ECU LAND ROVER DISCOVERY 1995 Service 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
8
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.

10MAINTENANCE
16
MAINTENANCE
LUBRICATE PROPELLER SHAFT SLIDING , AND
UNIVERSAL JOINTS
1.Clean all grease nipples on front and rear
propeller shafts.
2.Using a low pressure hand grease gun, apply
recommended grease, to grease nipples at front
and rear propeller shaft universal and sliding
joints.
NOTE: The rear propeller shaft flexible
coupling is not fitted with a grease nipple.
CHECK VISUALLY BRAKE, FUEL, CLUTCH
PIPES/UNIONS FOR CHAFING LEAKS AND
CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
CHECK FOR FLUID LEAKS FROM POWER
STEERING AND SUSPENSION SYSTEMS,
HYDRAULIC PIPES AND UNIONS FOR CHAFING
AND CORROSION
CHECK/TIGHTEN STEERING UNIT AND STEERING
ROD BALL JOINT FIXINGS, CHECK CONDITION
OF OF BALL JOINTS AND DUST COVERS
Ball joints are lubricated for their normal life during
manufacture and require no further lubrication. This
applies ONLY if rubber boot has not been dislodged
or damaged. Joints should be checked at specified
mileage intervals but more frequently if vehicle is used
under arduous conditions.
1.Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent fit a new joint assembly.

MAINTENANCE
17
MAINTENANCE
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN FUEL SEDIMENTER - Tdi
Fuel sedimenter
The sedimenter is attached to left-hand side of
chassis frame near fuel tank. It increases the working
life of the fuel filter by removing larger droplets of
water and larger particles of foreign matter from fuel.
Drain off water
1.Loosen drain plug, allow water to run out.
Tighten plug immediately pure diesel fuel starts
to flow.
RENEW FUEL FILTER
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction regarding fuel handling are
strictly adhered to when carrying out following
instructions.
See INTRODUCTION, Information,
Fuel Handling Precautions
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
1.Depressurise fuel system.
See FUEL SYSTEM,
Repair, Depressurising Fuel System
2.The fuel line filter is located on right hand
chassis side member forward of fuel tank filler
neck. Access to filter is gained through right
hand rear wheel arch.
3.Thoroughly clean area around hose connections
to prevent ingress of foreign matter into fuel
system.
4.Loosen two fuel unions and remove hoses from
filter canister.
5.Release securing bolt and bracket, remove filter
from chassis side member.
6.Fit a new filter observing direction of flow arrow
on canister.
7.Fit inlet and outlet hoses. Tighten to
30 Nm.
8.Refit fuel pump relay.
9.Reconnect battery negative lead.
10.Recode radio.
11.Start engine and inspect hose connections for
fuel leaks.

Tdi
3
REPAIR ENGINE
Service repair no - 12.41.01
Remove
CAUTION: Seal all exposed pipe ends
against ingress of dirt after disconnection.
1.Park vehicle on level ground and apply park
brake.
2.Disconnect battery negative lead.
3.Remove bonnet [hood].
See CHASSIS AND
BODY, Repair, Bonnet [Hood]
4.If air conditioning is fitted, remove RH footwell
side trim panel and disconnect harness multiplug
from relay.
5.Disconnect the two engine harness multiplugs
on LH side of footwell.
6.Remove engine harness grommet from
bulkhead and move harness into engine bay.
7.Release battery positive lead from retaining clip
at base of suspension turret.
8.Remove Radiator Assembly.
See COOLING
SYSTEM, Repair, Radiator
9.Discharge air conditioning system.See AIR
CONDITIONING, Adjustment, Refrigerant
Recovery Recycling Recharging
Remove retaining bolts and disconnect both pipe
adaptors from rear of compressor.
10.Remove rocker cover insulation.
11.Disconnect cyclone hose from air cleaner hose.
12.Remove air cleaner hose from turbocharger.
13.Remove feed pipe/hose from turbocharger and
intercooler.
14.Disconnect heater hoses from cylinder head and
heater rails.
15.Remove bolt securing transmission breather
pipe clip to cylinder head; move breather pipes
aside.
16.Disconnect inlet and outlet hoses from power
steering pump.
17.Disconnect bypass hose from thermostat
housing.
18.Release bypass hose from retaining clips on
front timing cover.
19.Remove split pin securing inner throttle cable to
injector pump.
20.Depress tags on outer cable adjusting nut,
remove cable from mounting bracket, and move
aside.
21.If automatic transmission is fitted, release
kickdown cable from injector pump and mounting
bracket.

12ENGINE
4
REPAIR 22.Disconnect feed pipe and spill return pipe from
injector pump.
23.Disconnect both pipes from fuel lift pump.
24.Disconnect servo hose from vacuum pump.
25.Remove three retaining nuts and disconnect
exhaust down pipe.
26.Remove oil cooler pipes from oil filter adaptor.
27.If automatic transmission is fitted, disconnect
feed and return pipes at gearbox oil cooler.
Remove retaining bracket from LH side of
cylinder block and release both oil cooler pipes.
28.Support gearbox.
29.Disconnect ground strap from starter motor.
30.On vehicles with automatic transmission, remove
fixings and detach drive plate housing access
panel and gasket.31.Working through drive plate housing aperture
mark the torque convertor and drive plate to
facilitate reassembly.
32.Remove the four convertor to flexible drive
securing bolts, rotating crankshaft to gain access
to each individual bolt.
33.Fit engine lifting bracket to the two RH rear
cylinder head fixing bolts.
34.Using suitable hoist, fit lifting chains to engine.
35.Remove four bolts, from both sides, securing
front engine mounting brackets to cylinder block.
36.Remove two bolts, from both sides, securing
front engine mounting bracket to bell housing.

Tdi
5
REPAIR
37.Remove nuts and plain washers securing front
engine mountings to chassis,and lift both engine
mounting bracket assemblies from vehicle.
38.Remove engine to bell housing fixings. Leave
starter motor attached.
39.Raise engine to separate from transmission.
40.Check all connections to engine have been
disconnected.
41.Remove engine.Refit
42.Apply Hylomar to mating faces of bell housing.
Lubricate splines of gearbox primary pinion with
Rocol MV 3.
If automatic transmission, coat the four drive
plate to torque convertor bolts with Loctite 290.
Tighten to
39 Nm.
43.Lower engine and locate with transmission.
If manual transmission locate primary pinion into
clutch and engage bell housing dowels. Fit
engine to bell housing fixings. Tighten to
40 Nm.
If automatic transmission fixings. Tighten to46
Nm.
44.Raise engine, refit front engine mounting
brackets to cylinder block and bell housing.
45.Remove gearbox support and lower engine.
46.Tighten front engine mountings to chassis
fixings. Tighten to
45 Nm.
47.Reverse removal procedure. 1 to 37.

12ENGINE
6
REPAIR CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1.Disconnect battery negative lead.
2.Drain coolant.
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous fan and coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
6.Remove fan cowl.
7.Remove drive belt.
See Drive Belt Renew
8.Fit crankshaft pulley retainer LRT-12-080 and
secure with four bolts.
9.Remove crankshaft pulley retaining bolt using
socket and suitable long bar.
10.Remove pulley retainer.
11.Remove pulley, if necessary using extractor
LRT-12-049 with thrust pad from LRT-12-031.Refit
12.Refit in reverse order, lightly greasing pulley
spigot. Tighten to
80 Nm + 90°.