drain bolt LAND ROVER DISCOVERY 1995 Service User Guide

V8i
15
REPAIR OIL SUMP
Service repair no - 12.60.44
Remove
1.Drain engine oil
See SECTION 10,
Maintenance, Under Vehicle Maintenance
2.Fit drain plug. Tighten to40 Nm.
3.If fitted, disconnect low oil level sensor multiplug.
4.Remove bolt securing dipstick tube to rocker
cover.
5.Working form the centre outwards, progressively
loosen and remove 17 bolts securing sump.
Remove sump.
6.Remove all traces of sealant from mating
surfaces of sump, cylinder block and front cover,
using a suitable solvent or plastic scraper.
7.Degrease mating surfaces of sump, cylinder
block and front cover.Refit
8.Apply RTV Hylosil White sealant to mating
surface of sump.
9.Position sump, tighten bolts finger tight.
10.Tighten bolts progressively in sequence shown.
Tighten to
18 Nm.
11.Fit bolt securing dipstick tube to rocker cover.
12.If fitted, connect low oil level sensor multiplug.

V8i
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Engine
Adaptor plate to crankshaft 84........................................................................
Generator and power steering mounting bracket to cylinder head 30............
Cylinder head:
Stage 1: 20.............................................................................................
Stage 2: - Further 180°±5°
Drive plate to converter 39..............................................................................
Engine mountings to engine and chassis 55..................................................
Engine mounting rubbers to brackets 30........................................................
Flexible drive plate to crankshaft adaptor plate 41.......................................... **
Flywheel to crankshaft bolts 78....................................................................... **
Lifting eye to cylinder heads 39......................................................................
Main bearing cap rear bolts 92....................................................................... *
Oil sump drain plug 40....................................................................................
Oil sump to cylinder block 18..........................................................................
Rocker cover to cylinder head 9....................................................................
Rocker shaft bracket to cylinder head 38........................................................
Spark plug 21..................................................................................................
Starter motor attachment 44...........................................................................
* These bolts must have threads coated in lubricant EXP16A before assembly.
** These bolts must have threads coated in sealant Loctite 270
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................
NOTE: Torque values above are for all screws and bolts used except for those specified.

4.0 V8
7
REPAIR 171.Route drive belt around pulleys.
172.Pivot tensioner downwards.
173.Align belt to tensioner and release tensioner.
174.Connect battery positive lead and tighten.
175.Secure terminal cover.
176.Align gearbox breather pipe, clip to engine lifting
eye and fit bolt. Tighten to
9 Nm.
177.Align and secure engine harness brackets to
inlet manifold and fit nuts. Tighten to
9 Nm.
178.Connect injector multiplugs.
179.Connect air intake temperature sensor multiplug.
180.Connect fuel temperature sensor multiplug.
181.Connect coolant temperature multiplug.
182.Connect temperature gauge connector.
183.Connect oil pressure switch Lucar.
184.Connect camshaft sensor multiplug and secure
to bracket.
185.Fit ignition coil bracket.
See FUEL SYSTEM
SFI, Repair, Ignition Coils
186.Position heater hose/pipe assembly.
187.Connect hose to inlet manifold.
188.Align pipe to bracket and fit bolt. Tighten to
9
Nm.
189.Tighten hose clip.
190.Connect heater return hose and tighten clip.
191.Remove plugs from fuel feed and return hose
connections.
192.Clean feed unions.
193.Connect return hose and tighten clip.
194.Connect feed hose union and tighten.
195.Remove cloth.
196.Connect purge hose.
197.Connect leads to generator, tighten terminal nuts
and fit cover.
198.Connect sensing Lucar.
199.Connect servo vacuum hose.
200.Position expansion tank and secure with fixings.
201.Connect hose and tighten clip.
202.Lower ramp.
203.Fit mass air flow sensor.
See FUEL SYSTEM
SFI, Repair, Mass Air Flow Sensor (MAF
Sensor)
204.Fit plenum chamber.See FUEL SYSTEM SFI,
Repair, Plenum Chamber
205.Fit radiator.See COOLING SYSTEM, Repair,
Radiator
206.Fit bonnet.See CHASSIS AND BODY, Repair,
Bonnet [Hood]
207.Reconnect battery negative lead.
208.Bleed power steering system.
See STEERING,
Repair, Power Steering System - Bleed
209.Drain engine oil and refill.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids - USA
Vehicles
210.Start engine. Check for fuel, coolant and oil
leaks.FRONT COVER GASKET
Service repair no - 12.65.04 - Front Cover Gasket
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
3.Remove radiatorSee COOLING SYSTEM,
Repair, Radiator
4.Remove water pump pulley.See COOLING
SYSTEM, Repair, Viscous Coupling, Fan
Blades, Pulley and Fan Cowl
5.Slacken bottom hose clip. Remove hose from
water pump.
6.Raise vehicle on ramp.
7.Disconnect oil cooler hoses from front cover and
position aside. Plug hoses and connections.
8.Disconnect Lucar from oil pressure switch.

