler neck.
Use a screen washer solvent/anti-freeze solution to
assist removing mud, flies and road film and protect
against freezing.
LUBRICATE ACCELERATOR AND CRUISE
CONTROL LINKAGES
CHECK/ADJUST IGNITION TIMING - V8i
CATALYST
Check ignition timing.See ENGINE TUNING
DATA, Information, Engine 3.9 V8i

MAINTENANCE
11
MAINTENANCE
CHECK/ADJUST ENGINE IDLE SPEED - Tdi
For idle speed.See ENGINE TUNING DATA,
Information, 300 Tdi Engine
CHECK ENGINE IDLE SPEED - Mpi
For idle speed.See ENGINE TUNING DATA,
Information, Engine - Mpi - 2.0 Litre
CHECK/ADJUST STEERING BOX V8i - Tdi - Mpi
Check steering box for fluid leaks.
Check that there is no backlash in steering box in
straight ahead position. Adjust steering box if
necessary.
See STEERING, Adjustment, Power
Steering Box
CLEAN BATTERY CONNECTIONS
NOTE: Some 96 models are fitted with
battery backed-up sounder
See
ELECTRICAL, Repair, Battery
Remove battery terminals, clean and coat with
petroleum jelly.
A low maintenance battery is installed in vehicle.
Dependent upon climate conditions electrolyte levels
should be checked as follows:
Temperate climates every three years.
Hot climates every year.
RENEW CAMSHAFT DRIVE BELT - Tdi
Renew camshaft drive belt.See ENGINE, Repair,
Camshaft Drive Belt and Gears
The engine timing gears are driven by a flexible
rubber belt which must be renewed at intervals
determined by the severity of operating conditions.
In reasonable, temperate climate operation, renew the
belt every 120,000 km (72,000 miles) or every 6 years
whichever occurs earlier.
In adverse operating conditions such as work in dusty
atmospheres, high ambient temperatures and desert
and tropical zones, renew the belt every 60,000 km
(36,000 miles) or every 3 years whichever occurs
earlier.
CAUTION: If the drive belt is not renewed
at the correct interval, it could fail,
resulting in serious damage.
RENEW CAMSHAFT DRIVE BELT - Mpi
Renew every 160,000 km (96,000 miles) or every 6
years. In adverse conditions every 80,000 km (48,000
miles).
For details of renewing camshaft drive belt.
See
ENGINE, Repair, Camshaft Drive Belt - Mpi
CHECK CAMSHAFT DRIVE BELT - Mpi
For details of checking camshaft drive belt.See
ENGINE, Repair, Check Camshaft Drive Belt - Mpi

10MAINTENANCE
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MAINTENANCE
EXTERNALLY CHECK INTERCOOLER FOR
OBSTRUCTION - Tdi
Clear any trapped dirt or flies from vanes of
intercooler
CLEAN INTERCOOLER ELEMENT - Tdi
Remove
1.Remove intercooler element.
2.Flush intercooler with ICI 'GENKLENE'or
à oD-SOLVE' propriety cleaner, following the
manufacturer's instructions.
3.Dry the intercooler completely ensuring that no
liquid remains in the element.
Refit
4.Refit intercooler element.UNDER VEHICLE MAINTENANCE
Vehicles operating under severe conditions of dust,
sand, mud and water should have oils changed and
lubrication carried out at more frequent intervals than
is recommended in maintenance schedules.
RENEW ENGINE OIL AND FILTER - Tdi
CAUTION: Serious damage to the
turbocharger will result if engine is run
above idling speed before oil pressure is
restored.
RENEW ENGINE OIL - V8i
RENEW ENGINE OIL AND FILTER - V8i
CAUTION: To prevent an airlock occuring
after removing filter, fill new filter with oil
and fit immediately after removing old
filter. If airlock does occur fill oil pump with
petroleum jelly.
RENEW ENGINE OIL AND FILTER - Mpi
CHECK/TOP UP MANUAL GEARBOX OIL - V8i
1.Site vehicle on lift or level ground.
2.Remove oil filler level plug. If necessary, inject
new oil into the gearbox until it runs out of filler
hole. Fit plug. Tighten to
30 Nm.
RENEW MANUAL GEARBOX OIL - Tdi - Mpi
RENEW MANUAL GEARBOX OIL - V8i

MAINTENANCE
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MAINTENANCE
RENEW AUTOMATIC GEARBOX FLUID AND OIL
SCREEN
1.Site vehicle on lift or level ground. Place
container to drain gearbox fluid into. Disconnect
battery negative lead.
2.Remove gearbox dipstick, located at rear of right
hand rocker cover, to aid oil drainage. Release
plug from bottom of sump and allow fluid to drain
completely.
3.Refit plug using a new sealing washer. Tighten
to
10 Nm
Refill ZF Automatic Gearbox and Check Fluid
Level.
NOTE: The fluid level must checked when
fluid is cold and engine idling in park.
4.Ensure vehicle is on level ground.
5.Refill or top-up with correct quantity and grade of
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
6.Start and run engine. Apply footbrake, select
position 1 then back to park. Check fluid level,
this must be between the two marks on the
dipstick.
Oil screen replacement ZF automatic gearbox.
See AUTOMATIC GEARBOX, Repair, Oil Screen

10MAINTENANCE
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MAINTENANCE
RENEW TRANSFER GEARBOX OIL
1.Site vehicle on lift or level ground.
2.Disconnect battery negative lead.
3.Clean immediate area around filler/level and
drain plugs.
WARNING: When draining gearbox care
should be taken to ensure that oil is not
hot as personal scalding could result.
4.Place a container under gearbox to drain oil into.
5.Remove filler/level plug to vent gearbox and
assist draining.
6.Remove drain plug and allow oil to drain.
7.Thoroughly clean drain plug threads prior to
applying fresh 'Hylomar' sealant. Fit plug
Tighten to
30 Nm.
8.Fill gearbox with correct quantity and grade of oil
until oil seeps from filler level hole. Wipe away
any surplus oil.
9.Thoroughly clean filler/level plug threads prior to
applying fresh 'Hylomar' sealant. Fit plug
Tighten to
30 Nm.
10.Reconnect battery negative lead.
CHECK/TOP UP TRANSFER GEARBOX OIL
1.Site vehicle on lift or level ground.
2.Disconnect battery negative lead.
3.Clean immediate area around filler/level plug.
4.Remove plug and fill gearbox with recommended
grade of oil, until oil starts to seep from filler/level
hole.
5.Clean any previously applied sealant from
filler/level plug.
6.Apply Hylomar sealant to threads of plug and
refit plug. Tighten to
30 Nm.
7.Wipe away any surplus oil.
8.Reconnect battery negative lead.