warning LAND ROVER DISCOVERY 1995 Repair Manual

V8i
1
REPAIR EXPANSION TANK
Service repair no - 26.15.01
Remove
WARNING: Do not remove expansion tank
filler cap when engine is hot. The cooling
system is pressurised and personal
scalding could result.
1.Remove expansion tank filler cap by first turning
it slowly anti-clockwise, pause to allow pressure
to escape. Continue turning in same direction
and lift off.
2.Disconnect two hoses from bottom of expansion
tank, allowing coolant to drain into a suitable
container.
3.Remove three fixing bolts, remove expansion
tank.
Refit
4.Reverse removal procedure.
5.Replenish cooling system.
6.Check for leaks around all hose connections.VISCOUS COUPLING, FAN BLADES, PULLEY AND
COWL
Service repair no - 26.25.19 - Viscous coupling
and fan assembly
Service repair no - 26.25.03 - Water pump pulley
Service repair no - 26.25.05 - Fan blades
Special tools:
LRT-12-093
LRT-12-094 - Viscous coupling removal
Remove
1.Disconnect battery negative lead.
NOTE: 4.0 V8 only:
Release coolant hose from cooling fan upper
cowl.
2.Release 2 clips securing cooling fan upper cowl.
Remove cowl.

26COOLING SYSTEM
6
REPAIR WATER PUMP
Service repair no - 26.50.01
Remove
WARNING: Disconnect battery negative
terminal to prevent engine being started
before removing or adjusting drive belts.
1.Drain engine cooling system.
See Adjustment,
Coolant
2.Remove fan blades and pulley.See Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
3.Disconnect inlet hose from water pump.
4.Remove water pump bolts.
5.Remove water pump and joint washer.
Refit
6.Lightly grease new joint washer, position on
timing cover.
7.Clean threads of all long bolts and coat with
Loctite 572 thread lubricant-sealant.
8.Locate water pump in position. Tighten
remaining water pump housing bolts evenly to
28 Nm.
9.Reverse removal procedure. 1 to 3.
10.Check for coolant leaks around all hose
connections and joint faces.

Mpi
1
REPAIR COOLANT PUMP
Service repair no - 26.50.01
Remove
1.Position drain tin below coolant pump hose.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Release clip and disconnect hose from coolant
pump housing cover.
3.Remove 5 bolts securing housing cover.
4.Remove housing cover.
5.Remove coolant pump from housing.
6.Discard 3 sealing rings.
Refit
7.Clean coolant pump housing and mating faces.
8.Lubricate new sealing rings with Loctite 405 and
fit to coolant pump.
9.Fit coolant pump to housing.
10.Position housing cover, fit 5 bolts. Tighten to
25Nm
11.Connect hose to housing cover and tighten clip.
12.Refill cooling system.

26COOLING SYSTEM
2
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect battery negative lead.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Slacken clip and release bottom hose from
radiator, allow coolant to drain into a suitable
container
3.Slacken clip and release bottom hose from
radiator rail.
4.Slacken clip and release top hose from radiator.
5.Release air cleaner to throttle housing hose from
securing brackets.
6.Slacken clip and release bypass hose from
radiator.
7.Slacken clip and release top expansion hose
from radiator.
8.Remove 2 bolts securing radiator side support
brackets.
9.Collect L.H. support bracket and position R.H.
support bracket aside.
10.Slacken clip and release heater hose from
radiator rail.
11.Disconnect 2 multiplugs from cooling fan
assemblies.

MANIFOLD AND EXHAUST SYSTEM
1
REPAIR EXHAUST SYSTEM COMPLETE
Service repair no - 30.11.01
To improve sealing and accuracy of assembly, a two
piece exhaust system is fitted.
NOTE: Ensure no exhaust leaks are
evident in either a new or old exhaust
system, as this will affect vehicle
performance.
WARNING: To prevent personal injury
occurring from a hot exhaust system, DO
NOT attempt to disconnect any
components until exhaust system has cooled
down.

R380
1
REPAIR R380 MANUAL GEARBOX
Service repair no - 37.20.02
Remove
WARNING: Where the use of a
transmission hoist is necessary, it is
absolutely essential to follow the
manufacturer's instructions to ensure safe and
effective use of equipment.
1.Install vehicle on a ramp [hoist].
2.Disconnect battery earth lead.
3.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre Console
4.Remove sound insulation from top of
transmission tunnel.
5.Remove bolt and remove upper gear lever.
6.Remove screws securing gear selector lever and
high/low selector lever draft excluders.
7.Remove draft excluder clamp rings.
8.Remove handbrake cable clevis pin clip and
clevis pin.
9.Remove 'C' clip and cable adjuster.
10.Select low range to prevent gear lever fouling
tunnel when removing gearbox.
11.Remove bolt securing gearbox breather pipe clip
to cylinder block.
12.Remove bolts securing fan cowl to radiator.
13.Release fan cowl from radiator and lay over fan
blades.
14.Raise ramp [hoist].
15.Drain oil from main gearbox and transfer
gearbox.
See SECTION 10, Maintenance,
Under Vehicle Maintenance
16.Remove exhaust front pipe(s).See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
System Complete
17.Release intermediate exhaust pipe(s) from
mountings and tie aside.
18.Remove bolts securing clutch slave cylinder.
19.Release slave cylinder from clutch housing and
collect spacer.
20.Mark propeller shaft drive flange relationships for
reassembly.
21.Disconnect front and rear propeller shafts from
transfer gearbox. Tie shafts aside.
22.Remove clamp and disconnect speedometer
cable from transfer gearbox.
23.Release handbrake cable from transmission
tunnel.
24.Temporarily support transmission in a way which
enables the crossmember to be removed and a
hoist cradle to be fitted.