4.0 V8
11
REPAIR ROCKER COVER GASKET - RIGHT HAND
Service repair no - 12.29.41 - RH Cover Gasket
1.Depressurise fuel system.
See FUEL SYSTEM
SFI, Repair, Fuel System - Depressurise
2.Disconnect battery negative lead.3.Drain cooling system.
See COOLING SYSTEM
V8, Adjustment, Coolant
NOTE: Leave hose disconnected.
4.Disconnect purge pipe from plenum chamber
hose.
5.Disconnect breather pipe from rocker cover.
6.Remove bolt securing coolant pipe brackets and
nut securing bracket to manifold.
7.Loosen hose clip and disconnect coolant return
hose from pipe.
CAUTION: Plug connection.
8.Loosen clip and disconnect fuel return hose from
pipe.
9.Disconnect fuel hose from injector pipe.
CAUTION: Use 2 spanners.10.Remove 2 nuts securing engine harness
brackets to manifold.
11.Release 4 ht leads from 2 brackets on rocker
cover.

12ENGINE
4
DESCRIPTION AND OPERATION CYLINDER BLOCK COMPONENTS
1. Cylinder block
2. Knock sensor
3. Crankshaft sensor
4. Bolt - crankshaft sensor
5. Locating dowel - cylinder head
6. Bolt - connecting rod
7. Piston
8. Piston ring - top compression
9. Piston ring - 2nd compression
10. Piston ring - oil control
11. Gearbox adapter plate
12. Bearing shell - big end - upper
13. Flywheel
14. Bolt - flywheel
15. Torx screw - gearbox adapter plate
16. Blanking plate
17. Bolt - blanking plate
18. Gasket
19. Bolt - crankshaft rear oil seal housing
20. Crankshaft rear oil seal and housing
21. Bolt - coolant pump cover
22. Coolant pump cover
23. Impeller
24. Sealing rings
25. 'O' ring
26. Bolts - coolant pump
27. 'O' ring
28. Coolant pump body
29. Thrust washer halves - upper
30. Bearing shell - main bearing - upper
31. Locating dowel - oil pump
32. Locating dowel - flywheel
33. Gudgeon pin34. Crankshaft
35. Bearing shell - big end - lower
36. Bearing cap - big end
37. Nut - big end bearing cap
38. Locating dowel - main bearing cap
39. Bearing caps - main bearings
40. Bolt - main bearing cap
41. Thrust washer halves - lower
42. Bearing shell - main bearing - lower
43. Woodruff keys
44. Dipstick
45. Bolt - dipstick tube
46. Dipstick tube
47. Bolts - sump
48. Gasket - sump
49. 'O' ring
50. Oil strainer
51. Bolts - oil strainer
52. Sump
53. Washer - drain plug
54. Drain plug
55. Oil filter element
56. Crankshaft front oil seal
57. Bolts - oil pump
58. Gasket - oil pump
59. Oil pump
60. Oil pressure switch
61. Crankshaft spigot bush
62. Crankshaft spigot bearing
63. Locating dowel - coolant pump
64. Connecting rod
65. Bolts belt tensioner mounting plate
66. Belt tensioner mounting plate
67. Bolt - gearbox adapter plate

Mpi
5
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
1.Remove gearbox.
2.Remove clutch assembly.
3.Remove flywheel.
4.Drain engine oil.
5.Fit sump plug, replacing sealing washer if
damaged and tighten to the correct torque.
6.Loosen 15 sump bolts by approximately 3 turns,
allowing sump to drop away from rear oil seal
housing. Do not loosen 3 boltsAaround oil
pump housing.
7.Remove bolts securing oil seal housing, remove
seal and housing assembly.
Refit
1.Clean seal seating area of block and accessible
area of sump gasket. Sump gasket must be
replaced if damaged.
2.Lubricate oil seal sealing surfaces with engine
oil.
3.Fit tool LRT-12-061 over crankshaft boss and fit
oil seal and housing assembly.
4.Remove tool.
5.Fit and tighten seal housing bolts to correct
torque in sequence shown.
10Nm
6.Tighten sump bolts to correct torque and in the
correct sequence.
See Engine Sump Gasket
7.Fit flywheel.
8.Fit clutch assembly.
9.Fit gearbox.

Mpi
13
REPAIR 19.Connect crankshaft sensor, knock sensor, air
conditioning compressor, fuel injector harness,
inlet manifold air temperature and fuel
temperature sensor multiplugs.
20.Connect fuel hose to pressure regulator and
secure with clip.
21.Fit and tighten fuel pipe to fuel rail union.
22.Connect multiplugs to throttle housing.
23.Connect vacuum hose to manifold.
24.Connect oil pressure switch multiplug.
25.Connect brake servo hose to manifold, secure
with clip.
26.Connect throttle cable to cam.
27.Position engine harness and connect breather
hose to inlet manifold, secure with clip.
28.Connect coolant temperature sensor multiplugs,
secure harness with cable tie.
29.Connect oxygen sensor multiplug, secure
harness with cable tie.
30.Connect alternator harness.
31.Connect heater hose to heater rail and secure
with clip.
32.Connect hose to coolant pump and secure with
clip.
33.Connect inlet hose to power steering pump and
secure with clip.
34.Fit and tighten outlet pipe union to power
steering pump.
35.Connect bypass and top hose, secure with clip.
36.Connect air cleaner to throttle housing hose and
secure with clip.
37.Remove engine lifting bracket.
38.Position spark plug cover and secure with
screws.
39.Fill engine with oil.
40.Fit bonnet [hood].
See CHASSIS AND BODY,
Repair, Bonnet [Hood]
41.Fit radiator.See COOLING SYSTEM, Repair,
Radiator - Mpi
42.Adjust throttle cable.See FUEL SYSTEM,
Adjustment, Throttle Cable Adjustment
ENGINE SUMP GASKET
Service repair no - 12.60.43
Remove
1.Drain engine oil.
2.Refit drain plug, use new sealing washer if
necessary, tighten to the correct torque.
3.Remove 18 bolts securing sump.
NOTE: 25mm long bolt is fitted at rear L.H.
corner of sump.
4.Release sump from cylinder block.
5.Discard gasket.

12ENGINE
14
REPAIR Refit
1.Clean sump, remove all traces of gasket from
mating faces of sump and cylinder block.
Visually check sump for damage.
2.Apply beads of RTV sealant to front main
bearing cap.
3.Position new gasket to sump, ensuring that
location pips on gasket are located in sump.
Check gasket lays flat on sump flange.
4.Fit sump. Fit bolts, ensuring that longest bolt is
inserted at position 7.
5.Working around the sump in the sequence
illustrated, tighten the bolts to the stage 1 torque
figure. Then, in the same sequence, tighten the
bolts to the stage 2 torque figure.
NOTE: For torque values.See
Specifications, torque, Torque Values
6.Fill engine with oil.CYLINDER HEAD GASKET
Service repair no - 12.29.01
Remove
1.Disconnect battery negative lead.
2.Position absorbent cloth around fuel pipe to fuel
rail union. Unscrew union to relieve pressure.
CAUTION: Plug the connections.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
3.Release clip and disconnect radiator bottom
hose, allowing coolant to drain into a suitable
container.

Tdi
3
REPAIR TURBOCHARGER OIL FEED PIPE
Service repair no - 19.42.14
Remove
1.Disconnect battery negative lead.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Manifold
and Exhaust System - Tdi
3.Remove banjo bolt securing oil feed pipe to
turbocharger, discard 2 sealing washers.
4.Unscrew union, disconnect oil feed pipe from
cylinder block.
CAUTION: Plug the connections.
5.Move oil feed pipe from behind turbocharger and
remove.
Refit
6.Reverse removal procedure. use new sealing
washers.
7.Tighten banjo bolt to
20 Nm.
8.Check/top-up engine oil level.TURBOCHARGER OIL DRAIN PIPE
Service repair no - 19.42.12
Remove
1.Disconnect battery negative lead.
2.Remove exhaust front pipe.
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Manifold
and Exhaust System - Tdi
3.Unscrew union and disconnect oil drain pipe
from cylinder lock.
4.Remove 2 bolts securing oil drain pipe to
turbocharger.
5.Remove oil drain pipe, remove and discard
gasket.
CAUTION: Plug the connection.
Refit
6.Ensure mating surfaces of oil pipe, turbocharger
and engine block are clean.
7.Reverse removal procedure. Use a new gasket.
8.Tighten oil drain pipe to turbocharger bolts to
25
Nm.
9.Check/top-up engine oil level.

19FUEL SYSTEM
6
REPAIR FUEL FILTER ELEMENT
Service repair no - 19.25.07
Remove
1.Disconnect battery negative lead.
2.Clean area around filter head.
3.Place a suitable container beneath filter bowl to
collect any spillage.
4.Loosen bleed screw.
5.Loosen drain tap, allow fuel to drain into
container.
6.Unscrew filter element, discard element.
Refit
7.Clean seal and seating in filter head.
8.Lubricate filter element seal with fuel.
9.Position filter element to filter head and hand
tighten.
10.Reconnect battery negative lead.
11.Crank engine until fuel is drawn through the
system and starts.INTERCOOLER
Service repair no - 19.42.15
Remove
1.Disconnect battery negative lead.
2.Release 2 clips securing fan cowl to radiator top
cover.
3.Remove 4 bolts securing radiator top cover,
remove top cover.
4.Remove nut, bolt and washers securing
intercooler side cover bracket to bonnet [hood]
platform.
5.Release bracket from side cover lug, position
bracket and power steering reservoir aside.
6.Position side cover away from intercooler.
7.Loosen 2 clips and disconnect top hose from
intercooler.
8.Loosen 2 clips and disconnect bottom hose from
intercooler.