TRANSFER GEARBOX
1
REPAIR LT230T TRANSFER GEARBOX
Service repair no - 41.10.25
Remove
Adaptor plate for removing transfer gearbox
The transfer gearbox is removed from underneath the
vehicle. Using a transmission hoist with an adaptor
plate for securing the transfer gearbox to the hoist.
The adaptor can be manufactured locally to the
drawing below.
WARNING: When using a transmission
hoist it is essential to follow the hoist
manufacturer's instructions.

41TRANSFER GEARBOX
2
REPAIR Remove
1.Site vehicle on a ramp [hoist].
2.Disconnect battery negative lead.
3.Remove fan cowl from radiator.
4.Remove transfer gear lever knob and gaiter.
5.Raise vehicle on ramp [hoist].
6.Drain oil and refit plug.
7.Detach heat shield at front exhaust pipe to
manifold.
8.Disconnect electrics to Lambda sensors.
9.Remove catalytic converter assembly.
10.Remove chassis crossmember from under
gearbox.
11.Remove heat shield from speedometer cable at
transfer gearbox.
12.Remove clamp and disconnect speedometer
cable from transfer gearbox. Tie cable to one
side.
13.Mark for reassembly then disconnect propeller
shaft to output flange, tie to one side.
14.Repeat on front propeller shaft to output flange.
15.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
16.Place four 30mm long spacers between top of
hoist and adaptor plate, at securing points, and
secure adaptor plate to hoist.17.Remove four central bolts from transfer gearbox
bottom cover, move hoist into position and
secure adaptor plate to transfer gearbox.
18.Adjust hoist to take weight of transfer gearbox.
19.Remove tie bar, transfer gearbox to main
gearbox.
20.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
21.Repeat for left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket.
22.Remove right side mounting bracket to flexible
mounting rubber.
23.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
24.Loosen park brake adjustment nut.
25.Remove park brake drum.
26.Remove park brake assembly complete from
rear output flange.
27.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
28.Remove banjo bolt from breather pipe, retrieve
sealing washers and lay pipe aside.
29.Remove split [cotter] pin and washers securing
differential lock to connecting rod and disconnect
rod from lever.
30.Select low range transfer gearbox position.
31.Remove high/low rod lower lock nut and remove
rod from yoke.
32.Position hoist jack channel under bell housing.
33.Using wooden block support the main gearbox
and bell housing.
34.Remove upper and lower bolts securing transfer
gearbox to main gearbox.
35.Fit guide studs 18G 1425 to main gearbox and
move transfer gearbox rearwards to detach.

ZF
1
REPAIR LT230T TRANSFER GEARBOX WITH AUTOMATIC
GEARBOX ASSEMBLY - V8i
Service repair no - 44.20.04
Removal from V8i engine
The assembled transfer gearbox, automatic gearbox
and torque converter is removed from underneath the
vehicle. Use a transmission hoist with an adaptor
plate for securing the assembly to the hoist. The
adaptor can be manufactured locally to the drawing
below or purchased from:- Straight Set Engineering,
England. Tel.01909 480055
WARNING: When using a transmission
hoist it is essential to follow the hoist
manufacturer's instructions.

ZF
3
REPAIR 19.Disconnect rear propeller shaft to output flange,
and tie to one side.
20.Repeat instructions 18 and 19 on front propeller
shaft to main gearbox.
21.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
22.Disconnect oil cooler feed and return pipes from
bottom and side of main gearbox.
23.Release cooler pipes from clamp at engine sump
and remove distance piece.
24.Blank pipe ends and unions.
25.Move oil cooler pipes clear of transmission and
tie aside.
26.Disconnect selector cable from operating lever.
27.Disconnect inhibitor switch at multiplug.
28.Attach adaptor plate to hoist.
29.Remove two bolts from transfer gearbox rear
cover.
30.Raise hoist to align adaptor plate with transfer
gearbox and transmission. Secure to transfer
gearbox at rear cover with two bolts removed.
31.Adjust hoist to take weight of transmission.
32.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
33.Repeat for the left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket
34.Remove right side mounting bracket to flexible
mounting rubber retaining nut.
35.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
36.Remove clip and clevis pin from park brake
lever.
37.Remove clip securing outer brake cable
38.The park brake cable is now free.
39.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
40.Remove ties securing breather pipes to harness.
41.Remove bell housing access plate complete with
gasket.
42.Rotate engine, using crankshaft pulley, until two
access holes are visible in drive plate/ring gear
assembly through bell housing bottom cover
opening.
43.Identify an access hole and bolt hole to aid
reassembly.
44.Remove bolts securing drive plate to convertor
through access holes.
45.Rotate crankshaft half turn to access and
remove remaining bolts.
46.Disconnect oil dipstick tube at main gearbox.
47.Remove bolt at bell housing and detach dipstick
tube. Blank pipe end and union.
48.Position hoist jack channel under engine and
support using a wooden block.
49.Remove bell housing to engine securing bolts,
also detach harness bracket from bell housing.
50.Ease transmission rearwards to allow access to
secure torque converter in bell housing.
51.Lower hoist and complete removal of
transmission.
Refit
52.Ensure torque converter is retained in bell
housing.
53.Secure transmission to adaptor plate on lifting
hoist.
54.Raise hoist and locate transmission with engine.
55.Remove torque converter retainer.
56.Complete attachment of transmission to engine
and fit bell housing bolts. Fit the dipstick tube
bracket and harness bracket to their respective
bolts.
57.Complete refitting by reversing removal
procedure. Note the following important points.
58.Drive plate to torque converter bolts are to be
coated with Loctite 290 prior to assembly.
59.Refill transfer and main gearboxes with correct
grade oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
60.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior